GMAXservice

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:
G-MAX 50 (ALLORO 50): abbreviated as M2-50 is 2
stroke engine (2T), 50cc displacement.
G-MAX 125 (ALLORO 125): abbreviated as M2-125
is 4 stroke engine (4T), 125cc displacement.
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 G-MAX (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)Front 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
B. Drive pulley, starter, clutch
C. Cylinder and piston
D. AC generator
E. Final transmission mechanism
F. Crankcase, crank shaft
G. Carburetor, reed valve
(3)G-MAX 125/150 Engine dismantling
A. Lubrication system
B. Drive pulley, starter, clutch
C. Cylinder and piston
D. AC generator
E. Final transmission mechanism
F. Crankcase, crank shaft
G. Carburetor
(4)Engine & 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)Switch operation
(7)Wiring diagram
1.1 G-MAX 50
SPECIFICATION
BRAND PGO FRAME STEEL PIPE
MODEL M2-50D FRONT TELESCOPE
LENGTH 1855 mm
S
U
S
P
E
N
S
I
O
N

REAR SWING
WIDTH 730 mm PRIMARY DIRECT
HEIGHT 1170 mm 2ND 52/13*44/13
D
I
M
E
N
S
I
O
N

AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL
FRONT 47 KG
T
R
A
N
S
M
I
S
S
I
SHIFTING V-BELT C.V.T
REAR 58 KG FRONT 120/70-12
G
R
O
S
S

TOTAL 105 KG
T
I
R
E

REAR 130/70-12
PASSENGER 2 (110KG) FRONT DISK
FRONT 82 KG
B
R
A
K
E

REAR DRUM
REAR 133 KG SPEEDOMETER 80 km/hr
W
E
I
G
H
T

T
O
T
A
L

TOTAL 215 KG HEAD(HILO) 12V-35W/35W
TOP SPEED 60 km/hr REAR 12V-5W
FUEL
CONSUMPTION
45 km/l BRAKE 12V-21W
P
E
R
F
O
R
M
A
N
GRADIENT 19
L
I
G
G
H
T

SIGNAL 12V-10W*4
ENGINE MODEL P2 HORN DC 12V
FUEL 92 UNLEADED SILENCER DIFFUSER
STROKE 2T AIR FORCED PARTICLE BELOW 15 %
BORE 40.0 mm CO BELOW 4.5%
STROKE 39.2 mm
E
X
H
A
U
S
HC BELOW 7000 ppm
C
Y
L
I
N
D
E
CYLINDER SINGLE EXHAUST LAYOUT RIGHT
DISPLACEMENT 49 cc LUBRICATE SEPARATE PUMP
C.R. 6.81 FUEL TANK 7.5 L
MAX H..P. 3.5kw/7000rpm
MAX TORQUE 5.0N-M/6500rpm
LAYOUR HORIZONAL
IGNITION CDI
E
N
G
I
N
E

STARTING ELECTRIC & KICK
1.2 G-MAX 125
SPECIFICATION
MODEL M2-50D FRONT TELESCOPE
LENGTH 1855 mm
S
U
S
P
E
N
S
I
O
N

REAR SWING
HEIGHT 1170 mm 2ND 43/14*42/13
D
I
M
E
N
S
I
O
N

FRONT 54 KG
T
R
A
N
S
M
I
S
S
I
G
R
O
S
S

TOTAL 130 KG
T
I
R
E

REAR 130/70-13
FRONT 94 KG
B
R
A
K
E

REAR DISK
W
E
I
G
H
T

T
O
T
A
L

FUEL
CONSUMPTION
P
E
R
F
O
R
M
A
N
GRADIENT 21
L
I
G
G
H
T

SIGNAL 12V-10W*4
ENGINE MODEL C1M HORN DC 12V
STROKE 60.0 mm
E
X
H
A
U
S
HC BELOW 7000 ppm
C
Y
L
I
N
D
E
DISPLACEMENT 124.9 cc LUBRICATE SEPARATE PUMP
C.R. 9.21 & SPLASH
MAX H..P. 6.5kw/7500rpm FUEL TANK 7.5 L
LAYOUR HORIZONAL
IGNITION CDI
E
N
G
I
N
E

1.3 G-MAX 150
SPECIFICATION
MODEL M2-150 FRONT TELESCOPE
LENGTH 1855 mm
S
U
S
P
E
N
S
I
O
N

REAR SWING
HEIGHT 1170 mm 2ND 42/15*42/13
D
I
M
E
N
S
I
O
N

FRONT 55 KG
T
R
A
N
S
M
I
S
S
I
G
R
O
S
S

TOTAL 132 KG
T
I
R
E

REAR 130/70-13
FRONT 95 KG
B
R
A
K
E

REAR DISK
W
E
I
G
H
T

T
O
T
A
L

FUEL
CONSUMPTION
P
E
R
F
O
R
M
A
N
GRADIENT 24
L
I
G
G
H
T

SIGNAL 12V-10W*4
ENGINE MODEL C5M HORN DC 12V
STROKE 57.8 mm
E
X
H
A
U
S
HC BELOW 7000 ppm
C
Y
L
I
N
D
E
DISPLACEMENT 147.5 cc LUBRICATE SEPARATE PUMP
C.R. 9.41 & SPLASH
MAX H..P. 7.7kw/7250rpm FUEL TANK 7.5 L
LAYOUR HORIZONAL
IGNITION CDI
E
N
G
I
N
E

.Service information
(1)The operation notice
(2)Locking torque value
1.For engine
2. For chassis
3. Others
(3) Lubrication instruction
a.For engine
b. For chassis
c. Wheel bearing
(4)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 & driven pulley
6.Handlebar steering was astray when running
7.Front and rear damper not balanced
8.Brake disorder
9.Oil 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 X pattern.

3.Please use PGO or PGO recommended parts.

4.After dismantling, please clean all parts involved or used for checking and
grease all contact surfaces when reassembling.

