SERVICE 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: 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
.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

Page

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 MODEL DIMENSION LENGTH WIDTH HEIGHT AXLE DISTANCE GROSS FRONT REAR TOTAL PASSENGER TOTAL FRONT REAR TOTAL PERFORMAN TOP SPEED FUEL CONSUMPTION GRADIENT ENGINE MODEL FUEL STROKE CYLINDE BORE STROKE CYLINDER 19 P2 92 UNLEADED 2T AIR FORCED 40.0 mm 39.2 mm SINGLE 49 cc 6.81 3.5kw/7000rpm 5.0N-M/6500rpm HORIZONAL CDI ELECTRIC & KICK EXHAUS PGO SUSP M2-50D 1855 mm 730 mm 1170 mm 1365 mm 47 KG 58 KG 105 KG 2 (110KG) 82 KG 133 KG 215 KG LIGGHT 60 km/hr 45 km/l ENSI FRAME ON FRONT REAR PRIMARY 2ND CLUTCH SHIFTING FRONT REAR KE FRONT REAR SPEEDOMETER HEAD(HILO) REAR BRAKE STEEL PIPE TELESCOPE SWING DIRECT 52/13*44/13 CENTRIGUAL V-BELT C.V.T 120/70-12 130/70-12 DISK DRUM 80 km/hr 12V-35W/35W 12V-5W 12V-21W

WEIGHT

BRA

TIRE

TRANSMISSI

SIGNAL HORN SILENCER PARTICLE CO HC

12V-10W*4 DC 12V DIFFUSER BELOW 15 % BELOW 4.5% BELOW 7000 ppm RIGHT SEPARATE PUMP 7.5 L

ENGINE

EXHAUST LAYOUT LUBRICATE FUEL TANK

DISPLACEMENT C.R. MAX H..P. MAX TORQUE LAYOUR IGNITION STARTING

1.2 G-MAX 125

SPECIFICATION
BRAND MODEL DIMENSION LENGTH WIDTH HEIGHT AXLE DISTANCE GROSS FRONT REAR TOTAL PASSENGER TOTAL FRONT REAR TOTAL PERFORMAN TOP SPEED FUEL CONSUMPTION GRADIENT ENGINE MODEL FUEL STROKE CYLINDE BORE STROKE CYLINDER 21 C1M 92 UNLEADED 4T AIR FORCED 51.5 mm 60.0 mm SINGLE 124.9 cc 9.21 6.5kw/7500rpm 9.1N-M/6250rpm HORIZONAL CDI ELECTRIC & KICK FUEL TANK EXHAUS PGO SUSP M2-50D 1855 mm 730 mm 1170 mm 1365 mm 54 KG 76 KG 130 KG 2 (110KG) 94 KG 146 KG 230 KG LIGGHT 84 km/hr 40 km/l ENSI FRAME ON FRONT REAR PRIMARY 2ND CLUTCH SHIFTING FRONT REAR KE FRONT REAR SPEEDOMETER HEAD(HILO) REAR BRAKE STEEL PIPE TELESCOPE SWING DIRECT 43/14*42/13 CENTRIGUAL V-BELT C.V.T 120/70-13 130/70-13 DISK DISK 140 km/hr 12V-35W/35W 12V-5W 12V-21W

WEIGHT

BRA

TIRE

TRANSMISSI

SIGNAL HORN SILENCER PARTICLE CO HC

12V-10W*4 DC 12V DIFFUSER BELOW 15 % BELOW 4.5% BELOW 7000 ppm RIGHT SEPARATE PUMP & SPLASH 7.5 L

ENGINE

EXHAUST LAYOUT LUBRICATE

DISPLACEMENT C.R. MAX H..P. MAX TORQUE LAYOUR IGNITION STARTING

1.3 G-MAX 150

SPECIFICATION
BRAND MODEL DIMENSION LENGTH WIDTH HEIGHT AXLE DISTANCE GROSS FRONT REAR TOTAL PASSENGER TOTAL FRONT REAR TOTAL PERFORMAN TOP SPEED FUEL CONSUMPTION GRADIENT ENGINE MODEL FUEL STROKE CYLINDE BORE STROKE CYLINDER 24 C5M 92 UNLEADED 4T AIR FORCED 57.0 mm 57.8 mm SINGLE 147.5 cc 9.41 7.7kw/7250rpm 10.6N-M/6250rpm HORIZONAL CDI ELECTRIC & KICK FUEL TANK EXHAUS PGO SUSP M2-150 1855 mm 730 mm 1170 mm 1365 mm 55 KG 77 KG 132 KG 2 (110KG) 95 KG 147 KG 242 KG LIGGHT 87 km/hr 40 km/l ENSI FRAME ON FRONT REAR PRIMARY 2ND CLUTCH SHIFTING FRONT REAR KE FRONT REAR SPEEDOMETER HEAD(HILO) REAR BRAKE STEEL PIPE TELESCOPE SWING DIRECT 42/15*42/13 CENTRIGUAL V-BELT C.V.T 120/70-13 130/70-13 DISK DISK 1400 km/hr 12V-35W/35W 12V-5W 12V-21W

