PGO G MAX 50 125 150 Scooter Full Service & Repair Manual

Manufactured by Motive Power Industry Co., Ltd

PREFACE This manual provides every service specialist with professional techniques of maintenance and repairing for G-MAX (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: z G-MAX 50 (ALLORO 50): abbreviated as “M2-50” is 2 stroke engine (2T), 50cc displacement. z G-MAX 125 (ALLORO 125): abbreviated as “M2-125” is 4 stroke engine (4T), 125cc displacement. z G-MAX 150 (ALLORO 150): abbreviated as “M2-150” is 4 stroke engine (4T), 150cc displacement. z G-MAX 200: abbreviated as “M2-200” is 4 stroke engine (4T), 200cc displacement. z G-MAX 220: abbreviated as “M2-220” is 4 stroke engine (4T), 220cc displacement. z G-MAX 250: abbreviated as “M2-250” is 4 stroke engine (4T), liquid cooled, 250cc displacement. At every section, we illustrate 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 Ⅰ.The specification of G-MAX (ALLORO) Ⅱ.Service information (1)The operation notice (2)Locking torque value (3)Lubrication instruction (4)Periodical maintenance table (5)Troubleshooting Ⅲ.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)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. (8)Carburetor, reed valve C. G-MAX 125/150 Engine dismantling (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 (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 (7)Wiring diagram 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

1.1 G-MAX 50 SPECIFICATION BRAND PGO FRAME STEEL PIPE MODEL M2-50D FRONT TELESCOPE LENGTH 1885 mm SUSP ENSI ON REAR SWING WIDTH 730 mm PRIMARY DIRECT HEIGHT 1170 mm 2ND 52/13*44/13 DIMENSION AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL FRONT 47 KG TRANSMISSI SHIFTING V-BELT C.V.T REAR 58 KG FRONT 120/70-12 GROSS TOTAL 105 KG TIRE REAR 130/70-12 PASSENGER 2 (110KG) FRONT DISK FRONT 82 KG BRA KE REAR DRUM REAR 133 KG SPEEDOMETER 80 km/hr WEIGHT TOTAL TOTAL 215 KG HEAD(HI、LO) 12V-35W/35W TOP SPEED 60 km/hr REAR 12V-5W FUEL CONSUMPTION 45 km/l BRAKE 12V-21W PERFORMAN GRADIENT 19° LIGGHT SIGNAL 12V-10W*4 ENGINE MODEL P2 HORN DC 12V FUEL 92 UNLEADED SILENCER DIFFUSER STROKE 2T AIR FORCED PARTICLE BELOW 15 % BORE φ40.0 mm CO BELOW 4.5% STROKE 39.2 mm EXHAUS HC BELOW 7000 ppm CYLINDE CYLINDER SINGLE EXHAUST LAYOUT RIGHT DISPLACEMENT 49 cc LUBRICATE SEPARATE PUMP C.R. 6.8：1 FUEL TANK 7.5 L MAX H..P. 3.5kw/7000rpm MAX TORQUE 5.0N-M/6500rpm LAYOUR HORIZONAL IGNITION CDI ENGINE STARTING ELECTRIC & KICK

1.2 G-MAX 125 SPECIFICATION BRAND PGO FRAME STEEL PIPE MODEL M2-125 FRONT TELESCOPE LENGTH 1885 mm SUSP ENSI ON REAR SWING WIDTH 730 mm PRIMARY DIRECT HEIGHT 1170 mm 2ND 43/14*42/13 DIMENSION AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL FRONT 54 KG TRANSMISSI SHIFTING V-BELT C.V.T REAR 76 KG FRONT 120/60-13 GROSS TOTAL 130 KG TIRE REAR 130/60-13 PASSENGER 2 (110KG) FRONT DISK FRONT 94 KG BRA KE REAR DISK REAR 146 KG SPEEDOMETER 140 km/hr WEIGHT TOTAL TOTAL 230 KG HEAD(HI、LO) 12V-35W/35W TOP SPEED 84 km/hr REAR 12V-5W FUEL CONSUMPTION 40 km/l BRAKE 12V-21W PERFORMAN GRADIENT 21° LIGGHT SIGNAL 12V-10W*4 ENGINE MODEL C1M HORN DC 12V FUEL 92 UNLEADED SILENCER DIFFUSER STROKE 4T AIR FORCED PARTICLE BELOW 15 % BORE φ51.5 mm CO BELOW 4.5% STROKE 60.0 mm EXHAUS HC BELOW 7000 ppm CYLINDE CYLINDER SINGLE EXHAUST LAYOUT RIGHT DISPLACEMENT 124.9 cc LUBRICATE SEPARATE PUMP C.R. 9.2：1 & SPLASH MAX H..P. 6.5kw/7500rpm FUEL TANK 7.5 L MAX TORQUE 9.1N-M/6250rpm LAYOUR HORIZONAL IGNITION CDI ENGINE STARTING ELECTRIC & KICK