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
Locking location
Thread
Dia (mm)
Locking
torque kg-m
Remarks
1 Cylinder head 7 1.0~1.4 When the engine is
cold
2 Flywheel outer 10 3.2~4.0
3 Rear brake lever 6 1.0~1.2
4 Driving pulley 10 3.2~4.0
5 Clutch outer 10 3.5~4.0
6 Right crankcase 6 1.0~1.2
7 Drive gear box cover 6 1.0~1.2
8 Left crankcase 6 1.0~1.2
9 Draining and filler bolt 8 1.8 When the engine is
cold
10 Inlet pipe 6 1.0~1.2
11 Flywheel magneto stator 6 1.0~1.2
12 Cooling fan 6 1.0~1.2
13 Muffler nut on cylinder
head
6 1.0~1.2 When the engine is
cold
14 Starting motor 6 1.0~1.4 When the engine is
cold
15 Bracket between eng. and
Rubber pad of central stand
6 1.0~1.2
16 Spark plug 14 2.5~3.0
17 Fan cover 6 1.0~1.2
18 Fixed plate, drive clutch 6 1.0~1.4
19 Nut of rear wheel axle 14 11~13 U TYPE NUT
20 Kick starter 6 1.0~1.2

NO Locking location Qty
Thread dia.
(mm)
Locking torque
(kg-m)
1 Fixing nut (Tappet screw nut) 2 5 0.7~0.8
2 Nut of oil pump sprocket 1 6 0.7~1.0
3 Cylinder head bolt A (intake) 2 6 0.9~1.1
4 Guiding pin bolt, chain extensioner 1 6 0.4~0.6
5 Screw, chain extensioner 2 6 0.9~1.1
6 Cylinder head bolt B (Exhaust) 2 8 2.0~2.3
7 Flange nut, cam shaft holder 4 8 2.0~2.3
8 Gear oil drain bolt 1 8 1.7~2.0
9 Spark plug 1 10 1.2~1.3
10 Nut of fly wheel 1 12 5.0~6.0
11 Fixing nut, clutch outer 1 12 5.0~6.0
12 Nut, driving plate 1 12 5.0~6.0
13 Bolt of engine oil drain 1 12 2.5~3.0
14 Bolt of 2
nd
oil filter 1 12 0.8
15 Nut (LH thread), one-way clutch 1 22 9.0~10.0
16 Cap, coarse oil filter 1 30 1.5~2.0

2. 4T Engine (125/150 CC)
NO Locking location QTY
Thread dia.
(mm)
Locking torque
(kg-m)
1 Air bleed bolt of caliper 1 6 0.6
2 Brake arm bolt, front drum 1 6 0.8~1.0
3 Brake arm bolt , rear drum 1 6 0.8~1.0
4 Nut of starter relay 2 6 0.5~0.6
5 Front brake caliper bolt 2 8 2.0 ~ 3.0
6 Bolt of disk 3 8 2.5~3.0
7 Locking nut, steering stem 1 10 3.5~4.5
8 Rear shock absorber bolt(lower) 1 10 3.5 ~ 4.5
9 Rear shock absorber bolt(upper) 1 10 3.5~4.5
10 Chassis bolt, engine hanger bracket 2 10 4.5 ~ 5.0
11 Engine bolt, engine hanger bracket 1 10 3.0 ~ 4.0
12 Hose bolt, master cyl. & caliper 2 10 2.5 ~ 3.0
13 Front axle nut 1 12 4.5 ~ 5.5
14 Nut, swing arm & connecting rod 1 14 4.5 ~ 5.5
14 Rear axle nut 1 16 10.0~11.0

3. Chassis

4. Other parts standard torque values:
No Item Torque
kg-m
1 5mm bolt and nut 0.45-0.6
6 5mm screw 0.35-0.5
7 6mm screw 0.7-1.4
8 6mm flange bolt and screw 1.0-1.4
(3) Lubrication instruction

A. 2T Engine (50 cc)

NO Lubrication location Oil type Remarks
1 Crankcase: rotating part,
Sliding part
2 Cylinder: rotating part,
Sliding part.

Premium 2 stroke
Motorcycle oil
Or SAE#30
Separated-pump
Lubrication
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
parts
Clean grease (#3)

B. 4T Engine (125/150 cc)

NO Lubrication location Oil type Remarks
1 Crankcase: rotating part,
Sliding part
2 Cylinder: rotating part,
Sliding part.

premium 4 stroke
motorcycle oil
or SAE15W40
Auto-Separated
Lubrication
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
parts
Clean grease (#3)

C. Chassis appearance

1. Apply oil : #1, #2

2. Apply grease (#3, #4, #5. #6 ,#7, #8)
1 2
3 4 5 6 7 8
D.Wheel bearing

Error!

(4)PERIODICAL MAINTENANCE TABLE

Model
MONTHS/DISTANCE(IN KM)FOR
CHECKING
Final transmission mechanism gear oil
Speedometer gear: clean grease
Item

2T or 4T
Checking Content
1 or
300 km
3 or
3000k
6 or
5000k
9 or
8000k
12 or
10000k
15 or
13000k
18 or
15000k
Engine oil 2T Add According to Oil warning light
Engine oil* 4T Replace (800cc, total 900cc) Replace it per 1000km
Oil Filter ALL Replace Clean it per 5000km or replace it if required
Coarse oil filter* (on oil
draining bolt)
4T
Clean or replace it if necessary 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)
Disk & drum brake ALL Leaking and function check
Clutch shoes* ALL Check or replace it if necessary
Rear brake arm ALL Function check and adjustment
Tires ALL Worn-out check or replace it if
necessary

Wheel bearing* ALL Fasten tightly if loosen
Front fork* ALL Leaking and function check
Steering head bearing* ALL Check looseness. Adjust it if
required

Rear absorber* ALL Leaking and function check
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
battery it required.
Clear the poles.

Valve gap* 4T Check and adjust when engine
is cool (0.08mm for IN & EX)
Adjust it when necessary
Carbon cleaning * 2T Clean combustion carbon when
engine output reduced

Spark plug* ALL Clear or replace if required
V belt* ALL Worn out check or replace if
necessary.

Fuel feeding system* ALL Crack and blockage check.
Replace it if necessary.