WEIGHT

BRA

TIRE

TRANSMISSI

SIGNAL HORN SILENCER PARTICLE CO HC

12V-10W*4 DC 12V DIFFUSER BELOW 15 % BELOW 4.5% BELOW 7000 ppm RIGHT SEPARATE PUMP & SPLASH 7.5 L

ENGINE

EXHAUST LAYOUT LUBRICATE

DISPLACEMENT C.R. MAX H..P. MAX TORQUE LAYOUR IGNITION STARTING

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

Thread

17 Fan cover 18 Fixed plate, drive clutch 19 Nut of rear wheel axle 20 Kick starter

6 6 14 6

1.0~1.2 1.0~1.4 11~13 1.0~1.2 U TYPE NUT

2. 4T Engine (125/150 CC)

NO

Locking location

Qty 2 1 2 1 2 2 4 1 1 1 1 1 1 1 1 1

1 Fixing nut (Tappet screw nut) 2 Nut of oil pump sprocket 3 Cylinder head bolt A (intake) 4 Guiding pin bolt, chain extensioner 5 Screw, chain extensioner 6 Cylinder head bolt B (Exhaust) 7 Flange nut, cam shaft holder 8 Gear oil drain bolt 9 Spark plug 10 Nut of fly wheel 11 Fixing nut, clutch outer 12 Nut, driving plate 13 Bolt of engine oil drain 14 Bolt of 2 oil filter 15 Nut (LH thread), one-way clutch 16 Cap, coarse oil filter
nd

Thread dia. Locking torque (mm) (kg-m) 5 0.7~0.8 6 0.7~1.0 6 0.9~1.1 6 6 8 8 8 10 12 12 12 12 12 22 30 0.4~0.6 0.9~1.1 2.0~2.3 2.0~2.3 1.7~2.0 1.2~1.3 5.0~6.0 5.0~6.0 5.0~6.0 2.5~3.0 0.8 9.0~10.0 1.5~2.0

3. Chassis

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14

Locking location Air bleed bolt of caliper Brake arm bolt, front drum Brake arm bolt , rear drum Nut of starter relay Front brake caliper bolt Bolt of disk Locking nut, steering stem Rear shock absorber bolt(lower) Rear shock absorber bolt(upper) Chassis bolt, engine hanger bracket Engine bolt, engine hanger bracket Hose bolt, master cyl. & caliper Front axle nut Nut, swing arm & connecting rod Rear axle nut

QTY 1 1 1 2 2 3 1 1 1 2 1 2 1 1 1

Thread dia. Locking torque (mm) (kg-m) 6 0.6 6 6 6 8 8 10 10 10 10 10 10 12 14 16 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

4. Other parts standard torque values:

No
1 2 3 4 5 6 7 8 9 10 11

Item
5mm bolt and nut 6mm bolt and nut 8mm bolt and nut 10mm bolt and nut 12mm bolt and nut 5mm screw 6mm screw 6mm flange bolt and screw 7mm flange bolt and screw 8mm flange bolt and screw 10mm flange bolt and screw

Torque kg-m
0.45-0.6 0.8-1.2 1.8-2.5 3.0-4.0 5.0-6.0 0.35-0.5 0.7-1.4 1.0-1.4 1.0-1.4 2.0-3.0 3.0-4.0

(3)Lubrication instruction A. 2T Engine (50 cc) NO Lubrication location 1 Crankcase: rotating part, Sliding part 2 3 4 5 Cylinder: rotating part, Sliding part. Drive gear box Gasket of starter shaft Start idle gear sliding parts Oil type Remarks Separated-pump Premium 2 stroke Lubrication Motorcycle oil Or SAE#30 SAE85-140 Clean grease Clean grease Total 110 c.c. Replacement 90c.c (#3) (#3)