1.3 G-MAX 150 SPECIFICATION BRAND PGO FRAME STEEL PIPE MODEL M2-150 FRONT TELESCOPE LENGTH 1885 mm SUSP ENSI ON REAR SWING WIDTH 730 mm PRIMARY DIRECT HEIGHT 1170 mm 2ND 42/15*42/13 DIMENSION AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL FRONT 55 KG TRANSMISSI SHIFTING V-BELT C.V.T REAR 77 KG FRONT 120/60-13 GROSS TOTAL 132 KG TIRE REAR 130/60-13 PASSENGER 2 (110KG) FRONT DISK FRONT 95 KG BRA KE REAR DISK REAR 147 KG SPEEDOMETER 140 km/hr WEIGHT TOTAL TOTAL 242 KG HEAD(HI、LO) 12V-35W/35W TOP SPEED 87 km/hr REAR 12V-5W FUEL CONSUMPTION 40 km/l BRAKE 12V-21W PERFORMAN GRADIENT 24° LIGGHT SIGNAL 12V-10W*4 ENGINE MODEL C5M HORN DC 12V FUEL 92 UNLEADED SILENCER DIFFUSER STROKE 4T AIR FORCED PARTICLE BELOW 15 % BORE φ57.5 mm CO BELOW 4.5% STROKE 58.6 mm EXHAUS HC BELOW 7000 ppm CYLINDE CYLINDER SINGLE EXHAUST LAYOUT RIGHT DISPLACEMENT 152.1 cc LUBRICATE SEPARATE PUMP C.R. 9.4：1 & SPLASH MAX H..P. 7.7kw/7250rpm FUEL TANK 7.5 L MAX TORQUE 10.6N-M/6250rpm LAYOUR HORIZONAL IGNITION CDI ENGINE STARTING ELECTRIC & KICK

1.4 G-MAX200 SPECIFICATION BRAND PGO FRAME STEEL PIPE MODEL M2-200 FRONT TELESCOPE LENGTH 1885 mm SUSP ENSI ON REAR SWING WIDTH 730 mm PRIMARY DIRECT HEIGHT 1170 mm 2ND 40/16*42/13 DIMENSION AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL FRONT 58 KG TRANSMISSI SHIFTING V-BELT C.V.T REAR 82 KG FRONT 120/60-13 GROSS TOTAL 140 KG TIRE REAR 130/60-13 PASSENGER 2 (110KG) FRONT DISK FRONT 99 KG BRA KE REAR DISK REAR 151 KG SPEEDOMETER 160 km/hr WEIGHT TOTAL TOTAL 250 KG HEAD(HI、LO) 12V-55W/60W TOP SPEED 108 km/hr REAR 12V-5W FUEL CONSUMPTION 40 km/l BRAKE 12V-21W PERFORMAN GRADIENT 25° LIGGHT SIGNAL 12V-10W*4 ENGINE MODEL C7 HORN DC 12V FUEL 92 UNLEADED SILENCER DIFFUSER STROKE 4T AIR FORCED PARTICLE BELOW 15 % BORE φ65.0 mm CO BELOW 4.5% STROKE 60.0 mm EXHAUS HC BELOW 7000 ppm CYLINDE CYLINDER SINGLE EXHAUST LAYOUT RIGHT DISPLACEMENT 199.1 cc LUBRICATE SEPARATE PUMP C.R. 9.7：1 & SPLASH MAX H..P. 10.2kw/7250rpm FUEL TANK 7.5 L MAX TORQUE 15.0N-M/6000rpm LAYOUR HORIZONAL IGNITION TRENISENT ENGINE STARTING ELECTRIC