Engine idle speed* ALL 2T engine: 1900100 rpm
4T engine: 1700100 rpm

Carburetor idle A/F
Adjustment*
ALL Check and adjust referring to
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 cant start:

Check and adjust Trouble condition The reason

Ccheck there is fuel or not
Cpipe between ful tank and
carburetor is blocked
CFloat is blocked
CFuel gauge is blocked
Cfuel pump is malfunctioned

Cspark plug out of order
Cdirty
CCDI unit out of order
CA.C. generator out of order
Cignition coil disconnect or
short circuit
ignition coil disconnect or
short circuit
Cmain switch out of order
defective magneto coil

Cstarting clutch out of order
Cpiston ring stuck
Creed valve deteriorated
Ccylinder, piston, piston
ring worn out
Ccylinder gasket leakage
cylinder body has sand hole

Cbad action of auto choke
Cair trapped in intake manifold
Cwrong ignition timing
Cbad adjustment of carburetors
fuel adjusting screw

Ccarburetor fuel level too high
Cmalfunction of auto choke
Cthrottle valve open too largely
Loose carburetor draining
Screw, check if in side of
Carburetor have fuel or not
The fuel supply in carburetors
Is enough or smooth
No fuel supply in
carburetor
Remove spark plug, insert
Spark plug cover, and touch
With engine check there is
Any spark
There is sparking
In spark plug
No sparking or
Weak sparking
Measurement of
Compression pressure
Pressure is
normal
Insufficient or
No Pressure
Start engine: follow the
Instruction of starting
engine
Engine has no
knocking
Engine knocking
But cant start
Remove spark plug
And check again
dry wet
2.Weak acceleration:

Cair cleaner blocked
Cfuel supply system abnormal
Cfuel tank cover blocked
Cmuffler blocked
Cfuel pump is malfunctioned
auto chock is malfunctioned

CCDI unit is out of order
Calternator flywheel magneto
out of order

Ccylinder, piston ring worn out
Ccylinder gasket leakage
Ccylinder body has sand hole
CReed valve malfunction(2T engine)

Clean the carburetor

Cclean the dirt

Cspecification is not correct

Check and Adjust
Trouble condition
The reason
Start engine and open throttle
Gradually, check and inspect
Engine can rotate up
Engine cant rotate
Up completely
Check ignition timing, check
With ignition timing lamp
Timing is correct
Timing is not correct
Check cylinder
Compression pressure
(use cylinder compression
pressure gauge)
Pressure is normal
Pressure is
Not normal
Check carburetor
Is blocked or not
No blocked blocked
Remove spark plug and Check it
No dirty and no color change Dirty, color change

For 4T engine only:

Coil level is too high
Coil level is too low
Coil does not interchange

Coil route is blocked
Cinsufficient oil pumping from
oil pump

Cpiston and cylinder worn out
Cmixture is too lean
Cbad quality of the fuel
Ctoo much carbon in the combustion room
Cignition timing is too early

Ctoo much carbon in the combustion room
Cbad quality of the fuel
Cclutch slip
Cmixture is too lean
Cignition timing is too early
Check the oil level in crankcase
Is too much or dirty
Oil level is normal
Oil level is
Not normal
Check the lubrication
of cylinder head
Normal Abnormal
Check engine overheat
Or not
Not overheat
overheat
Running accelerately or
High speed continuously
No knocking knocking
3.Engine running unsmoothly (low speed and idling)

CCDI faulty
CAC generator faulty

Cmixture too thick
( loose the screw)
Cmixture too lean
( tight the screw)

Cheat protector gasket broke
Ccarburetor locking nut loosen
C gasket crack
C hose leakage
C lntake manifold gasket broken
Carburetor O ring distorted

Cspark plug dirty
CCDI out of order
CAC magnet abnormal
Cignition coil faulty
CH.V. coil disconnect or
short circuit
main switch is abnormal

CA.C. generator malfanction
Chose is damaged
Cair pipe is blocked or
damaged

Check ignition timing
Correct Not correct
Adjust carburetor air screw
Good
adjustment
Faulty
Not correct
Check if there is air
Leakage on carburetor
gasket
No leakage leakage
Good sparking
Sparking abnormal
Or no sparking
Check generator
good fault
Remove spark plug, insert
To spark plug cover and
Connect with ground
Start engine, then check
The sparking
4.Engine running unsmoothly (high speed)

CCDI sets faulty
CAC generator faulty

Cfuel level is too low
Cfuel pipe, fuel filter
is blocked
Cfuel pump faulty

Cclean and wash it

Check ignition
timing
correct Not correct
Check fuel pump,
Fuel supply system
good unsmoothly
Check carburetor
Is blocked or not
No blocked
blocked
5.Clutch, drive and driven pulley

Cdriving belt worn out, distortion
Cdriven plate worn-out
Cdriven plate spring distorted
C driven lining worn-out
Cdriving pulley shaft gear teeth
cracked
final gear damage

C driven lining spring cracked or
worn out
Cweight rollers melt and stick to
driving face
Cshaft worn-out
(rear wheel rotates while idling)

Cdriving belt worn-out, distorted,
or slipping
Cweight roller worn-out
Cdriving plate worn-out
Cdriving plate spring distorted
Cdriving pulley shaft worn-out

Cdriving belt worn-out or slipping
Cweight roller worn-out

Cadherent grease on driving belt,
pulley
Cdriving belt worn-out
Cdriven plate spring distorted

Trouble condition The reason
Engine can start but cant
Move the vehicle
Engine runs, but it stops
Suddenly and seems to rush out
Climbing is not smoothly
Cant reach high speed
Noise, or bad smell when
running
6.Handlebar steering astrayed when running.

(front and rear wheel pressure are normal)
Csteering column lock screw locked too
tightly
Csteel ball cracked

Crear, front wheel bearing swings
Cfront, rear wheel rim distorted
Cloosen front axle nut

Cfront and rear wheel center not well-
digned
Cfront fork crooked

7.Front, rear damper not in balanced

(front and rear wheel pressure is normal)

Cdamper spring is too soft
Ccarrying weight is too large
Cdamper oil leakage

Cfront fork guide rod crooked
Cdamper and damper cover cracked

Cproblems in damper tube and spring
Cdamper and damper cover cracked

8.Brake disorder.