B. 4T Engine (125/150 cc) NO Lubrication location 1 Crankcase: rotating part, Sliding part 2 Cylinder: rotating part, Sliding part. Oil type Remarks Auto-Separated Lubrication

premium 4 stroke motorcycle oil or SAE15W40 3 4 5 Drive gear box Gasket of starter shaft Start idle gear sliding parts SAE85-140 Clean grease Clean grease Total 110 c.c. Replacement 90c.c (#3) (#3)

C. Chassis appearance 1. Apply oil : #1, #2

2. Apply grease (#3, #4, #5. #6 ,#7, #8)

D.Wheel bearing

Final transmission mechanism gear oil

Speedometer gear: clean grease

(4)PERIODICAL MAINTENANCE TABLE

Item Engine oil Engine oil* Oil Filter Coarse oil filter* (on oil draining bolt) Air cleaner Air filter Gear oil* Disk & drum brake Clutch shoes* Rear brake arm Tires Wheel bearing* Front fork* Steering head bearing* Rear absorber* Main/Side Stand Nuts, bolts, fasteners Battery Model 2T or 4T 2T 4T ALL 4T ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL
MONTHS/DISTANCE(IN KM)FOR CHECKING

Checking Content
Add Replace (800cc, total 900cc) Replace Clean or replace it if necessary Clean or replace it if necessary Clean or replace it if required Replace (90cc, total 110 cc) Leaking and function check Check or replace it if necessary Function check and adjustment Worn-out check or replace it if necessary Fasten tightly if loosen Leaking and function check Check looseness. Adjust it if required Leaking and function check Function check or replace it if required Tighten it if required Make sure that the voltage stayed over 12.8V. Recharge the battery it required. Clear the poles. Check and adjust when engine is cool (0.08mm for IN & EX) Clean combustion carbon when engine output reduced Clear or replace if required Worn out check or replace if necessary. Crack and blockage check. Replace it if necessary. 2T engine: 1900100 rpm 4T engine: 1700100 rpm Check and adjust referring to CO/HC Percentage.

1 or 3 or 300 km 3000k

6 or 9 or 12 or 15 or 18 or 5000k 8000k 10000k 13000k 15000k According to Oil warning light Replace it per 1000km Clean it per 5000km or replace it if required Clean it per 3000km or replace it if required

Valve gap* Carbon cleaning * Spark plug* V belt* Fuel feeding system* Engine idle speed* Carburetor idle A/F Adjustment*

4T 2T ALL ALL ALL ALL ALL

Adjust it when necessary

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 Loose carburetor draining Screw, check if in side of Carburetor have fuel or not check there is fuel or not pipe between ful tank and carburetor is blocked Float is blocked Fuel gauge is blocked fuel pump is malfunctioned Trouble condition The reason

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

spark plug out of order dirty CDI unit out of order A.C. generator out of order ignition coil disconnect or short circuit ignition coil disconnect or short circuit main switch out of order defective magneto coil

Measurement of Compression pressure starting clutch out of order piston ring stuck reed valve deteriorated cylinder, piston, piston ring worn out cylinder gasket leakage cylinder body has sand hole

Pressure is normal

Insufficient or No Pressure

Start engine: follow the Instruction of starting engine

bad action of auto choke air trapped in intake manifold wrong ignition timing bad adjustment of carburetors fuel adjusting screw

Engine has no knocking

Engine knocking But cant start

Remove spark plug And check again

carburetor fuel level too high

dry

wet

malfunction of auto choke throttle valve open too largely

2.Weak acceleration:
Check and Adjust Trouble condition The reason

Start engine and open throttle Gradually, check and inspect air cleaner blocked fuel supply system abnormal fuel tank cover blocked muffler blocked fuel pump is malfunctioned auto chock is malfunctioned

Engine can rotate up

Engine cant rotate Up completely

Check ignition timing, check With ignition timing lamp

Timing is correct Timing is not correct

CDI unit is out of order alternator flywheel magneto out of order

Check cylinder Compression pressure (use cylinder compression pressure gauge)

Pressure is normal

Pressure is Not normal

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

Check carburetor Is blocked or not

No blocked

blocked

Clean the carburetor

Remove spark plug and Check it

No dirty and no color change

Dirty, color change

clean the dirt specification is not correct

For 4T engine only:

Check the oil level in crankcase Is too much or dirty

Oil level is normal

Oil level is Not normal

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

Check the lubrication of cylinder head

Normal

Abnormal

oil route is blocked insufficient oil pumping from oil pump

Check engine overheat Or not piston and cylinder worn out mixture is too lean bad quality of the fuel
too much carbon in the combustion room

