(G-Max) Service Manual
Contents
1. Push starting switch And check the function Of start relay i normal No function Connect starting motor EE battery directly D Ocarben brush worn out Starting Starting motor Motor runs up Has no motion it plug is loose drop off main wiring broken b Starting motor running slowly or no pick up Check and adjust Trouble condition Turn signal lamp On to check wi ring of battery normal Lamp dims no e Flashing light Wbaftery has no power j Starting Connect motor to the starting motor to Eh ee ee d Battery directly Runni electric plug is loose br drop off startrelay bad E SEN connection Kick the kickstarter lever UA Easy ose Difficult to kick L eytinder burn out wire broken or shout circuit Starting motor can not stop after starting Check and adjust Trouble condition Main switch Turn off The reason Motor stops Motor can t stop start relay capacitor melted or short circuit 12 No sparking Check and adjust Trouble condition Q Replace new spark Plug then check IS again Good sparking Weak sparkin Or no paring plug faulty x Er d ES i And H V cable is Loose not loosen Sparkplug cap is loose good m Blue ie poor loosen connec2. loose or damage Brake cable Change brake cable 2 ears F Brake cam worn out a a clearance between hub and lining Wheel hub brake shoe and brake e and brake lining worn out shor standard c wheel hub worn and dia rear 110 0mm damaged g 9 limit of use rear 111 0mm Rint Wheel damaged or distorsion axle Rear ne damaged or distorsion axle unit kg c 01 driver Pressure front tire rear tire 2 0 2 0 tire Cracked or damaged tire thread worn out Change according to mark 2 tire surface or other intruders Front axle nut torque Axle Tighten the bolt and nut GORE A Dut rear axle nut torque location 11 0 13 0kg m Swingness limit Vertical below swingness and damage Rim condition 9 o 2 0mm Horizontal below 2 0mm Checking period gen era first home office d Item 1 month every12 everyl every3 everyl2 Judgement Remark chec ki months months months months standard ng Initial 300km 5000 10000km 1000km 2500km 10000km Clearance on o o o o gt Front axle O Clearance on 5 Sp
3. Recharge system diagram for M2 125 150 JUR Rial CHARGING amp LIGHTING WIRING Rare HIGH BEAN INDIDATAR aoa TO AUTO BY ST GARBURETOR 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 4 Ignition system 1 the wiring or ignition aX E IGNITION WIRING DIAGRAM GENERATOR soda COL 5 d amp T EIERE ENGINE RUH FF SWITCH TACHOMETER 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 CDI 5 The starting system 1 The wiring of starting RP ELH ROME ELECTRICAL STARTING WIRING AR AJH n PAHE SAFETY SMITCHLH Th STARTING BUTTON o xem esl kee STARTINS RELAY Selb NM DOE RUNOFF ERT TAFRH SAFETY SMTCHRH 2 Make sure the Engine RUN OFF switch is in position 3 Check the safety switch by operating the brake lever and the brake lamps shall light on 4 check the starting rela
4. HH E ess ty ENGINE RPM METER HI LO LAMP SWITCH ades 2 ce FEE a lt p STARING SWITCH HORN SWITCHSIGNAL LAMP SWITCH STARING SWITCH E E uS facro cB ON STARING SWITCH ENGINE STOP SWITCH 5 F 2 m e ke VERTAKING SWITCH EM T S E B W le s FREE a RUN ca LO O I1 an Bi FREE i us 8 oB RI uM cut ofo 1 5 6 Br W Eb B r W D d 8 w B W 9 nm NIB esp 58 eo N R Y Z 53 52 B W pr Dg Grog BI 54 18 p9 I Y 74 23 G Y bs GrBr W 99 _ B W G 78 bai DC12V B 7 HORN O gt 1 ww Tse amp n5w 12V 10W 48 P n 48 HE LH FR SIGNAL LAMP 49B dr W STARTER RELAY 215 E SWITCH 1 85 BIAN A ay zi RELAY B4 S e 32 c mere 486 ei BI Y R CDI UNIT ES d Orr Ser OUTPUT a PULSE 59 1 TBA VOL REGULATOR 1 mS GENERATOR 4 R Y 14 Y G 45 x B d BATTERY d R W R a 2 E du CT ODEL M2 125 4T HELMET CASI 4 LIGHTING LAI S rut DS o SCH EI ODEL 2 150 4 P 2z R W dee o lt ad 22 is iii T B R Black witch Red t B Black R 7 wite CHASSIS GROUND BI B Blue witch Black tracer BI Blue ey HEADLAMP RELAY S Blue witch White tracer Br Brown Sr IGNITION COIL BIZY Blue witch Yellow tracer 09 Dark Green Br W B
5. switch out of order Gdefective magneto coil Measurement of Compression pressure starting clutch out of order piston ring stuck Insufficient or lreed valve deteriorated No Pressure cylinder piston piston ring worn out Pressure is normal cylinder gasket leakage nt tylinder body has sand hole Start engine follow the Instruction of starting euge engine Obad action of auto choke airtrapped in intake manifold Engine has no Engine knocking Bwrong ignition timing knocking But can t start D bad adjustment of carburetor s fuel adjusting screw Remove spark plug And check again Geen carburetor fuel level too high dry Geer B malfunction of auto choke throttle valve open too largely 2 Weak acceleration Trouble condition TEN Gegen Start engine and open throttle Graduallv check and inspect EE eaner blocked uel supply system abnormal j Engine can t rotate ank cover blocked Up completely er blocked ump is malfunctioned chock is malfunctioned heck ignition timing check ME i With ignition timi Timing is correct nit is out of order Timing is not correct alternator flywheel magneto out of order Check cylinder i Compression pressure i use cylinder compression f E i pressure gauge cylinder piston r
6. This scooter is using CDI set it is no need to adjust ignition timing If ignition timing is not correct check the CDI sets AC magneto change it if it is abnormal checking ignition timing remove seat the luggage compartment 2 Remove right body cover 3 Remove the fan case 4 Check with ignition timing lamp keep the engine running at 1 900 100 r p m the checking mark should lay in 3 apart From mark 5 ignition timing B T D C 17 3 1900rpm 8 Throttle cables adjustment l check the clearance of throttle 2 Normal clearance 1 5 3 5mm 3 Adjust it by rotating the adjust nut change it if the throttle cables can t be adjusted 9 Idle adjustment Note adjust it when the engine is warm 1 left body cover 2 start the engine and connect the tachometer 3 adjust the throttle valve screw to the specified revolution 1900 100rpm 4 if the idling rpm is still unsteady or fuel up is not smooth please adjust it by followings a Screw in the air adjust screw clockwise then screw out counterclockwise Recommended loop 1 3 8 1 2 b Rotate air adjust screw clockwise and counterclockwise to find out the highest revolution location c Rotate the throttle valve screw to idling condition d Fuel up gradually until the idling running rpm is steady e If the rpm is still not steady please repeat above procedure 10 front brake adjustment l check the clearance of front brake
7. too thick loose the screw mixture too lean No leakage leakage tight the screw heat protector gasket broke carburetor locking nut loosen t crack Remove spark plug insert To spark plug cover and Connect with ground Start engine then check The sparking Good sparking hose leakage Intake manifold gasket broken Carburetor O ring distorted plug dirty out of order agnet abnormal ition coil faulty coil disconnect or hort circuit main switch is abnormal generator malfanction Ze is damaged ir pipe is blocked or damaged 4 Engine running unsmoothly high speed Check and adjust Trouble condition The reason j Check ignition i timing et correct Not correct verias faulty generator faulty Fuel supply system uel level is too low 1 pipe fuel filter good unsmoothly is blocked feel pump faulty Check carburetor Is blocked or not DEEN No blocked blocked clean and wash it 5 Clutch drive and driven pulley Trouble condition Engine can start but can t Move the vehicle Engine runs but it stops Suddenly and seems to rush out The reason iving belt worn out distortion iven plate worn out rear wheel rotates while idling Climb