(adjustment according to standard procedure)

Cbrake lining worn-out
Cbake lining cam worn-out
Cbrake cam worn-out
Cbrake hub worn-out

Cbrake lining worn-out
Cunknow matenals attached on brake lining
CContact surface of the wheel hub becomes
rough

Cbrake cable over stretching or moving
unsmoothly
Cbrake contacting surface wi6h brake lining does
not comtact 100%
Cwater or sand drop into brake mechanism
Csome grease on brake lining surface
Handlebar operates heavily
Front and rear wheel swings
Handlebar astrayed to one direction
Trouble condition
Damper is too soft
Damper is too hard
Damper has abnormal noise
The reason
Brake platemark
points to mark
Noise when brake
Faulty performance
9.Oil indicator malfunction (Only available for 2T engine)
(a)The oil lamp doesnt light up, (when the main switch is at ONposition)

Cfuse burn-out
Cbattery has no power
Cmain switch abnormal
Ccircuit plug dropped off
Cmain wiring disconnected

Cbulb burn out

Celectric plug is loose
or disconnected
Cwrong wiring connection

Float upward: lamp Extinguishes Cfloat faulty
Coil 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)

Celectric plug is loose
or drop-off
Cwrong wire connection

Cfloat faulty
Coil gauge switch
disconnected or short circuit

Float upward: lamp
Extinguishes Coil tank distorted
Float downward: lamp Csome impure material
Turns on dropping in
Turn the signal lamp
On. Check wiring
Of battey
Normal
Lamp dims, light does
Not flash, no light
Remove the oil lamp,
And connect with
Battery directly
Lamp lights Lamp does not light up
Check electric plug
Good condition No good
Remove oil gauge,
Check the lamp light
Up or not by moving
The float
Good No good
Check all electric
plug
Good Disorder
Remove oil gauge,
Check the lamp by
Moving the floating
Good Disorder
10.Fuel indication malfunction
(a)wrong fuel level indication(when the main switch is ON)

Cfuse burn-out

CFloat abnormal

Fuel gauge abnormal

Celectric plug dropped off
Cwrong connection
Cwire broken or short
circuit
Turn the signal lamp
On; check wiring of
battery
normal
Lamp dims, light
Not flash, not light
Remove the fuel gauge
Moving float up and
Down to check
The needle movement
Indicator moves Indicator no motion
Do the short and opening
Circuit test on the fuel
Gauge plug which connect
To wire harness. Check the
indicator movement
Indicator
moves
Indicator on
motion
Check electric plug
good
abnormal

(b)Fuel gauge needle is not steady and sometimes moves up and down (when the main switch is ON)

Cfuse burn-out
Ccircuit plug dropped off or
broken

Cfuel gauge contact
abnormal

Insufficient or no damping
Oil inside the fuel gauge

Celectric plug drop-off or
loose
Cwire broken or short
circuit

Check and adjust
Trouble condition
The reason
Turn signal lamp on,
Check wiring of
battery
normal No motion
Indicator moves
good
No
movement
Move needle up and
Down quickly(I move/
Second), check the
Needles movement
Check electric plug
Connecting condition
good abnormal
Remove the float
Inside the tank,
Move up and down to
Check the needles
movement
Indicator
moves
Indicator no
movement
11.The starting motor abnormal
(a)Starting motor can not rotate

Cfuse burn-out


Cstart switch bad
connetion
Crelay wire broken or
short circuit
Ccircuit plug is loose

Ccarbon brush worn out
Ccoil broken or short
circuit
Cstarting motor wire
broken
Ccircuit plug is loose,
drop-off
main wiring broken

Check brake switch
Turn signal lamp
No to check wiring
Of battery
Brake lamp
Lights up
Brake lamp
no light
normal Lamp does not
Flashing no light
Push starting switch
And check the function
Of start relay
normal No function
Connect starting motor
To battery directly
Starting
Motor runs up
Starting motor
Has no motion
(b)Starting motor running slowly or no pick-up


Celectric; plug is loose
or drop off
Cstart relay bad
connection

Ccylinder burn out

Cwire broken or shout
circuit

Starting motor can not stop after starting

Cstart gear cant
return
Cstart relay capacitor
melted or short circuit
Turn signal lamp
On, to check wi-
ring of battery
normal Lamp dims, no
Flashing, no light
Starting Connect motor
to the starting motor to
Battery directly
Running
normal
Runing slowly
Kick the kickstarter
lever
Easy to kick
Difficult to kick
Main switch,
Turn off
Motor cant
stop
Motor stops
12.No sparking

Spark plug faulty

Spark plug cap is loose

Plug is poor
connection

Cmin switch faulty
Cdefective magneto
coil
Cpulse generator faulty
Cdefective ignition
coil

Cmain cable broke
Cpoor connection of
joints or sockets

defective CDI

Defective ignition
coil

Replace new spark
Plug, then check
again
Good sparking Weak sparking
Or no sparking
Check spark plug, cap
And H.V. cable is
Loose or not
Check the CDI plug
Is loose or not
good loosen
Check the connection
Between CDI plug and
Each terminals, check
The resistivity of
Each terminals
good abnormal
Check relative parts
good abnormal
good abnormal
Check ignition coil
By the CDI tester
abnormal
good loosen
13.Charging abnormal(battery over charging or over discharging)

Cbattery is dead
Cbattery
malfunction

Cpoor
connection
Cred cable
disconnected

Cvoltage
rectifier
malfunction
Cwhite cable
disconnect

Cdefective coil
Cpoor
connection
CA.C.
generators
charging abnormal (over charging) white
Measure batterys
Voltage then start
engine
Voltage remain
The same
Voltage goes up
To normal value,
But after engine
Stop, the voltage
Goes down again
Check voltage rectifier
Plug is loose or not
good loosen
Check the voltage
Between chassisand
The red cableof
Voltage rectifier
good No voltage
Check the resistivity
Of A.C. generator coil
normal abnormal
cable
disconnected