Not overheat

overheat

ignition timing is too early

Running accelerately or High speed continuously

too much carbon in the combustion room

No knocking

knocking

bad quality of the fuel clutch slip mixture is too lean ignition timing is too early

3.Engine running unsmoothly (low speed and idling)

Check and adjust Trouble condition The reason

Check ignition timing

Correct

Not correct

CDI faulty AC generator faulty

Adjust carburetor air screw

Good adjustment Check if there is air Leakage on carburetor gasket No leakage

Remove spark plug, insert To spark plug cover and Connect with ground Start engine, then check The sparking

Faulty Not correct

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

leakage

heat protector gasket broke carburetor locking nut loosen gasket crack hose leakage lntake manifold gasket broken Carburetor O ring distorted

Good sparking

Sparking abnormal Or no sparking

spark plug dirty CDI out of order AC magnet abnormal ignition coil faulty H.V. coil disconnect or short circuit main switch is abnormal

Check generator

good

fault

A.C. generator malfanction hose is damaged air pipe is blocked or damaged

4.Engine running unsmoothly (high speed)

Check and adjust Trouble condition The reason

Check ignition timing

correct

Not correct

CDI sets faulty AC generator faulty

Check fuel pump, Fuel supply system

good

unsmoothly

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

Check carburetor Is blocked or not

No blocked

blocked

clean and wash it

5.Clutch, drive and driven pulley

Trouble condition The reason

Engine can start but cant Move the vehicle

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

Engine runs, but it stops Suddenly and seems to rush out (rear wheel rotates while idling)

driven lining spring cracked or worn out weight rollers melt and stick to driving face shaft worn-out

Climbing is not smoothly

driving belt worn-out, distorted, or slipping weight roller worn-out driving plate worn-out driving plate spring distorted driving pulley shaft worn-out

Cant reach high speed

driving belt worn-out or slipping weight roller worn-out driving pulley shaft worn-out

Noise, or bad smell when running

adherent grease on driving belt, pulley driving belt worn-out driven plate spring distorted driving pulley shaft worn-out

6.Handlebar steering astrayed when running.

Trouble condition The reason
(front and rear wheel pressure are normal) steering column lock screw locked too tightly steel ball cracked rear, front wheel bearing swings front, rear wheel rim distorted loosen front axle nut front and rear wheel center not welldigned front fork crooked

Handlebar operates heavily

Front and rear wheel swings

Handlebar astrayed to one direction

7.Front, rear damper not in balanced

Trouble condition The reason
(front and rear wheel pressure is normal)

Damper is too soft

damper spring is too soft carrying weight is too large damper oil leakage

Damper is too hard

front fork guide rod crooked damper and damper cover cracked

Damper has abnormal noise

problems in damper tube and spring damper and damper cover cracked

8.Brake disorder.
Trouble condition The reason
(adjustment according to standard procedure)

Brake platemark points to mark

brake lining worn-out bake lining cam worn-out brake cam worn-out brake hub worn-out brake lining worn-out unknow matenals attached on brake lining Contact surface of the wheel hub becomes rough brake cable over stretching or moving unsmoothly brake contacting surface wi6h brake lining does not comtact 100% water or sand drop into brake mechanism some grease on brake lining surface

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) Check and adjust Turn the signal lamp On. Check wiring Of battey Normal Remove the oil lamp, And connect with Battery directly Lamp dims, light does Not flash, no light
fuse burn-out battery has no power main switch abnormal circuit plug dropped off main wiring disconnected

Trouble condition

The reason

bulb burn out

Lamp lights

Lamp does not light up

Check electric plug

electric plug is loose or disconnected main wiring disconnected wrong wiring connection

Good condition

No good

Remove oil gauge, Check the lamp light Up or not by moving The float
Float upward: lamp Extinguishes Float downward: lamp turn on

Good

No good

float faulty oil gauge switch disconnected or short circuit

(b)Oil is enough but the indicator turns on all the time (when the main switch is ON)

Check and adjust Check all electric plug

Trouble condition

The reason

Good Remove oil gauge, Check the lamp by Moving the floating Good

Disorder

electric plug is loose or drop-off main wiring disconnected wrong wire connection float faulty oil gauge switch disconnected or short circuit