8. Dashboard Function o o o o o o Muffler Losseness or Damage on silencer Ass y part Function o o o Loose or chassis o o o Damaged The previous Confirm it does Abnormal case Not 2 Again Chassis otliers Lubrication Decarbonate on Combustion room And muffler 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 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 Positive Pole Negative Pole Note A The battery is totally sealed do not remove seal bolts when recharging B It s no need to add any electrolyte for this re filling free battery Please recharging 12V by the following currency 50 Standard recharging 0 4A 5 10 hr or rapid recharging 3A 30min G MAX125 150 Standard recharging 0 7A 5 10 hr or rapid recharging 3A 30min 3 Cleaning air cleaner 1 Remove air cleaner cover 2 Take out the air cleaner filter 50 125 150 4 Assemble the air cleaner by the opposite procedure Note Do not start the engine When the air cleaner is Not installed 4 The final reduction mechanism oil 1 Change the oil in the gear box a Turn off the engine
9. Roundness change it when above 0 005mm Cylindrility change it when above 0 005mm d Checking the flatness of cylinder contact surface Limit of use change it when above 0 05mm Straight rule e Connecting rod small end inner diameter measurement Limit of use change a new one when above 13 06mm 125CC 15 06mm 150CC 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 2 Clean up the residual gasket on the crankcase NOTICE Do not drop other objects into the crankcase Over 20mm Em Top ring Second ring Side track 011 spacer ring scraper Side track ring i ring m 3 Assembly the piston piston pin and piston pin clip NOTICE a The mark IN on the piston tip should face to the INLET side b Do not drop the piston pin clip into the crankcase and to clog the crankcase with rags b Installing piston Fix the lock pin and gasket on the crankcase 2 Lubricate the Cylinder inner surface piston and piston rings by Motor Oil 3 Install the piston ring into the cylinder carefully NOTICE a The piston ring cannot be damaged or cracked b
10. Front tire 120 60 13 Rear tire 130 60 13 Note a Check and adjust the tire pressure when it is too low The pressure is according to the carrier Driver passenger accessories and cruise Speed b Proper loading is very important for steering riding braking performance and safety c Never carry any parcel unfastened d Load the heaviest parcel on the center of vehicle balancing the weight on both sides e Beware of the weight loaded properly and check the tire pressure The total weight of carrier driver passenger and accessories cannot exceed the approved limit An overload vehicle is easy to cause tire damage and accident for rider 4 Check is there any sharp Object pierce the tire 5 Check the depth of tire Thread a Depth front amp rear According to mark of tire change a new tire 4 G MAX 125 150 engine Dismantling Maintaining Repairing and assembling operation 1 2 3 4 5 6 7 8 9 Lubrication system Engine dismantling Drive pulley starter clutch driven pulley Cylinder head and valve Cylinder and piston AC generator Final transmission mechanism Crankcase crank shaft Carburetor 1 Lubrication System am l 0 1L CYLINDER HEAD 2 CYLINDER 3 CON ROD 4 CRANKSHAFT 5 GEAR BOX 6 CARBURE TOR 7 PISTON 8 0IL COOLER Oil Pump Dismantling Remove the rear section of muffler 2 Remove the AC flyw
11. 1 Main jet blocked 2 Float valve blocked 3 Fuel level too low 4 Fuel system blocked 5 Second air sucked into intake system 6 Bat vacuums during piston movement 7 Throttle valve malfunction Too much fuel in the engine 1 Air cleaner blocked 2 Mixed air is too dilute in the idle system Sparking unsteady while increasing speed 1 Ignition system malfunction 2 Air mixture is too dilute e Difficult to start Ignition off Unstable idling 1 Fuel system blocked 2 Ignition system malfunction 3 Air mixture is too dilute or too thick 4 Fuel deterioration 5 Second air sucked into intake system 6 Bad idle adjustment 7 Bad fuel volume adjustment 8 Idle system or fueling system blocked 9 Bad adjustment of fuel level Mixture air too thick 1 Auto chock system malfunction 2 Float valve malfunction 3 Fuel level is too high 4 Air route blocked 5 Dirty air cleaner 6 Fuel overwhelming in carburetor B 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 Idle adjustment Adjustment of fuel volum
12. 125CC 15 T 150CC 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 Assemble the final transmission mechanism please follow the opposite procedure Of disassembling After locking the drain bolt refill 90cc of gear ol SAE90 Locking torque M6 1 0 1 2kg M M10 3 5 4 0kg M Drain bolt 8 1 8kg M 9 Crankcase Crankshaft A Disassembling diagram B Troubleshooting C Data D Remove crankcase and crankshaft E Check crankshaft Assemble the crankcase 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 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 2 Remove the muffler 3 The carburetor 4 Engine corer 5 Cylinder head 6 Cylinder 7 The driving plate EE 8 flywheel magneto D 9 The starter clutch 10 0il pump 11 Bolts of left right cran
13. 60 km hr REAR 12V 5W 2 FUEL 45 km l 12V21W CONSUMPTION 2 GRADIENT 19 SIGNAL 12V 10W 4 ENGINE MODEL P2 HORN DC 12V FUEL 92 UNLEADED SILENCER DIFFUSER STROKE 2TAIR FORCED 2 PARTICLE BELOW 15 96 A 940 0 mm S CO 4 5 2 STROKE 39 2 mm m HC BELOW 7000 ppm CYLINDER SINGLE EXHAUST LAYOUT RIGHT DISPLACEMENT 49 cc LUBRICATE SEPARATE PUMP 6 801 FUEL TANK 7 51 3 5kw 7000rpm MAX TORQUE 5 0N M 6500rpm LAYOUR HORIZONAL IGNITION CDI STARTING ELECTRIC amp KICK 1 2 125 SPECIFICATION BRAND PGO FRAME STEEL PIPE MODEL M2 50D 2 2 FRONT TELESCOPE 2 1855 REAR SWING 2 WIDTH 730 mm 7 PRIMARY DIRECT z HEIGHT 1170 mm 2ND 43 14 42 13 A AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL FRONT 54 KG SHIFTING V BELT C V T S REAR 16 KG FRONT 120 70 13 E TOTAL 130 KG E REAR 130 70 13 z PASSENGER 2 110KG 5 FRONT DISK FRONT 94 KG e DISK REAR 146KG SPEEDOMETER 140 km hr TOTAL 230 KG HEAD HIULO 12V 35W 35W TOP SPEED 84 km hr REAR 12V 5W 2 FUEL 40 km l 12V21W CONSUMPTION Ga GRADIENT 21 SIGNAL 12V 10W 4 ENGINE MODEL DC 12V FUEL 92 UNLEADED SILENCER DIFFUSER STROKE 4TAIR FORCED 2 PARTICLE BELOW 15 96 51 5 mm E CO BELOW 4 596 2 STROKE 60 0 mm m HC BELOW 7000 ppm CYLINDER SINGLE EXHAUST LAYOUT RIGHT
14. DISPLACEMENT 124 9 LUBRICATE SEPARATE PUMP e 9 201 amp SPLASH MAX 6 5kw 7500rpm FUEL TANK 7 51 MAX TORQUE 9 1N M 6250rpm LAYOUR HORIZONAL IGNITION CDI STARTING ELECTRIC amp KICK 1 3 150 SPECIFICATION BRAND PGO FRAME STEEL PIPE MODEL M2 150 2 2 FRONT TELESCOPE 2 1855 8 REAR SWING 2 WIDTH 730 mm 7 PRIMARY DIRECT z HEIGHT 1170 mm 2ND 42 15 42 13 A AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL FRONT 55 KG SHIFTING V BELT C V T S REAR 77 KG FRONT 120 70 13 E TOTAL 132 KG z REAR 130 70 13 z PASSENGER 2 110 5 FRONT DISK FRONT 95 KG e DISK REAR 147KG SPEEDOMETER 1400 km hr TOTAL 242 KG HEAD HIIILO 12V 35W 35W Z TOP SPEED 87 km hr REAR 12V 5W 2 FUEL 40 km l z BRAKE 12V 21W CONSUMPTION Ga GRADIENT 24 SIGNAL 12V 10W 4 ENGINE MODEL C5M HORN DC 12V FUEL 92 UNLEADED SILENCER DIFFUSER STROKE 4TAIR FORCED 2 PARTICLE BELOW 15 96 57 0 mm E CO BELOW 4 596 2 STROKE 57 8 mm m HC BELOW 7000 ppm CYLINDER SINGLE EXHAUST LAYOUT RIGHT DISPLACEMENT 147 5 cc LUBRICATE SEPARATE PUMP e 9 401 amp SPLASH MAX 7 7kw 7250rpm FUEL TANK 7 51 MAX TORQUE 10 6N M 6250rpm LAYOUR HORIZONAL IGNITION CDI STARTING ELECTRIC amp KICK Service information 1 The operation notice 2 Locking torque value 1 For engine 2 For chassis 3 Ot