Ccable poor
connection
Cpoor
connection of
green cable

Voltage
rectifier
faulty

Start engine, connect
green cable to
Chassis, then
measure the voltage
between chassis
and red cableof
voltage of
rectifier
Voltage higher
Than specification
Voltage normal
Check the connection
Of the cable of
Voltage rectifier
Check the resistivity
Of the body of
Voltage rectifier
good Poor connection
Out of spec
3. Checking and Adjustment:
(1)Regular checking table
(2)Battery
(3)Clean air cleaner
(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.Omark indicates periodical checking
2.indicates changing the parts
Checking period
home office
Item
gen-era
l
che-cki
ng
first
month
or
Initial
300km
every6
months
or
5000km
every12
months
or
10000km
every1
months
or
1000km
every3
months
or
2500km
every12
months
or
10000km
Judgement
standard
Remark
Loose or swing
Operation
Handlebar
steering
column
Turning angle
Damaged
Shaft fixed condition
Check from
Stering column
S
u
s
p
e
n
s
i
o
n

front fork
Shaft:loose
Check from
Stering column
a. clearance
Clearance:
Front:10-20mm
Rear :

Lever
b. movement of brake
loose or damage
Brake cable
Change brake cable every 2 ears
Brake cam worn out

a. clearance between hub
and lining

b. brake shoe and brake
lining worn-out

B
r
a
k
e

Wheel hub
and brake
shor
c. wheel hub worn and
damaged

standard
dia:rear:110.0mm
limit of
use:rear:111.0mm

Front wheel
axle
damaged or distorsion

Rear wheel
axle
damaged or distorsion

unit: kg/c ;1 driver
front tire rear tire
Pressure
2.0 2.0

Cracked or damaged
tire thread worn out
Change tire
according to mark

tire
tire surface or other
intruders

Axle Tighten the bolt and nut
Front axle nut torque
5.0-6.0kg-m
rear axle nut torque
11.0-13.0kg-m
Nut
location
W
h
e
e
l

Rim
swingness and damage
condition

Swingness limit
Vertical: below
2.0mm
Horizontal: below
2.0mm

Checking period
home office
Item
gen-era
l
chec-ki
ng
first
month
or
Initial
300km
every6
months
or
5000km
every12
months
or
10000km
every1
months
or
1000km
every3
months
or
2500km
every12
months
or
10000km
Judgement
standard
Remark
Clearance on
Front axle

w
h
e
e
l

Bearing
Clearance on
rear axle

Spring
Damage
Condition

Assy part Loose or damaged
condition

Connecting
part
loose or

Bracket
loose or damage
condition

Suspension
arm
Looseness on
Connecting
Part

Oil leakage
Damaged
Condition

R
e
a
r

D
a
m
p
e
r

Absorber
Loose on assy
part

Function
Clutch and
Shift mec-
hanism
Gear oil
leakage

LH crank
case
T
r
a
n
s
m
i
s
s
i
o
n

Gear oil Change gear oil
90C.C. / replace
110C.C/ total
Ignition Spark plug
Clearance:
0.6~0.7mm
NCK:BP7HS
OR SAME
SPEC

Start
Mechanism
Starting motor
gear

Wiring
Recharge
Function

Electrolyte
level

Level between
UPPER and
LOWER
Battery
Electrolyte
gravity

When 20
Specific gravity:
1.270-1.290

E
l
e
c
t
r
i
c

Wire
circuit
Looseness or Damage
on connection plug

Checking period
home office
Item
gen-era
l
che-cki
ng
first
month
or
Initial
300km
every6
months
or
5000km
every12
months
or
10000km
every1
months
or
1000km
every3
months
or
2500km
every12
months
or
10000km
Judgement
standard
Remark
Performance,
Noise

Low speed,
Acceleration

Idling: 1900
100rpm

Exhaustion

Check the
color of
exhausting-air
Air cleaner

Cylinder, cy1inder
head, inlet pipe, locking
Condition

Locking torque
Cylinder head:
(cold)
1.0-1.2KG-m
inlet pipe: cold)
1.0-1.2kg-m

Compression
Pressure
(G-MAX 50)

.
6kg/c
@ 600rpm
Using
starting
motor
Compression
Pressure
G-MAX 125

.
12kg/c
@ 750rpm
Using
starting
motor
E
n
g
i
n
e

p
a
r
t
s

Compression
Pressure
G-MAX 150

.
11kg/c
@ 650rpm
Using
starting
motor
Oil leakage
Oil quantity,
Dirty

Oil quantity,
L
u
b
r
i
c
a
t
i
o
n

s
y
s
t
e
m

Oil filter
blocked

Fuel quantity
Fuel leakage
Clean
Carburetor

Carburetors
Throttle and
Choke function

Carburetor
Float height

Carburetor
Adjustment

E
n
g
i
n
e

m
e
c
h
a
n
i
s
m

F
u
e
l

s
y
s
t
e
m

Change fuel pipe every 4 years

Checking period
home office
Item
gen-era
l
che-cki
ng
first
month
or
Initial
300km
every6
months
or
5000km
every12
months
or
10000km
every1
months
or
1000km
every3
months
or
2500km
every12
months
or
10000km
Judgement
standard
Remark
Function

Lamp system
Dirty or broken

Horn, signal
Lamp, reflector
Function

lock Function

Rear view
mirror
Dirty or broken

License plate Dirty or damaged

Dashboard Function

Losseness or
Damage on
Assy part

Muffler
silencer
Function

chassis
Loose or
Damaged

The previous
Abnormal case
Confirm it does
Not happen
Again

Chassis
Lubrication

others
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.

Note:
A. The battery is totally sealed, do not remove seal bolts when recharging
B. Its no need to add any electrolyte for this re-filling free battery
Please recharging (12V) by the following currency
G-MAX50: 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.
Positive Pole Negative Pole
(3)Cleaning air cleaner
1.Remove air cleaner cover
2.Take out the air cleaner filter

3.Clean the filter by the compressor air.

4.Assemble the air cleaner by the opposite procedure.
Note: Do not start the engine When the air cleaner is Not installed
G-MAX50 G-MAX125/150
Draining Filling Bolt
1.Change the oil in the gear box:
a. Turn off the engine after warm up.
b. Put a bowl under the engine.
c. Remove the draining bolt and
Filler bolt to drain the gear
oil off.
d. Lock the draining bolt before
refill 90c.c gear oil and
then lock the filling bolt.
e. Locking torque: 1.8kg-m

(5)Spark plug
1.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
Note: Be sure the crankcase, tire or wheel are cleaned if there is grease/oil on it
(6)Compression pressure measurement:

1.Measure it when the engine is warm.