Disorder

Float upward: lamp Extinguishes Float downward: lamp Turns on

oil tank distorted some impure material dropping in

10.Fuel indication malfunction

(a)wrong fuel level indication(when the main switch is ON) Check and adjust Turn the signal lamp On; check wiring of battery normal Lamp dims, light Not flash, not light
fuse burn-out battery has no power main switch abnormal circuit plug dropped off main wiring disconnected

Trouble condition

The reason

Remove the fuel gauge Moving float up and Down to check The needle movement Indicator moves Do the short and opening Circuit test on the fuel Gauge plug which connect To wire harness. Check the indicator movement Indicator moves Check electric plug good abnormal
electric plug dropped off wrong connection wire broken or short circuit

Indicator no motion

Float abnormal

Indicator on motion

Fuel gauge abnormal

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

Check and adjust Turn signal lamp on, Check wiring of battery

Trouble condition

The reason

normal Remove the float Inside the tank, Move up and down to Check the needles movement Move needle up and Down quickly(I move/ Second), check the Needles movement

No motion

fuse burn-out battery has no power main switch abnormal circuit plug dropped off or broken main wiring disconnected

Indicator moves good

No movement

fuel gauge contact abnormal

Indicator moves

Indicator no movement

Insufficient or no damping Oil inside the fuel gauge

Check electric plug Connecting condition good abnormal

electric plug drop-off or loose wire broken or short circuit

11.The starting motor abnormal

(a)Starting motor can not rotate

Check and adjust Check brake switch

Trouble condition

The reason

Brake lamp Lights up Turn signal lamp No to check wiring Of battery normal

Brake lamp no light

fuse burn-out battery has no power main switch abnormal circuit plug dropped off main wiring disconnected

Lamp does not Flashing no light

battery has no power

Push starting switch And check the function Of start relay normal Connect starting motor To battery directly Starting Motor runs up Starting motor Has no motion No function

start switch bad connetion relay wire broken or short circuit circuit plug is loose

carbon brush worn out coil broken or short circuit starting motor wire broken circuit plug is loose, drop-off main wiring broken

(b)Starting motor running slowly or no pick-up

Check and adjust Turn signal lamp On, to check wiring of battery normal Starting Connect motor to the starting motor to Battery directly Running normal Kick the kickstarter lever Easy to kick Difficult to kick Runing slowly
electric; plug is loose or drop off start relay bad connection

Trouble condition

The reason

Lamp dims, no Flashing, no light

battery has no power

cylinder burn out wire broken or shout circuit

Starting motor can not stop after starting

Check and adjust Trouble condition The reason

Main switch, Turn off Motor cant stop Motor stops

start gear cant return start relay capacitor melted or short circuit

12.No sparking
Check and adjust Replace new spark Plug, then check again Good sparking Check spark plug, cap And H.V. cable is Loose or not good Check the CDI plug Is loose or not loosen
Spark plug cap is loose

Trouble condition

The reason

Weak sparking Or no sparking

Spark plug faulty

good Check the connection Between CDI plug and Each terminals, check The resistivity of Each terminals

loosen

Plug is poor connection

good

abnormal

min switch faulty defective magneto coil pulse generator faulty defective ignition coil

Check relative parts good abnormal

main cable broke poor connection of joints or sockets

good Check ignition coil By the CDI tester

abnormal

defective CDI

abnormal

Defective ignition coil

13.Charging abnormal(battery over charging or over discharging)

Check and adjust Measure batterys Voltage then start engine Voltage remain The same Check voltage rectifier Plug is loose or not Voltage goes up To normal value, But after engine Stop, the voltage Goes down again
battery is dead battery malfunction

Trouble condition

The reason

good Check the voltage Between chassisand The red cableof Voltage rectifier good

loosen

poor connection red cable disconnected

No voltage

voltage rectifier malfunction white cable disconnect

Check the resistivity Of A.C. generator coil normal abnormal

defective coil poor connection A.C. generators white cable disconnected

charging abnormal (over charging)

Start engine, connect green cable to Chassis, then measure the voltage between chassisand red cable of voltage of rectifier

Voltage higher Than specification

Voltage normal

Check the connection Of the cable of Voltage rectifier good Poor connection
cable poor connection poor connection of green cable

Check the resistivity Of the body of Voltage rectifier Out of spec

Voltage 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.Omark indicates periodical checking 2.indicates changing the parts
Checking
gen-era

period office
every3 every12 months months or or 2500km 10000km

Item
Handlebar steering column Loose or swing Operation Turning angle Damaged Shaft fixed condition Shaft:loose a. clearance b. movement of brake Brake cable loose or damage Change brake cable

first home month every6 every12 l every1 months months months che-cki or Initial or or or ng 300km 5000km 10000km 1000km