15. NO Lubrication location Oil type Remarks 1 Crankcase rotating part Separated pump Sliding part Premium 2 stroke Lubrication Motorcycle oil 2 Cylinder rotating part Or SAE 30 Sliding part 3 Drive gear box SAE85 140 Total 110 c c Replacement 90c c 4 Gasket of starter shaft Clean grease 313 5 Start idle gear sliding Clean grease 3 parts B 4T Engine 125 150 cc NO Lubrication location Oil type Remarks 1 Crankcase rotating part Auto Separated Sliding part Lubrication premium 4 stroke 2 Cylinder rotating part Sliding part motorcycle oil or SAE15W40 3 Drive gear box SAE85 140 Total 110 c c Replacement 90c c 4 Gasket of starter shaft Clean grease 3 5 Start idle gear sliding Clean grease 3 parts Chassis appearance 1 Apply oil 1 2 1 2 V Wr Swi 2 Apply grease 3 4 5 6 7 8 D Wheel bearing Final transmission mechanism gear oil Error 4 PERIODICAL MAINTENANCE TABLE Model MONTHS DISTANCE IN KM FOR CHECKING Item 2T or 4T lor 3 or 6 or 120 150 180 Checking Content 300 km 3000k 5000k E 10000k 13000 15000k Engine oil 2T Add According to Oil warning light Engine oil Replace 800cc total 900cc Re
16. Thread Locking Bi Locking location torque kg m Remarks Cylinder head 1 0 1 4 When the engine is cold Flywheel outer 3 2 4 0 Rear brake lever 1 0 1 2 4 Driving pulley 3 2 4 0 Clutch outer 35 40 O 6 Right crankcase 1 0 1 2 7 Drive gear box cover 1 0 1 2 8 Left crankcase 1 0 1 2 d an and filler bolt 1 8 cold 10 Inlet pipe 10 12 Flywheel magneto stator 10 12 Cooling fan 10 312 Je 13 Muffler nut on cylinder 1 0 1 2 When the engine is head Starting motor 1 0 1 4 When the engine is cold 15 Bracket between eng and 1 0 1 2 Rubber pad of central stand 17 Fan cover 1 0 1 2 18 Fixed plate drive clutch 1 0 1 4 ah 19 of rear wheel axle 20 Kick starter 11 13 TYPE NUT Z 2 4T Engine 125 150 CC Locking location Thread dia mm Locking torque kg m Fixing nut Tappet screw nut 0 7 0 8 Nut of oil pump sprocket 0 7 1 0 Cylinder head bolt A intake 0 9 1 1 Guiding pin bolt chain extensioner 0 4 0 6 Screw chain extensioner 0 9 1 1 Cylinder head bolt B Exhaust 2 0 2 3 Flange nut cam shaft holder 2 0 2 3 Gear oil drain bolt 1 7 2 0 1 2 3 4 5 6 7 8 9 Spark plug 1 2 1 3 Nut of fly wheel 5 0 6 0 Fixing nut clutch outer 5 0 6 0 Nut driving plate 5 0 6 0 Bolt of engine oil drain 2 5 3 0 Bolt of 2 oil f
17. 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 drop the clip into the crankcase 2 Remove the piston pin and take off the piston 3 Check piston piston pin piston ring 4 Remove the piston ring NOTICE NOTICE Don t make piston ring worn out or damaged 5 Clean the carbon in the groove of the piston ring c PISTON OUTER DIA MEASUREMENT 1 Measuring location Perpendicular to the piston pin hole down to 7mm 125CC or 5mm 150CC form the piston skirt Limit of use change it when less than 51 4mm 125CC Limit of use change it when less than 56 9mm 150CC 2 The clearance between the piston and piston pin Limit of use change it when ahove 0 005m 3 Checking any wearing damage inside the cylinder Cylinder gauge Vertical to piston pin and in X Y direction to measure cylinder bore from the upper middle and lower location Limit of use Change it when above 51 6mm 125CC 57 1mm 150CC 4 The maximum clearance between the cylinder and Limit of use Change it when above 0 1mm piston pin 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
18. to be operated by the valve spring contractor eTo assemble the cylinder head please follow the opposite procedure as above 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 56 990 57 010 57 100 0 005 Cylinder Cyiindrility 0 005 Roundness 0 005 Clearance b w Piston st ring 0 03 0 07 0 10 and 2 ring 0 02 0 06 0 10 Piston ring Cl Ist ring 0 10 0 25 0 50 A Mage LA ETT 0 10 0 25 0 50 Piston ring side ring 0 2 0 7 Piston outer diameter 56 975 56 990 56 90 Measuring location of piston outer dia Se Clearance b w piston and cylinder 0 025 0 035 0 10 Piston pin hole inner dia 15 006 15 012 15 030 Piston pin outer diameter 14 990 14 992 14 96 Clearance between piston and piston pin 0 020 0 017 0 025 Connecting rod small end inner dia 15 010 15 028 15 060 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 Engine overheating abnormal noise 1 piston tip has too much carbon accumulated c Abnormal pisto
19. 3 Compression pressure is too high There is too much carbon accumulated in the combustion chamber 4 There is white fume coming out from the exhaust pipe The valve stem or valve guide pipe is worn out Valve stem s oil seal is damaged B The operation data information Description IN EX Standard Value Limit of use mm mm Clearance between adjuster tapped IN 0 08 Screw and valve stem EX 0 08 Before warm up Compression pressure throttle open full 12k 750rpm 125CC 11kg 700rpm 150CC IN 26 3 125CC 25 9 125CC Height of the cam s convex part 26 625 150 SE 26 3 125CC 25 9 125CC 26 53 150CC 26 13 150CC Inner diameter of rocker arm shaft HN 10 00 10 015 10 10 10 00 10 015 10 10 IN 9 972 9 987 9 91 Outer diameter of rocker arm shaft EX 9972 9 987 9 91 Valve base angle IN amp EX 1 0 1 8 Outer diameter of valve stem IN 4 975 4 200 2 70 EX 4 955 4 970 4 90 Inner diameter of valve guide 3 000 5 012 7 EX 5 000 5 012 5 30 Clearance between valve stem and IN 0 010 0 037 0 08 Valve guide EX 0 030 0 057 0 10 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 mark on the flywheel point to the crankcase mar
20. 507 T CHASSIS GROUND LIGHTING SWITCH B R Black witch Red tracer B Black IGNITION COIL Blue witch Black tracer BI Blue BI W Blue witch White tracer Br Brown e a BI Y witch Yellow tracer Dark Green T Br W Brown witch White tracer Db Dark Blue E DU OW RA REAR LAMP G W Green witch White tracer Lb Light Blue TAIL LAMP 4 Gr Grey Orange 12V 5W 21W 1 R W Red witch White tracer Pi Pink L W B White witch Black tracer R Red Y B Yellow witch Black tracer W White Y Yellow Y G Yellow witch Green tracer B Wiring diagram for M2 125 150 E Sees 5 5 3 358g PB 5888 2 5 55 BEES 8 amp ee 55
21. A 5 10Hr or Rapid 3A 60min 125 150cc NOTICE This battery is totally sealed Do not remove seal bolt when recharging Notice Keep away from fire when recharging The ON or of recharging currency must be operated by the switch of recharge It will cause spark or explosive if plug or unplug the cable directly 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 Connect currency meter between red white cable and fuse While testing the red wire cable must not touch the frame Starting Switch d Set the head lamp switch at OFF engine revolution is at 2000 rpm while testing Then increase the rpm slowly Assume the battery is fully charged situation Head Lamp Switch Recharging rpm 2 500rpm 6 000prm OFF DAY Under2 000rpm 0 6A MIN 1 5A MIN ON NIGHT Under2 000rpm 0 6A MIN 1 5A MIN e If the testing result does not match the standard value check the regulator 3 Recharge system A Recharge system diagram for M2 50 regulator white mE red white yellow Head lamp switch 8A fuse battery Generator 3 c PNE S rear lamp JI Head lamp 18 18w Head lamp Hi light indicator