2.Remove the cover.

3.Remove spark plug then place compression pressure gauge.

4.Fully open the throttle, and using starting motor 5 seconds continuously, measure the
compression pressure.

5.Compression pressure:
50cc: 6 kg/c @600rpm
125cc: 12 kg/c @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.If the compression pressure is too high it may be due to the carbon piled up on combustion
chamber and piston tip.

(7) Ignition timing:

checking ignition timing:
1.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
0
apart From F, mark.
5.ignition timing: B.T.D.C.
17 3 / 1900rpm

(8)Throttle cables adjustment:
1.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
cant be adjusted.

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.
(9) Idle adjustment:

1.remove left body cover
2.start the engine and connect the tachometer
3.adjust the throttle valve screw
to the specified revolution 1900100rpm.
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 3/81/2
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:
1.check the clearance of front brake lever.
Clearance:10-20mm
2.if the clearance is beyond, standard check whether:
a. The air mix into the pipe/caliper.
b. The oil brake system is leaking.

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&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.
Note:
Try brake lever to see if its loose.
Check the brake fluid. Once air mixed in
The fluid pipe, which will reduce or
Damage the brake efficiency or even its
Function.
Note: adjust it when the engine is warm.

(11)Rear brake adjustment (drum brake only)
1.Check the clearance
Of rear brake lever.
Clearance: 10-20mm
2.If 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.

(12)Tire:
1.Check the tire air pressure(when its 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:
Front tire: 120/60-13
Rear tire: 130/60-13

Note:
When the arrow of rear brake indicator align with the arrow of left
crankcase, change the brake lining.

4.Check is there any sharp Object pierce the tire.
5.Check the depth of tire Thread.
a. Depth(front & rear):
According to mark of tire to change a new tire

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

(1) Lubrication system
(2) Engine dismantling
(3) Drive pulley, starter, clutch, driven pulley
(4) Cylinder head and valve
(5) Cylinder and piston
(6) AC generator
(7) Final transmission mechanism
(8) Crankcase, crank shaft
(9) Carburetor

(1) Lubrication System

Oil Pump Dismantling
1.Remove the rear section of muffler.
2.Remove the AC flywheel magneto.

3.Remove the AC generator coil.
4.Tale off the locking bolts of the
right crankcase cover.
5.Remove the crankcase cover

6.Remove the washer, lock pin
7.Remove starter reduction gear and
the starting clutch.

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.

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
to assure installation.
7.Place the oil pump into the crankcase.

8.Tighten the oil pump after installation.
Note:
The notch of the oil pump shaft should comply
With the notch of the inner gear.
Note:
When installing, the arrow on the oil pump
body should be pointed upwards. Then fill in
the recommended oil before the installation.

Measurement data
item
Standard Value
( mm )
Limit of use
( mm )
Clearance between the inner gear
And outer gear
_ 0.12
Clearance between the outer gear
And oil pump body
0.045-0.10 0.12
Oil
pump
Clearance between gear end and
Oil pump body
0.045-0.10 0.12

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 valves 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 & 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: 3.0-4.0kgf.m
M12: 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 dont move.
1.driving belt worn out
2.driving plate worn out
3.clutch lining worn out
4.driving plates spring broken
b.the vehicle stops or tremble when running.
1.clutch lining spring cracked or broken.
c.Cant 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
plate
24.011~24.052
24.10
The outer dia. Of boss, movable
Driving plate
23.960.~23.974 23.940
Belt width
20.0~21.0
19.0
Clutch lining thickness
3
1.5
Clutch outer inner diameter 125.0~125.2
125.5
Driven plate spring, free length 151
127
The outer diameter of driven
Plate sets
33.965~34.025 33.95
The inner diameter of slide
Driven plate
34.000~34.025 34.06
The outer diameter of weight
Roller set
17.920~18.080 17.40

(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 engines speed slowly and notice
the RPM at which the motorcycle begins to move forward.

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 RPM : 5200 400 rpm

5.To assemble the driving pulley, reverse the whole procdeure.

6.Checking driving belt
(1)check driving belt is cracked or not
rubber and fiber is loosened or not
also check if they are extraordinary
worn out.
(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
weight roller.
Limit of use : change it below 17.4mm

(2)Check gasket inner dia of
Locking torque:
1.Nut of driving pulley M12: 4.0-5.5kg/m.
2.Locking nut of clutch M12: 4.0-5.5kg/m

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 procedure 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 : M6: 1.0~1.2kg/m.

Note:
CMake 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.
CPut some grease in every shaft and gear sets
before assembly.

E. Clutch driven pulley

1.Dismantling the clutch
a. Remove left crankcase cover.
b. Remove driving plate.
c. Remove driving belt.
d. Remove locking nut, then remove clutch.

2.Assemble the clutch : follows the opposite procedure of dismantling.

3.Checking clutch:
dismantling tool

a.Check clutch driving face.
Check clutch cover about its wearing condition
And inner diameter measurement.
limit of use: change it above 125.5mm

b.Check clutch lining wearing condition and
Measure the lining thickness.
limit of use : change it below 1.5mm.
Locking torque:
M12: 4.0~5.5kg.m

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.
limit of use: change it above 33.95mm.

e.Check wearing condition of slide driven plate.
And measure its Inner diameter.
limit 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.
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 stems oil seal is damaged.