Judgement standard

Remark

Check from Stering column Check from Stering column Clearance: Front:10-20mm Rear :

Suspension Brake Wheel

front fork

Lever

every 2 ears

worn out a. clearance between hub and lining Wheel hub b. brake shoe and brake lining worn-out and brake shor c. wheel hub worn and damaged Front wheel axle Rear wheel axle damaged or distorsion damaged or distorsion Pressure tire Cracked or damaged tire thread worn out tire surface or other intruders Axle Tighten the bolt and nut

Brake cam

Front axle nut torque 5.0-6.0kg-m rear axle nut torque 11.0-13.0kg-m Swingness limit Vertical: below 2.0mm Horizontal: below 2.0mm Nut location Change tire according to mark unit: kg/c ;1 driver front tire rear tire 2.0 2.0 standard dia:rear:110.0mm limit of use:rear:111.0mm

Rim

swingness and damage condition

Checking
gen-era

period office
every3 every12 months months or or 2500km 10000km

Item
Clearance on Front axle Clearance on rear axle Damage Condition Loose or condition

first home month every6 every12 l every1 months months months chec-ki or Initial or or or ng 300km 5000km 10000km 1000km

Judgement standard

Remark

wheel Rear Damper Transmission

Electric

Bearing

Spring Assy part

damaged

Connecting loose or part loose or damage Bracket condition Looseness on Suspension Connecting arm Part Oil leakage Damaged Absorber Condition Loose on assy part Clutch and Function Shift mec- Gear oil hanism leakage

LH crank case
90C.C. / replace 110C.C/ total

Gear oil

Change gear oil

Clearance: 0.6~0.7mm NCK:BP7HS OR SAME SPEC

Ignition

Spark plug

Start Starting motor Mechanism gear Recharge Wiring Function Electrolyte level Battery Electrolyte gravity Wire circuit Looseness or Damage on connection plug

Level between

UPPER and LOWER

When 20 Specific gravity: 1.270-1.290

Checking
gen-era

period office
every3 every12 months months or or 2500km 10000km

Item
Performance, Noise Low speed, Acceleration Exhaustion Air cleaner

first home month every6 every12 l every1 months months months che-cki or Initial or or or ng 300km 5000km 10000km 1000km

Judgement standard

Remark

Idling: 1900100rpm Locking torque Cylinder head: (cold) 1.0-1.2KG-m inlet pipe: cold) 1.0-1.2kg-m . 6kg/c @ 600rpm . 12kg/c @ 750rpm . 11kg/c @ 650rpm
Check the color of exhausting-air

Cylinder, cy1inder head, inlet pipe, locking Condition

Engine parts

Compression Pressure (G-MAX 50) Compression Pressure G-MAX 125 Compression Pressure G-MAX 150 Oil leakage Oil quantity, Dirty Oil quantity, Oil filter blocked Fuel quantity Fuel leakage Clean Carburetor Carburetors Throttle and Choke function Carburetor Float height Carburetor Adjustment Change fuel pipe Fuel system

Using starting motor Using starting motor Using starting motor

Engine mechanism
Lubrication system

every 4 years

Checking
gen-era

period office
every3 every12 months months or or 2500km 10000km

Item
Function Lamp system Dirty or broken Horn, signal Lamp, reflector lock Rear view mirror Function Function

first home month every6 every12 l every1 months months months che-cki or Initial or or or ng 300km 5000km 10000km 1000km

Judgement standard

Remark

Dirty or broken

License plate

Dirty or damaged

Dashboard Muffler silencer

Function Losseness or Damage on Assy part Function

Loose or chassis Damaged

The previous Abnormal case

Confirm it does Not happen Again

Chassis others 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 Note:

Negative Pole

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.

(3)Cleaning air cleaner

1.Remove air cleaner cover 2.Take out the air cleaner filter G-MAX50 G-MAX125/150

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

(4)The final reduction mechanism oil

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

Draining

Filling Bolt

Note: Be sure the crankcase, tire or wheel are cleaned if there is grease/oil on it

(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

(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:

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: 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 30 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.

(9) Idle adjustment:

Note: adjust it when the engine is warm. 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. 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. 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.

(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. 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 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: 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 & rear): According to mark of tire to change a new tire

4.1 Plastic part dismantle Overview

Dismantle the plastic parts according to above figure sequence by sub-assembly, especially pay attention to followings: Before dismantle front fender, dismantle the front wheel assy. First. (G-MAX125/150 only) Windshield & frt signal lamp cover shall be dismantled together. LH & RH body cover shall be dismantled together.