22. METER a d z z NONE REM METER OVERTAKING SWITCH o 5 PEP Ba OVERTAKING SWITCH BrHI LO LAMP SWITCH 5 2g 5 H STARING SWITCH POMON LAMP 2 2 25 X RH STARING SWITCH HEAD LAMP SWITCH oic ENGINE EXTINGUISH SWITCH FREE FREE 7 Re EC aly vel ed 65 G R 9o ototo FREE RUN oto of o BL ch Dj m B 75 to 64 59 nge 61 i LbO ss 56 2 129 GP B lg GWB _ P gt BW 74 73 79 B 57 es _ L 11 BW 99 OBr w y Cw 2 Lb 29 BIBAW 4 OIL GAUGE L 9 15 Les 4 eoo X DIODE 17 LAMP BALANCE RESISTOR HORN 78 79 RESISTOR DC12V B L Li j DON 9 SS LH FR SIGNAL LAMP AUTO CHOCK RESISTOR MANE LOW t 119 FR SIGNAL LAMP B 12V 10W 121 B STARTER RELAY 88 R 25 DC12V SN 43 ae 3808 MAIN SWITCH oa 2 at c E 85 36 FLASHER RELAY 34 BIZY 16 T CDI UNIT CZ G R DIODE 14 89 E 0 9 ik OUTPUT I PUSLE 39 VOL REGULATOR Be xY GENERATOR R W t 4 Y W 13 B i1 FU j BATIERY 4 R W Ig AUTO CHOCK 7 30 H 34 G B 124 1 91 1 d FUEL GAUGE Sr HELMET CASE o MODEL 2 50 2 L Ee 1 B LIGHTING LAMP 28 B P Lb Dg Br B 57 12 10 HELMET CASE 3 q 4 R 29 25 22 20 19
23. PREFACE This manual provides every service specialist with professional techniques of maintenance and repairing for ALLORO It provides a detailed guide for those who may concern with how to maintain repair reassemble and change parts of their scooters This manual includes 3 kinds of engine displacement G MAX 50 ALLORO 50 abbreviated as M2 50 is 2 stroke engine 2T 50cc displacement GMAX 125 ALLORO 125 abbreviated as M2 125 is 4 stroke engine 4T 125cc displacement G MAX 150 ALLORO 150 abbreviated as M2 150 is 4 stroke engine 4T 150cc displacement At every section we illstrate each important point by assembling procedures explosive diagrams and photographs Although we have tried our best to make this manual as perfect as possible please kindly inform us if any fault needs to be corrected in this manual Thank you for purchasing our PGO scooters FACTORY Motive Power Industry Co Ltd CONTENTS Page The specification of ALLORO Service information 1 The operation notice 2 Locking torque value 3 Lubrication instruction 4 Periodical maintenance table 5 Troubleshooting Checking and adjustment 1 Regular checking table 2 Battery 3 Cleaning 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 Fr
24. SY EJ P SETE wile AS FUEL FLOW DIRECTION 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 8 When re assembling please follow the opposite procedure of disassembling Locking torque 1 0 1 2kgf m S a m 2 ra lt Oil tank disassembling diagram only available for M2 50 Oil Gauge Oil Tank 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 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 check spark plug 3 check H T cable and H V coil 4 check C D I set 5 Starting system 1 the wiring of starting 2 checking the starter 3 d
25. The cutting section of three rings must be arranged at intervals of 120 7 Generator A Dismantling AC generator B Installing AC generator 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 B Installing AC generator To install please reverse the dismantling procedure Locking torque M6 1 0 1 2kg m M12 3 2 4 0kg m 8 transmission mechanism A Troubleshooting B Dismantle the final transmission mechanism C Check the final transmission mechanism D Assemble the final transmission mechanism A Troubleshooting eEngine can be started but the vehicle doesn t move 1 Gear worn out or cracked 2 Gear burnt out eNoise occur when running 1 Gear worn out burnt or gear surface 2 Bearing worn out of loosen leakage 1 Too much oil 2 Seal worn out or damaged Disassemble the final transmission mechanism 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 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
26. 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 Lock the draining bolt before refill 90c c gear oil and then lock the filling bolt e Locking torque 1 8kg m Draining Filling Bolt Note Be sure the crankcase tire or wheel are cleaned if there is grease oil on it 5 Spark plug Remove spark plug 2 Check the spark plug electrode and check if it is Burnt out or not and carbonized or not 3 Clean the electrode whether it is dirty 4 Spark plug specification G MAX50 BP7HS NGK or equivalent spec G MAX125 150 C7HSA NGK or equivalent spec Gap of spark plug 0 6 0 7mm Electrode burn out Carbon piled up Washer is Distorted or not Procelain is Cracked or not 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 50 6 kg c O 600rpm 125cc 12 kg c 750rpm 150cc 11 kg c 650rpm 6 when the compression pressure is too low check the following a cylinder head gasket cracked b piston cylinder worn out c piston ring worn out 7 the compression pressure is too high it may be due to the carbon piled up on combustion chamber and piston tip 7 Ignition timing
27. austing air Air cleaner Locking torque Cylinder head Cylinder cylinder cold head inlet pipe lockin S 1 0 1 2KG m 9 Condition a E inlet pipe cold E 1 0 1 2kg m Compression Using Pressure 6kg c starting Compression E Using E Pressure 12kg e 0 starting 125 750rpm motor Compression Using 3 Pressure 11kg c starting S G MAX 150 650rpm motor S E Oil leakage o o o o o Le 3 d Oil quantity 8 5 Dirty S o Oil quantity o E Oil filter 3 blocked Fuel quantity Fuel leakage Clean Carburetor d 9 Carburetor s lt Throttle and 8 Choke function Carburetor Float height Carburetor Adjustment Change fuel pipe every 4 years Checking period gen era first home office Item 1 month every6 12 even even everyl2 Judgement Remark che cki H months months months months months standard ng Initial or or or or or 300km 5000km 10000km 1000km 2500km 10000km Function 2 Q 9 Q 9 Lamp system e m 6 D o Dirty or broken Horn signal Function Lamp reflector lock Function Rear view Dirty or broken mirror License plate Dirty or damaged
28. d main wiring disconnected wrong wiring connection Remove oil gauge Check the lamp light i Up or not by moving i The float Float upward lamp Extinguishes Cfloat faulty iL gauge switch dis Float downward lamp turn on connected or short circuit b Oil is enough but the indicator turns on all the time when the main switch is ON Check and adjust Trouble condition plug plug is loose Good Disorder drop off Remove oil gauge wiring disconnected Check the lamp by ko e Moving the floating Ofloat faulty Good Disorder oil gauge switch e disconnected or short circuit Float upward lamp Extinguishes oil tank distorted Float downward lamp some impure material Turns on dropping in 10 Fuel indication malfunction a wrong fuel level indication when the main switch is ON Check and adjust Trouble condition j Turn the signal lamp On check wiring of battery Ofuge burn out battery has no power Lamp dims light Not flash not light main wiring disconnected Remove the fuel gauge i Moving float up and Down to check i The needle movement Float abnormal Indicator moves Indicator no motion Do the short and opening Circuit test on the fuel i Gauge plug which connect To wire harness Check the i indicat
29. e adjusting screws Note Fuel volume adjusting screws have been set up properly before sale thus there is no need for self adjustment However when dismantling a record of the turning loop has to be dept for future assembling purpose Put up the center stand while adjustment 1 After the engine is warm up adjust the stopping screw throttle of throttle valve to the standard rpm Idle rpm 1 700 100rpm 2 Adjust the fuel volume adjusting screws to the highest stable rotation This rotation value is the optimum setting of throttle 3 Fuel up for several times make sure that the idle rpm is within the standard rpm Repeat the above procedure if the idle rpm is unstable C The float nozzle 1 Dismantling eRemove the screws to take off the float chamber eRemove the float the float pin and float valve 2 Checking eCheck the float valve valve base to see whether it is blocked or damaged eCheck the float valve valve base surface if sectional worn out or dirty Note When the valve is too dirty or severely worn not the Valve base will not close completely thus will result In increasing of fuel level and fuel leakage problem A new replacement is needed eRemove the main jet needle jet base needle jet slow jet and fuel adjusting screws O Note eAvoid any damage on the jets and the fuel adjusting main jet s screws P eBefore dismantling record the number of turning loops eNo screwing