B.The operation data information
Description IN/EX
Standard Value
(mm)
Limit of use
(mm)
IN 0.08
Clearance between adjuster tapped
Screw and valve stem
(Before warm up)
EX 0.08
Compression pressure(throttle open full)
12kg/750rpm
11kg/700rpm
(125CC)
(150CC)
IN 26.3(125CC)
26.625(150CC)
25.9(125CC)
26.23(150CC)
Height of the cams convex part
EX 26.3(125CC)
26.53(150CC)
25.9(125CC)
26.13(150CC)
IN 10.00~10.015 10.10
Inner diameter of rocker arm shaft
EX 10.00~10.015 10.10
IN 9.972~9.987 9.91
Outer diameter of rocker arm shaft
EX 9.972~9.987 9.91
Valve base angle IN&EX 1.0 1.8
IN 4.975~4.900 4.90
Outer diameter of valve stem
EX 4.955~4.970 4.90
IN 5.000~5.012 5.30
Inner diameter of valve guide
EX 5.000~5.012 5.30
IN 0.010~0.037 0.08
Clearance between valve stem and
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
mark 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.

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.

2.Cam shaft holder and cam rocker arm outer dia
measurement:

3.Cam rocker arm inner dia measurement:

4.Cam rocker arm shaft and rocker arm outer dia measurement:

5.Clearance between the Cam rocker arm and rocker arm shaft.

WHEN INSTALLING:
1.The mark EX on the cam shaft holder is the exhaust rocker arm, one-way stopper.
Install the exhaust rocker arm, the inlet rocker arm, and the rocket arm shaft.

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

7.Adjust the valves clearance.
Limit of Use:
IN :replace it below 25.90(125CC), 26.23mm(150CC)
EX :replace it below 25.90(125CC), 26.13mm(150CC)
NOTICE:
Do check if there is any damage on the cam rocker arm
Sliding surface.
Limit of use : replace it above 10.10mm.
Limit of use : replace it below 9.91mm.
NOTICE:
a.The tangen angle of the heat side of intake valves rocker arm shaft is to match
with the bolt of the cam holder.
b.The tangent angle of the exhaust valves rocker arm shaft is to match with the bolt
of the cam holder.
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.

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

Further dismantling
Use the valve contracting tool to remove valve pin,
supporter, the vlave spring collar, valve spring
and valve stem oil seal.

Notice:
Not to injure the contact
Surface of the cylinder.
Avoid any object dropping info the engine.
Notice:
Valve Spring has to be operated by the valve spring contractor.
To 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
( mm )
Limit of use
( mm )
Bore
56.990~57.010 57.100
Curve
- 0.005
Cylindrility
- 0.005
Cylinder
Roundness
- 0.005
lst ring 0.03~0.07 0.10
Clearance b/w Piston
and
Piston ring
2
nd
ring 0.02~0.06 0.10
lst ring 0.10~0.25 0.50
2
nd
ring 0.10~0.25 0.50
Clearance of cutting
section
side ring 0.2~0.7 ---
Piston outer diameter
56.975~56.990 56.90
Measuring location of piston outer dia.
Down to 5 mm from the
piston skirt
---
Clearance b/w piston and cylinder
0.025~0.035 0.10
Piston/
Piston ring
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 piston 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 cant be injured. Contact
Surface should lubricate by specified oil.
C.Data (125CC)
Part name /description
Standard value
( mm )
Limit of use
( mm )
Bore
51.490~51.510 51.60
Curve
- 0.005
Cylindrility
- 0.005
Cylinder
Roundness
- 0.005
lst ring 0.03~0.07 0.10
Clearance b/w Piston
and
Piston ring
2
nd
ring 0.02~0.06 0.10
lst ring 0.15~0.35 0.50
2
nd
ring 0.15~0.35 0.50
Clearance of cutting
section
side ring 0.2~0.8 -
Piston outer diameter
51.460~51.480 51.40
Measuring location of piston outer dia.
Down to 7mm from the
piston skirt
-
Clearance b/w piston and cylinder
0.025~0.035 0.10
Piston/
Piston ring
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 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:

2.Remove the piston pin and take off
the piston.
3.Check piston, piston pin, piston ring.
4.Remove the piston ring
NOTICE: NOTICE:

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.

2.The clearance between the piston and piston pin:

3.Checking any wearing, damage inside the cylinder.
Vertical to piston pin, and in X-Y direction to
measure cylinder bore from the upper, middle and
lower location.

4.The maximum clearance between the cylinder and
piston pin.

Dot drop the clip into the crankcase.
Dont make piston ring worn out or damaged
Limit of use : change it when less than 51.4mm.( 125CC)
Limit of use : change it when less than 56.9mm.( 150CC)
Limit of use : change it when above 0.005m.
Limit of use : Change it when above 51.6mm.( 125CC)
57.1mm(150CC)
Limit of use : Change it when above 0.1mm.

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.

d.Checking the flatness of cylinder contact
surface.

e.Connecting rod small end inner diameter
measurement.

Limit of use : Roundness:change it when above
0.005mm.
Cylindrility:change it when above
0.005mm.
Limit of use : change it when above 0.05mm.
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.

3.Assembly the piston, piston pin and piston pin
clip.

b.Installing piston
1.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:
Do not drop other objects into the crankcase.
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.
NOTICE:
a.The piston ring cannot be damaged or cracked.
b.The cutting section of three rings must be arranged at intervals of 120

(7)A.C. 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)Final transmission mechanism

A. Troubleshooting.
B. Dismantle the final transmission mechanism.
C. Check the final transmission mechanism.
D. Assemble the final transmission mechanism.

A. Troubleshooting
Engine can be started, but the vehicle doesnt move.
1.Gear worn-out or cracked.
2.Gear burnt out.
Noise occur when running.
1.Gear worn out, burnt or gear surface.
2.Bearing worn out of loosen.
Oil leakage
1.Too much oil
2.Seal worn out or damaged.

B. Disassemble the final transmission mechanism:
1.Remove the rear wheel.

2.Drain the oil in the gear box.

3.Remove the bolt in the gear box
cover.
Take off the gear box.

3.Remove the final reduction gear
And idle gear.

5.Clean up the gear box.

C. Check the final transmission mechanism
1.Check the wearing condition of driving shaft and gears.
Gear teeth number: 14 T (125CC) ; 15 T (150CC)

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 oil SAE90.