Actual dismantle procedure:

Dismantle the upper cover & windshield. Loosen 2 tapping screws at the upper with the inner cover. Withdraw the windshield decorated cover.

Dismantle the handle upper cover. Loosen 5 tapping screw under the handle.

Dismantle windshield & turn signal front cover. Loosen 1 tapping screw under windshield. Loosen 1(LH) & 1(RH) tapping screw under turn signal front cover.

Loosen 3(LH) & 3(RH) tapping screws of front inner cover.

Loosen 3(LH) & 3(RH) tapping screws of front inner cover.

Loosen 1 machine screw in the middle of windshield. Dismantle windshield & front turn signal cover together.

Dismantle the front fender. Only for G-MAX125/150: Loosen nut of front wheel, dismantle the front wheel & brake disc together. Loosen screws at LH & RH of front fender, dismantle front fender

Open the seat. Loosen 3 bolts of rear luggage bracket, dismantle it.

Loosen 4 bolts of front luggage compartment. Disconnect the coupling of lighting lamp, dismantle the front luggage compartment.

Loosen 2 bolts of rear luggage compartment

Lift the cover with finger, withdraw the cover of rear luggage compartment. Withdraw the rear luggage compartment.

Turn the tank inner cover counterclockwise a little bit, dismantle it. Dismantle the tank upper cover by releasing coupling ribs Withdraw fuel tank decorated cover.

Dismantle the keel cover. Loosen 2(LH) & 2(RH) screws at the front upper section.

Loosen 2(LH) & 2(RH) inner socket screws, dismantle the keel cover.

Dismantle the LH & RH lower cover Loosen 4 tapping screws on the top of LH & RH lower cover Dismantle quick plastic screw(2 EA in each side)

Dismantle 1 tapping screw in the front side. Withdraw LH & RH lower cver.

Dismantle other PP covers.

Dismantle the license plate Push the middle of quick plastic screw.

Loosen 2 screws at the rear of vehicle. Withdraw the license plate.

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

(1)Lubrication system and oil pump

1.Lubrication system diagram.

2.Trouble shooting. A. If there is too much white fume from exhaust system, which means too much Carbon piled up on the spar plug or the oil quality is not good.

B. Engine over heating: a. The adjustment of oil pump is not properly.(1ack of oil) b. The quality of oil is not good. C. Piston over burning. a. There is air in the oil pump system. b. Oil pump is out of order. D. The route from oil tank to oil pump is blocked. a. Ventilation hole on the tank cover is blocked. Note:1.When removing oil pump, do not drop any unexpected objects into the oil pipe. 2.Please release the air if there is air trapped in the oil pipe. 3.Locking torque of oil pump:0.8-1.2kg-m

3.Removing the oil pump. Clean the oil pump and Crank case before operation

a. Remove the luggage. b. Remove the input/output oil pipe. c. Take out the oil pump by removing The locking screw on oil pump and Oil gauge cable.

4.check the oil pump. Remove oil pump and check: a. O-ring is distorted or not. b. contact area of crankcase is injured or not. d. Oil pump body is damaged or not e. The movement of control lever is free or not (110 cc model only) f. The gears are damaged or not. g. Check seal and see if there Is oil leakage or not. h. Never dismantle oil pump, it can not function well after dismantling.

5.Assemble the oil pump. a. Assemble the oil pump by reversing above procedure. O-ring of oil pump should be lubricated by grease or oil, then place on crankcase. The contact surface of oil pump and crankcase should be assembled firmly. The gears of oil pump should be lubricated by grease.

b. Be sure oil pump screw is tightened. After assembling, check the following: a. the adjustment of control cables b. Is there air in oil pipe. c. oil leakage at any location.

6.Releasing air in the oil pump. a. If there is air in the oil pipe, it will cause engine lubrication trouble b. Releasing air operation means the release of air trapped in the air pipe and oil pump. Please firstly release air from the oil pipe

(a)Fill up specific amount of oil to oil tank. (b)Place dry cloth under the oil pump. Remove oil pipe. (d)Use injector to fill up the oil in the oil pipe and oil pump body . Be sure the oil pipe and oil pump are full of oil before assembling. (e)After assembling check if there is still air trapped in the oil pipe.

(3)Engine Dismantling A. Dismantling engine. 1.Take off the luggage compartment. 2.Take off the left and right body covers. 3.Take off the lower mudguard fender.