30. f use change it above 125 5mm b Check clutch lining wearing condition and Measure the lining thickness elimit of use change it below 1 5mm c Check driving spring free length Standard 151mm Limit of usage Change it below 127 mm d Check wearing condition of driving plate sets And measure outer diameter elimit of use change it above 33 95mm e Check wearing condition of slide driven plate And measure its Inner diameter elimit of use change it above 34 00mm f Check is there any wearing occur to the ditch g Check wearing condition of oil seal if necessary change a new one 5 Cylinder head and valve A Trouble shooting B The operation data information C Dismantling and installing 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 Valve being burned out or bent Valve burned or damaged spring Valve timing is not correct Camshaft is worn out Valve spring is damaged Chain adjuster is worn out Poor sealing of valve base Camshaft valve rocker arm is worn out Leakage in Cylinder head gasket Cylinder head twisted or cracked Spark plug is not properly installed
31. heel 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 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 2 Install the oil pump shaft Note The notch of the oil pump shaft should comply With the notch of the inner gear outer gear inner gear 3 Install the lock pin 4 Match the lock pin hole to the pump cover and install the oil pump cover 5 Put on the screws and tighten them 6 After installing turn the shaft lightly Oil pump to assure installation am Lock pin Cover 7 Place the oil pump into the crankcase Note When installing the arrow on the oil pump body should be pointed upwards Then fill in the recommended oil before the installation 8 Tighten the oil pump after installation Measurement data Standard Value Limit of use item mm Clearance between the inner gear 0 12 And outer gear Oil 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 b
32. hers 3 Lubrication instruction a For engine b For chassis c Wheel bearing 4 Wiring diagram 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 amp driven pulley 6 Handlebar steering was astray when running 7 Front and rear damper not balanced 8 Brake disorder 9 indicator malfunction 10 Fuel indicator malfunction 11 Starting motor malfunction 12 No sparking 13 Charging abnormal 1 The operation notice 1 For parts like the gasket o ring clips and circlets please change a new part whenever re assembled 2 When trying to tighten screws or nuts please lock tightly according to each recommended locking torque and in the sequence of the 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 5 Use grease recommended by P G O 6 When removing the battery please disconnect the negative pole first However please connect the positive pole first when assembling 7 Before installing a new fuse please be sure that the specification is correct 8 After reassembling please re confirm that all connecting point locking parts circuits polar characteristics are functioning well before selling out 2 Locking Torque Value 1 2T Engine 50CC No
33. if D Fuel feeding system ALL Crack and blockage check e Replace it if necessary Engine idle speed ALL 2T engine 1900x100 rpm 5 2 2 engine 1700x100 rpm Carburetor idle A F ALL Check and adjust referring to 5 4 E E e Adjustment CO HC Percentage NOTE 1 Items with mark indicate our recommendation to have it done by PGO dealer 2 A denotes that function check or replace it when the engine performance reduces significantly 3 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 5 Trouble shooting 1 difficult starting or can t start Check and adjust Trouble condition Loose carburetor draining Screw check if in side of Carburetor have fuel or not The fuel supply in carburetors Ts enough or smooth chleck there is fuel or not ipe between ful tank and No fuel supply in carburetor is blocked carburetor at is blocked gauge is blocked ump is malfunctioned Remove spark plug insert i Spark plug cover and touch With engine check there is i Any spark k plug out of order CD unt out of order generator out of order nition coil disconnect or hort circuit Gipgnition coil disconnect or There is sparking No sparking or short circuit In spark plug Weak sparking
34. ilter 0 8 Nut LH thread one way clutch 9 0 10 0 Cap coarse oil filter 1 5 2 0 3 Chassis Thread dia Locking torque mm kg m 0 6 0 8 1 0 0 8 1 0 0 5 0 6 2 0 3 0 2 5 3 0 3 5 4 5 3 5 4 5 3 5 4 5 4 5 5 0 3 0 4 0 2 5 3 0 4 5 5 5 4 5 5 5 10 0 11 0 Locking location 1 Air bleed bolt of caliper 2 Brake arm bolt front drum 3 Brake arm bolt rear drum 4 Nut of starter relay 5 Front brake caliper bolt 6 Bolt of disk 7 Locking nut steering stem 8 Rear shock absorber bolt lower 9 Rear shock absorber bolt upper 10 Chassis bolt engine hanger bracket 11 Engine bolt engine hanger bracket 12 Hose bolt master cyl amp caliper 13 Front axle nut 14 swing arm amp connecting rod La 14 axle nut 4 Other parts standard torque values oe kg m 1 Smmboltandnut 045 0 6 2 ban and nut 0812 3 Bmmboltandnt 1825 4 10mm bolt and nut 3 0 4 0 5 Dmmboltandnut 59 60 6 LL 03505 7 Gmmseew _ 0714 8 flange bolt and screw 10 14 9 Dem flange bolt and screw 1 0414 10 8mm flange bolt and 2 0 3 0 11 10mm flange bolt and screw 3 0 4 0 3 Lubrication instruction A 2T Engine 50 cc
35. in movement by force to avoid any damages eUse the detergent solution to clean the jets Fuel ecd UM nr Fuel adjusting f adjusting Screw After cleaning off the blockage and the dirt screw blow dry by compressed air Note Remove the vacuum and air interrupt valve for Cleaning 3 Assembling eAssemble the slow jet needle jet main jet and fuel adjusting screws eNotice Record the number of turning loops before dismantling eAssemble the float valve float and float pin 4 Checking fuel level Notice eCheck after the checking on the float valve and the float is done ePut the float gauge on the float chamber perpendicularly to the main jet for measurement 12 Fuel tank 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 auto cock is over swell 2 The membrance of auto cock is over extended a Fuel tank cover s ventilation hole is blocked b Fuel pipe is crooked squeezed or blocked c Auto cock and fuel filter is dirty B Fuel supply system diagram EN WE 2 FUEL TANK CAP a FUEL PUMP Uel FILTER AS