Locking torque:M6: 1.0~1.2kg/M
M10: 3.5~4.0kg/M
Drain bolt: M8: 1.8kg/M

(9)Crankcase, Crankshaft:

A. Disassembling diagram.
B. Troubleshooting.
C. Data
D. Remove crankcase and crankshaft.
E. Check crankshaft.
F. 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
axle direction
0.10~0.35 0.55
Clearance of connecting rod big end
vertical direction.
- 0.04
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.
8.AC flywheel magneto.
9.The starter clutch.
10.Oil pump.
11.Bolts of left/right crankcase.

E.Check crankshaft
1.Measure the difference of the connecting
rod big end between the X and Y

2.Measure the swing ness of the crankshaft
journal.
Limit of use
A B
Change it when above
0.1mm
Change it when above
0.1mm

3.Check the looseness of crankshaft bearing.
If it is loosen, replace to a new one.

F.Assemble crankcase:

1.assemble crankcase according to the opposite procedure of disassembling.
2.The locking torque of bolts and nuts are described in previous chapter please refer.

Limit of use : replace it when above 0.04mm.
A B

(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
I.D. 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

(A) Troubleshooting
Difficult to start
1.No sparking in spark plug.
2.Compression pressure too low.
3.No fuel in the carburetor
-air cleaner blocked
-oil pipe blocked
-bad adjustment of the fuel level
float valve is jell

Mixed air too dilute
1.Main jet blocked
2.Float valve blocked
3.Fuel level too low
4.Fuel system blocked
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

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 volume adjusting screws

1.After the engine is warm up, adjust the stopping screw throttle of throttle valve to the
standard rpm.
Idle rpm 1,700100rpm
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.
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.

(C)The float nozzle
1.Dismantling
Remove the screws to take off the float chamber.
Remove the float, the float pin, and float valve.

2.Checking
Check the float valve, valve base to see
whether it is blocked or damaged.
Check the float valve, valve base surface
if sectional worn out or dirty.

Remove the main jet, needle jet base, needle jet,
slow jet and fuel adjusting screws.

Use the detergent solution to clean the jets. Fuel
adjusting
After cleaning off the blockage and the
dirt, screw
blow dry by compressed air.

3.Assembling
Assemble the slow jet, needle jet, main jet and
fuel adjusting screws.

Assemble the float valve, float and float pin.
4.Checking fuel level

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.
Note:
Avoid any damage on the jets and the fuel adjusting
screws.
Before dismantling, record the number of turning
loops.
No screwing-in movement by force to avoid any
damages.
Note:
Remove the vacuum and air-interrupt valve for
Cleaning.
Notice
Record the number of turning loops before
dismantling
Notice
Check after the checking on the float valve
and the float is done.
Put the float gauge on the float chamber
perpendicularly to the main jet for
measurement.

(12)Fuel tank
A. Troubleshooting.
1.Engine cant 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 covers 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:

B. 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: M6: 1.0-1.2kgf-m

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

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

2.Disconnect plug of oil gauge.

3.Remove the oil tank.

4.Clean the oil tank.

5.To assemble the oil tank, please follow the opposite procedures of dismantling.

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. dismantling the starting motor
4. checking the starting motor

(1)Troubleshooting:
A. Recharge system:
No power:
1.Battery over discharging
CNo electrolyte in battery.
CBattery is bleached
CShort circuit in the Battery.
CRegulator malfunction
2.The battery wires are disconnected.
3.Fuse is broken.
4.Ignition switch is abnormal.
Voltage is too low:
1.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.
Cbetween A.C. generator and CDI sets
Cbetween CDI sets and High Voltage coil.
Cbetween CDI sets and main switch.
Cbetween 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:
Starting motor cant rotated:
1.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.
1.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 circuit.
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:
1.Ignition primary circuit.
Cthe wire or plug of wiring connection is not good.
Cmain switch disconnects.
2.Ignition secondary circuit.
CIgnition coil is not in good function
CSpark plug is dead.
CH.V. coil is not in good function.
CThe spark plug cap is not in good function.
3.Ignition timing
CA.C. generator is out of order.
CA.C. coil is not in good function.
CC.D.I. sets is out of order.
Starting motor runs weakly.
1.Battery recharges insufficiently.
2. Wiring system disconnects.
3. The alien objects drop in the motor or gear.
Starting motor can rotate, but
engine cant 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.

M2-50
M2-125/150

2.Recharge
Connection procedure:
connect the positive cable(+) of the negative cable(+) of the battery, and the
negative cable(-) of the recharge to the negative cable(-) of the battery.
Recharging currency:
Please recharge (12V) according to the following current and time.
Standard: 0.4A * 4-10Hr or Rapid:3A * 60min(50cc)
Standard: 0.7A * 5-10Hr or Rapid:3A * 60min(125/150cc)

NOTICE:
This battery is totally sealed. Do not remove seal bolt when recharging.
Notice:
Keep away from fire when recharging.
The ON or OFF 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

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.

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.
While testing, the red wire cable must not touch the frame.
This test needs to be done when the battery is fully recharged.
This test needs to be done after engine is warm-up.

(3)Recharge system:
A. Recharge system diagram for M2-50

B. Recharge system diagram for M2-125/150

2.Check A.C. Generator
a. Open the seat cover and remove the luggage box.
b. Measure the resistance value of terminals.

3.Check regulator
Measure the resistance value between each terminal,
It should be in the specified range, otherwise change a new one.
Yellow V.S. black 0.1-1.0
White V.S. black 0.2-2.0
ACG inside
M2-50 M2-125/150

(4)Ignition system:
1.the wiring or ignition

2.Check spark plug.
3.Check the H.V. cable and H.V. coil by using the CDI tester.
4.CDI sets checking.
Check with the CDI tester and please follow the instruction manual.
If the CDI test failed, please change a new one.
Ignition coil CDI

(5)The starting system:
1.The wiring of starting

2.Make sure the Engine RUN/OFF switch is in Run position.
3.Check the safety switch by operating the brake lever, and the brake lamps shall light on.

4.check the starting relay
a. Find the control coil by measuring the resistance.

b. Connect green/white cable to positive pole of battery, connect black cable of
negative pole of battery, It means starter is function well if above connection
and both Red Black cable of staring motor have currency passing through.

3.Dismantling the starting motor
(a)Remove 2 screws on starting motor.
(b)Remove starting motor cables.

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

Wiring diagram for M2-125/150

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