1.5 G-MAX220 SCOOTER SPECIFICATION BRAND P G O FRAME STEEL TUBE MODEL M2-220BAE FRONT TELESCOPE LENGTH 1885 mm SUSPENSION REAR UNI-ABSORBER WIDTH 730 mm 1 ST REDUCTION 0.81~2.43 HEIGHT 1170 mm 2 ND REDUCTION 8.077 SCALE WHEEL BASE 1365 mm CLUTCH CENTRIFUGAL FRONT 57 KG TRANSMISSIO GEARBOX C.V.T. REAR 87 KG FRONT 120/60-13 MASS OF VEHICLE TOTAL 144 KG TYRE REAR 130/60-13 RIDER 2 (150KG) FRONT DISK FRONT 115 KG BRAKE REAR DISK REAR 179 KG SPEEDOMETER 199 km/hr MASS TOTAL MASS TOTAL 294 KG HEAD LAMP 12V-60W/55W TOP SPEED 110 km/hr TAIL LAMP 12V-5W FUEL CONSUMPTION 33 km/l BREAKING LAMP 12V-21W PERFORMA NCE HILL CLIMB 30°↑ LIGHT TURNING LIGHT 12V-16W*4 TYPE C8E5 HORN DC 12V FUEL 92 UNLEADED MUFFLER C-D ABSORPTION CYCLE/COOLING 4T/FORCE AIR&OIL COOL PARTICLE BELOW 15 % BORE φ67.5 mm CO BELOW 3.0% STROKE 61.5 mm IDLE EMISSION HC BELOW 1600 ppm CYLINDER NUMBER SINGLE EXHAUST DIRECTION RIGHT HAND SIDE& BACKWARD DISPLACEMENT 220 cc LUBRICATION COMPRESS & SPLASH COMPRESSION RATIO 10.0：1 E. E. C. NO MAX POWER 11.0kw/7000rpm P. C. V. YES MAX TORQUE 16.5N-M/5500rpm CATALYST YES ARRANGEMENT HORIZONTAL S. A. I. YES IGNITION TRANSISTOR ENGINE STARTER ELECTRIC RREMARK 1. FUEL SUPPLY：INJECTION

1.6 G-MAX250 SPECIFICATION BRAND PGO FRAME STEEL PIPE MODEL M2-250 FRONT TELESCOPE LENGTH 1990 mm SUSP ENSI ON REAR SWING WIDTH 730 mm PRIMARY DIRECT HEIGHT 1170 mm 2ND 39/15*43/16 DIMENSION AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL FRONT 58 KG TRANSMISSI SHIFTING V-BELT C.V.T REAR 90 KG FRONT 120/60-13 GROSS TOTAL 148 KG TIRE REAR 140/60-13 PASSENGER 2 (110KG) FRONT DISK FRONT 88 KG BRA KE REAR DISK REAR 170 KG SPEEDOMETER 160 km/hr WEIGHT TOTAL TOTAL 258 KG HEAD(HI、LO) 12V-35W/35W TOP SPEED 120 km/hr REAR 12V-5W FUEL CONSUMPTION 34 km/l BRAKE 12V-21W PERFORMAN GRADIENT 27° LIGGHT SIGNAL 12V-10W*4 ENGINE MODEL SH50B HORN DC 12V FUEL 92 UNLEADED SILENCER DIFFUSER STROKE 4T LIQUID COOLED PARTICLE BELOW 15 % BORE φ72.7 mm CO BELOW 4.5% STROKE 60.0 mm EXHAUS HC BELOW 7000 ppm CYLINDE CYLINDER SINGLE EXHAUST LAYOUT RIGHT DISPLACEMENT 249.1 cc LUBRICATE SEPARATE PUMP C.R. 10.3：1 & SPLASH MAX H..P. 13.5kw/7250rpm FUEL TANK 7.5 L MAX TORQUE 20.2N-M/6000rpm LAYOUR HORIZONAL IGNITION TRENISENT ENGINE STARTING ELECTRIC

PGO G MAX 50 125 150 Scooter Full Service & Repair Manual

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