36. ing is not smoothly driven plate spring distorted riven lining worn out driving pulley shaft gear teeth cked final gear damage iven lining spring cracked or worn out weight rollers melt and stick to iving face shaft worn out driving belt worn out distorted or slipping Can t reach high speed weight roller worn out driving plate worn out driving plate spring distorted JQOdriving pulley shaft worn out driving belt worn out or slipping Noise or bad smell when running weight roller worn out driving pulley shaft worn out adherent grease on driving belt pulley driving belt worn out driven plate spring distorted iving pulley shaft worn out 6 Handlebar steering astrayed when running Trouble condition The reason front and rear wheel pressure are normal column lock screw locked too Handlebar operates heavily tly steel ball cracked SEENEN front wheel bearing swings __ Front and rear wheel swings front rear wheel rim distorted loosen front axle nut Handlebar astrayed to one direction front and rear wheel center not well digned front fork crooked 7 Front rear damper not in balanced Trouble condition The reason ts front and rear wheel pressure is normal amper spring is too soft Damper is too soft ca
37. ing worn out Pressure is normal Pressure is inder gasket leakage Not normal cylinder body has sand hole eed valve malfunction 2T engine Check carburetor i Is blocked not blocked Clean the carburetor 7 7 leamthe dirt No dirty and no color change Dirty color change specification is not correct For 4T engine only Check the oil level in crankcase i Is too much or dirty Oil level is normal j Check the lubrication i of cylinder head level is too high Oil level is Not normal Tevel is too low Gail does not interchange Or not Running accelerately or High speed continuously overheat No knocking knocking oil route is blocked insufficient oil pumping from ibpump Opiston and cylinder worn out D mixture is too lean ad quality of the fuel Dtoo much carbon in the combustion room ignition timing is too early too much carbon in the combustion room quality of the fuel lip is too lean timing is too early 3 Engine running unsmoothly low speed and idling Check and adjust Check if there is air i Leakage on carburetor gasket Trouble condition The reason Correct Good adjustment Faulty Not correct OCDI faulty Not correct A erator faulty
38. ismantling the starting motor 4 checking the starting motor 1 Troubleshooting A Recharge system No power Battery over discharging ONo electrolyte in battery Battery is bleached Short circuit in the Battery Regulator malfunction 2 The battery wires are disconnected 3 Fuse is broken 4 Ignition switch is abnormal Voltage is too low Battery recharges insufficiently 2 The bad connection on wiring system 3 Recharge system is abnormal 4 Regulator malfunction B Ignition system The sparking of spark plug is abnormal 1 Spark plug is dead 2 Wire connectsion is broken or short Circuit Obetween generator and CDI sets between CDI sets and High Voltage coil Gbetween CDI sets and main switch Gbetween main switch and spark plug 3 Main switch is out of order 4 H V coil is not in good function 5 CDI sets is out of order 6 A C generator is not in good function C Starting system eStarting motor can t rotated The fuse is broken 2 Battery recharges in sufficiently 3 Main switch is out of order 4 Starting motor switch is out of order 5 Front rear brake switch is out of order 6 Starter relay is out of order 7 Wire disconnects or broken 8 Starting motor is out of order Currency is unstable The wiring of batter connection is not good 2 Ignition system connection is not good 3 Ignition system is short circuit 4 Lamp system connection is not good or short circu
39. it Abnormal recharge system 1 The plug connection is not good wire broken or short circuit 2 Rectifier is out of order 3 A C flywheel magneto is abnormal D Engine running unsmoothly Ignition primary circuit D the wire or plug of wiring connection is not good OQ main switch disconnects 2 Ignition secondary circuit Olgnition coil is not in good function Spark plug is dead GH V coil is not in good function G The spark plug cap is not in good function 3 Ignition timing generator is out of order A C coil is not in good function GC D I sets is out of order eStarting motor runs weakly Battery recharges insufficiently 2 Wiring system disconnects 3 The alien objects drop in the motor or gear Starting motor can rotate but engine can t start up 1 Starting gear is abnormal 2 Starting motor is reversedly rotating 3 Battery is out of order 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 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 7
40. k and make the round hole on the cam chain gear point upwards This is the upper dead point of compression 5 Take off the cam shaft holder the nut and the locking pin 6 Remove the cam gear from the cam chain 7 Remove the cam shaft 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 90 125 26 23mm 150CC EX replace it below 25 90 125 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 out NOTICE Do check if there is any damage the cam rocker arm Sliding surface 2 Cam shaft holder and cam rocker arm outer dia measurement Limit of use replace it above 10 10mm 3 Cam rocker arm inner dia measurement Limit of use replace it above 10 10mm 4 Cam rocker arm shaft and rocker arm outer dia measurement T imit of use renlace it helow 9 91mm 5 Clearance between the Cam rocker arm and rocker arm shaft Limit of use replace it above 0 10mm WHEN INSTALLING 1 The mark EX on the cam shaft holder is the exhaust rocker arm one way stopper nstall the exhaust rocker arm the inlet rocker arm and the rocket arm shaft NOTICE a The tangen angle of the heat side of i
41. kcase 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 2 Measure the swing ness of the crankshaft journal Limit of use A B Change it when above Change it when above 0 1mm 0 1mm 3 Check the looseness of crankshaft bearing If it is loosen replace to a new one Crankshaft bearing Assemble crankcase 1 crankcase according to the opposite procedure of disassembling 2 The locking torque of bolts and nuts are described in previous chapter please refer 10 Carburetor A Troubleshooting B Dismantling the carburetor C 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 LD NO 013 046 Idle r min 1700 100 1700 100 Float height 18 0 0 5 mm 18 0 0 5 mm Main jet 102 102 Jet needle 4HGGN 4HLGL Needle jet P O P O Pilot jet 35 35 Pilot screw PRE OPENING 2 1 4 turns out 1 1 2 turns out Troubleshooting e 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
42. lever Clearance 10 20mm 2 1f the clearance is beyond standard check whether a The air mix into the pipe caliper b The oil brake system is leaking Note Try brake lever to see if it s loose Check the brake fluid Once air mixed in The fluid pipe which will reduce or Damage the brake efficiency or even its Function 3 check the fluid level a Refill the brake fluid when the level is under the LOWER line b Brake fluid specification SAE J 1703F DOT3 amp DOT4 Note a To prevent the fluid splitting onto the parts or clothes put a piece of cloth on the bottom when refilling b Be caution not to mix water or particles into the master cylinder when refilling c Never use the fluid not complied with spec d In case the fluid stains on the eyes wash with water at once and then ask for medical care immediately 11 Rear brake adjustment drum brake only 1 Check the clearance Of rear brake lever Clearance 10 20mm 2 1 the clearance is beyond the above standard Adjust it by rotating the screw a Left handed rotation enlarge the clearance b Right handed rotation reduce the clearance Note When the arrow of rear brake indicator align with the arrow of left crankcase change the brake lining 12 Tire 1 Check the tire air pressure when it s cold 2 Tire pressure Front tire 2 0 kg c Front 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
43. n Voltage higher Volt Check the connection Lee Of the cable of Voltage rectifier q poor connection poor connection of green cable Check the resistivity Of the body of Voltage rectifier rectifier faulty 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 1 Regular checking table 1 O 2 mark indicates periodical checking indicates changing the parts Checking period gen era first home office d Item 1 month 12 everyl every3 everyl2 Judgement Remark che cki 91 months months months months months standard ng Initial 300km 5000 10000km 1000km 2500km 10000km Handlebar Loose or swing steering Operation o o o o o o g column Turning angle 9 9 Damaged 2 A NN Check from front fork Shaft fixed condition s 9 Stering column Shaft loose check froni Stering column Clearance a clearance Front 10 20mm Lever Rear b movement of brake
44. n noise 1 Cylinder and piston worn out 2 Piston pin hole or Piston pin worn out 3 Connecting rod small end or bearing worn out d Abnormal piston or cylinder noise 1 Piston ring worn out or cracked 2 Cylinder worn out or cracked B The operation notice 1 Clean before operation to avoid particles dropping into the engine 2 The contact surface of gasket must be clean 3 Dismantle cylinder and cylinder head by screw driver Do not injure the contact surface 4 Cylinder inner surface and piston outer face can t be injured Contact Surface should lubricate by specified oil C Data 125CC Part name description Standard value Limit of use mm mm Bore 51 490 51 510 51 60 Curve 0 005 Cylinder Cyiindrility 0 005 Roundness 0 005 Clearance b w Piston st ring 0 03 0 07 0 10 and 2 ring 0 02 0 06 0 10 Piston ring Cl er Ist ring 0 15 0 35 0 50 o Meee e EE 0 15 0 35 0 50 Piston ring side ring 0 2 0 8 Piston outer diameter 51 460 51 480 51 40 Measuring location of piston outer dia D Clearance b w piston and cylinder 0 025 0 035 0 10 Piston pin hole inner dia 13 022 13 013 13 045 Piston pin outer diameter 12 996 13 00 12 96 Clearance between piston and piston pin 0 02 0 017 0 025 Connecting rod small end inner dia 13 015 13 028 13 060 D Dismantling a Dismantling Cylinder 1 Remove the cylinder head 2 Remove 2 bolts then the camshaft
45. ntake valve s rocker arm shaft is to match with the bolt of the cam holder b The tangent angle of the exhaust valve s rocker arm shaft is to match with the bolt of the cam holder 2 Turn the flywheel to make the T mark pin correctly The hole on the cam chain gear should point upwards Both the left and right concave points and the cylinder head are at parallel position convex part of cam shaft points upwards then install the cam shaft on the cylinder head 3 Install the cam chain onto the cam shaft gear 4 Install the locking pin 5 Install the camshaft holder washer and nuts on the cylinder head 6 Lock tightly the cylinder head nuts Locking torque Cam shaft holder nuts 2 0kg m NOTICE a Put some grease on the bolt thread of cam shaft holder b Lock the nuts of the cam shaft bracket in cross sequence for 2 3 times 7 Adjust the valves clearance 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 eNot to injure the contact Surface of the cylinder eAvoid any object dropping info the engine Further dismantling eUse the valve contracting tool to remove valve pin supporter the vlave spring collar valve spring and valve stem oil seal Notice eValve Spring has
46. ody Troubleshooting Reduction in fuel oil volume a Natural consumption b Leakage of fuel c Piston loop seizes or improperly install ation d Worn out of valve s oil seal Engine burning out a Zero or too low oil pressure b Blockage in oil route c Did not use the fuel oil recommended A Dismantling engine 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 6 Remove the rear section of muffler dismantle the 2 bolts of rear brake caliper then remove the rear brake system assembly away from rear fork 7 Loosen bolts of upper amp lower engine hanger 8 Remove the engine B Installing Engine 1 To install engine please reverse the Above procedures 2 Locking torque M8 2 0 3 0kgf m M10 3 3 0 4 0kgf m 12 3 5 0 6 0kgf m 3 After installing pleas do the following Checking and adjustment a Wiring for each circuit b Throttle cable c Rear brake check d fuel and oil route 2 Drive pulley starter clutch driven pulley A Troubleshooting B Measurement data C Driving pulley D Starter E Clutch driven pulley A Troubleshooting a Engine starts but vehicle don t move 1 driving belt worn out 2 driving plate worn
47. ont brake adjustment 11 Rear brake adjustment 12 Tire Dismantling maintaining repairing and assembling operation 1 Plastic parts 2 G MAX 50 Engine dismantling A Lubrication system Drive pulley starter clutch Cylinder and piston AC generator Final transmission mechanism 2 DD a Crankcase crank shaft Q Carburetor reed valve 3 G MAX 125 150 Engine dismantling A Lubrication system Drive pulley starter clutch Cylinder and piston AC generator Final transmission mechanism pa Cc p Crankcase crank shaft G Carburetor 4 Engine amp chassis suspension 5 Steering column front wheel front brake comp front fork 6 Rear wheel rear brake rear damper 7 Fuel tank oil tank 8 Reverse Differential gear comp Electric equipment 1 Troubleshooting 2 Battery 3 Recharge system 4 Ignition system 5 Starting system 6 S witch operation 7 Wiring diagram 1 1 50 SPECIFICATION BRAND PGO FRAME STEEL PIPE MODEL M2 50D 2 2 FRONT TELESCOPE 2 1855 REAR SWING 2 WIDTH 730 mm 7 PRIMARY DIRECT z HEIGHT 1170 mm 2ND 52 13 44 13 AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL FRONT 47 KG SHIFTING V BELT C V T S REAR 58 KG FRONT 120 70 12 E TOTAL 105 KG E REAR 130 70 12 z PASSENGER 2 110KG 5 FRONT DISK FRONT 82 KG e DRUM REAR 133KG SPEEDOMETER 80 km hr TOTAL 215 KG HEAD HIIILO 12V 35W 35W Z TOP SPEED
48. or movement Indicator on Fuel gauge abnormal motion Gelectric plug dropped off connection abnormal Indicator moves ire broken or short circuit b Fuel gauge needle is not steady and sometimes moves up and down when the main switch is ON Check and adjust Trouble condition Turn signal lamp on Check wiring of battery 1 N o Aifrswitch abnormal norma 9 Mougn it plug dropped off or Remove the float Na s iring disconnected Move up down to Check the needle s movement Ae moves ee t et contact normal Move needle up and Down quicklyI Second check the Needle s movement Indicator Indicator no I SC TONES movement nsufficient or no damping Oil inside the fuel gauge Check electric plug Connecting condition electric plug drop off or good abnormal lodse broken or short circuit 11 The starting motor abnormal a Starting motor can not rotate Check and adjust Trouble condition Ofuse burn out ery has no power lain switch abnormal circuit plug dropped off Gmain wiring disconnected Brake lamp Lights up Brake lamp no light Tumsignallamp No to check wiring Of battery normal Lamp does not has no power Flashing no light
49. 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 2 Driving plate spring distortion 3 Weight roller worn out 4 Driving plate dirty Note No grease and oil should be distributed over driving belt and driving plate B Measurement data Item Standard value mm Limit of use mm The inner dia Of slide driving 24 011 24 052 plate The outer dia Of boss movable 23 960 23 974 23 940 Driving plate Belt width 20 0 21 0 19 0 Clutch lining thickness 3 15 Clutch outer inner diameter 125 0 125 2 125 5 Driven plate spring free length 151 127 The outer diameter of driven 33 965 34 025 33 95 Plate sets The inner diameter of slide 34 000 34 025 34 06 Driven plate The outer diameter of weight 17 920 18 080 17 40 Roller set 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 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 fo
50. place it per 1000km Oil Filter ALL Replace o Clean per 5000km or replace it if required ES Se Clean or replace it if necessary o Clean it per 3000km or replace it if required Air cleaner ALL Clean or replace it if necessary Air filter ALL Clean or replace it if required Gear oil ALL Replace 90cc total 110 cc o o o o Disk amp drum brake ALL Leaking and function check o o o o o o Clutch shoes ALL Check or replace it if necessary Rear brake arm ALL Function check and adjustment Tires ALL check or replace it if Wheel bearing ALL Fasten tightly if loosen o o o o o o Front fork ALL Leaking and function check Steering head bearing ALL Check looseness Adjust it if o o o required Rear absorber ALL Leaking and function check o o o Main Side Stand ALL Function check or replace it if required Nuts bolts fasteners ALL Tighten it if required Battery ALL Make sure that the voltage stayed over 12 8V Recharge the i 9 9 9 9 e battery it required Clear the poles Valve gap 4T Check and adjust when engine m E is cool green for IN amp EX Adjust it when necessary Carbon cleaning 2T Clean combustion carbon when engine output reduced Spark plug ALL Clear or replace if required belt ALL Worn out check or replace
51. re refers to the opposite procedure of disassembling 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 8 Checking starter a Check the wearing condition of the outer diameter of spindle comp and the inner diameter of bush and gear b Check the wearing condition of shaft of driven gear comp Gear sets and ratchet 9 Assembling the starter Assemble the starter follows the Opposite procedure of dismantling Locking torque 1 0 1 2kg m Note sure one end of the torsion spring is hooked on the groove of driven gear and another end of torsion spring is hooked on the pole of inside of left crankcase Put some grease in every shaft and gear sets before assembly 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 Check clutch cover about its wearing condition And inner diameter measurement elimit o
52. rin D mage prng Condition Ass y part Loose or damaged o o o o o condition Connecting loose or o o AS Bracket loose o damage o o condition 2 Looseness 5 Suspension 3 nn Connecting Part Oil leakage Damaged Absorber Condition gt M Loose on ass y part Clutch and Function Shift mec LH crank hanism leakage 9 9 9 2 E case B 90C C replace Gearoil Ch ar oil Ze S THESES 110C C total Clearance 0 6 0 7mm Ignition Spark plug NCK BP7HS OR SAME SPEC Start Starting motor 5 E amp Mechanism gear D St Recharge 5 Wiring Function 2 e d Level between d ti ievel De 9 UPPER and Battery LOWER When 200 Electrolyte e mes Se Specific gravity gravity 1 270 1 290 Wire Looseness or Damage H circuit connection plug Checking _ period gen era first home office Jud Item 1 month every6 12 everyl every3 12 udgement Remark che cki H months months months months months standard ng Initial or or or or or 300km 5000 10000 1000km 2500km 10000km Performance Noise Low speed o o o Idling 1900 Acceleration 100rpm Check the Exhaustion o o o color of exh
53. rown witch White tracer Db Dark Blue 2 REAR LAMP REAR_LAMP G W Green witch White tracer Lb Light Blue E 12V 16W LAMP 12V 16W EN d grange 12V 21W 5W ed witc ite tracer i Pini W B White witch Black tracer R Red Y B Yellow witch Black tracer W White Y G witch Green tracer Y Yellow
54. rrying weight is too large damper oil leakage Damper is too hard Ofront fork guide rod crooked damper and damper cover cracked Damper has abnormal noise OQ problems in damper tube and spring damper and damper cover cracked 8 Brake disorder rouble condition ee eae Le epa ct DPI EE adjustment according to standard procedure Brake plate points Io mark Obrake lining worn out e lining cam worn out ake cam worn out brake hub worn out ake lining worn out unknow matenals attached on brake lining Contact surface of the wheel hub becomes ugh Noise when brake Faulty performance brake cable over stretching or moving unsmoothly contacting surface wi h brake lining does comtact 100 water or sand drop into brake mechanism some grease on brake lining surface 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 Turn the signal lamp On Check wiring Of battey Normal Lamp dims light does Not flash no light it plug dropped off main wiring disconnected Remove the oillamp i And connect with pee Battery directly i urn out Lamp lights Lamp does not light up electric plug is loose Good condition No good or disconnecte
55. rward Specified Engagement RPM 3100 300 rpm 6 Clutch LOCK UP inspection Apply the rear brake as firm as possible Briefly open the throttle fully and notice the maximum engine RPM sustained during the test cycle Specified Clutch LOCK UP 5200 400 rpm 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 Belt width worn out 2 driving belt width limit of use change it below 19mm 7 Disassemble slide driving plate set 1 Remove bush of slide driving plate 2 Remove screw and disassemble the cover of slide driving plate 3 Remove ramp plate 4 Remove weight roller 8 Checlomg 1 Check the wearing condition of Check the wearing condition weight roller Limit of use change it below 17 4mm 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 9 Assemble the slide driving plate 1 Clean up the inside surface of slide driving plate then assemble the roller 2 Assemble the ramp plate 3 Other procedu
56. tion Check the CDI plug Is loose or not Check the connection Between CDI plug and Each terminals check The resistivity of Omin switch faulty Each terminals defective magneto b M good abnormal bir pulse generator faulty defective ignition coil good abnormal cable broke connection of joints or sockets good abnormal 4defective CDI IP SOS GENS Defective ignition coil abnormal 13 Charging abnormal battery over charging or over discharging Check and adjust Trouble condition Measure battery Voltage then start engine Voltage remain Voltage goes up The same To normal value But after engine Stop the voltage Goes down again loosen red eable dig Check the voltage i Between chassiseand i cable Jof Voltage rectifier Dvoltage rectifier No voltage malfunction white cable disconnect Check the resistivity Of A C generator coil connection generator s charging abnormal over charging white Start engine connect measure the voltage between chassisO and red cable o voltage of ONE disconnected reen cable to hassis the
57. y a Find the control coil by measuring the b Connect green white cable to positive pole of negative pole of battery It means starter is and both Red Black cable of staring motor have 3 Dismantling the starting motor a Remove 2 screws on starting motor b Remove starting motor cables resistance battery connect black cable of function well if above connection currency passing through 4 Checking the starting motor Check the function by connecting the starting motor to battery Check if it is rotating counter clockwise Note Do not operate starting motor for a long time Wiring diagram for M2 50 3 RE d zz E S 8 828 OI INDICATOR HORN SWITCH SIGNAL LAMP SWITCH lt S 2 S ENGINE RPM
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