4.Remove vacuum pipe, fuel pipe, auto choke, cap of spark plug, rear Brake cable carburetor pipe, engine flywheel shelfs nut, starter Motor cable plate and rear damper bolt. 5.Remove the engine. B. Installing Engine. 1.To install engine, please reverse the above procedures. 2.Locking torque: M8: 2.0~3.0kg-m M10: 3.0~4.0kg-m M12: 5.0~6.0kg-m 3.After installing, please do the following checking and adjustment: Checking and adjustment: a. Wiring connection. b. Throttle cable and oil control cable. c. Rear brake adjustment. d. Fuel and oil route.

(4)Drive pulley, starter & clutch

A. Troubleshooting: a. Engine starts, but vehicle does not move. 1.driving belt worn out 2.driven plate worn out 3.clutch lining worn out 4.driving plates spring broken b. The vehicle stops or trembles 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 abnormal. Note: No grease and oil allowed to stain on driving belt and driven plate.

B. CVT parts measurement data Item Model The inner dia. of Slide driving plate The outer dia..of boss, movable Driving plate Belt width Clutch lining thickness Clutch outer diameter Driving plate spring, free length The outer diameter of driven plate sets The inner diameter of slide Driven plate The outer diameter of weight Roller set

Standard value(mm) 50cc 20.035-20.085 19.960-19.974 18.0-19.0 3 117.0~117.2 87.9 33.965~34.025 34.000~34.025 15.992~16.008

Limit of use(mm) 50cc 20.123 19.911 17.0 1.5 117.5 82.5 33.95 34.070 15.50

C. Driving pulley. 1.Take off the 10 screws of left Cover, remove the left cover.

2.Take off the left cover.

3.Remove the fixing nut of the clutch.

4.Take off the ramp plate.

5.Take off the belt and the rear clutch. 6.Take off the driving plate. Take off the driving gear start set.

7.Remove the start idle gear fixing plate.

8.Take off the idle gear.

9.To assemble the driving pulley, please reverse above procedure. Locking torque: 1.Nut of driving pulley:M10: 3.2~4.0kg-m 2.Locking nut of clutch:M10: 3.5~4.0kg-m

10.Checking the driving belt (1)check whether it is cracked or not or its rubber and fiber are loose or not check also if they are extraordinarily worn out. (2)driving belt width: limit of use : change it below 17.0mm.

11. Disassemble the slide driving plate set (1)Remove the bush of slide driving plate (2)Remove the screw, and disassemble the cover of slide driving plate. (3)Remove RAMP plate. (4)Remove weight roller. 12.Checking list: (1)Check the wearing condition of the weight roller. limit of use:change it when below 15.5mm. (2)Check inner dia of slide driving plates gasket. Limit of use: 50cc:Change it when above 20.123 mm (3)Check the wearing condition for driving pulley surface. (4)Check the outer diameter of the driving plates boss.

Limit of use: change it when below 19.911mm

13.Assemble the slide driving plate. (1)Clean the inner surface of slide driving plate, then assemble the roller. (2)Assemble the ramp plate. (3)Please reverse the procedures of disassembling to finish assembling.

D. Starter dismantling 1.Dismantle the left crankcase cover 2.Remove the hexagon nut, then remove the starter lever. 3.Remove five screws of isolating plate. 4.Remove the stater spring from the start returning positioner. 5.Remove the driven gear comp of kick starter. 6.Remove the retaining c-type clip 7.Remove the spindle comp. Of kick starter. 8.Checking the starter a. Check the wearing condition of the outer diameter of the spindle comp and the inner diamter of bush and gear. b. Check the wearing condition of the shaft of driven gear comp, gear sets and ratchet. 9.Assembling the starter To assemble the starter, please follow the opposite procedures of dismantling. Locking torque: M6:1.0~1.2kg-m Note: Make sure that on end of the torsion spring is hooked on the groove of driven gear, and another end of the torsion spring is hooked on the poled inside the left crankcase. Put some grease on shaft and gear sets before assembling.

E. Clutch driven pulley 1.Dismantle the clutch a. Remove left crankcase cover. b. Remove driving plate. c. Remove driving belt. d. Remove the M10 locking nut, then the clutch. 2.Assembling the clutch: please follow the opposite procedure of dismantling.

Locking torque: M10: 3.5~4.0kg-m

3.Checking the clutch: Dismantling the clutch needs the special Tool. please contact your dealers.

a. Check the clutch driven face. Check the clutch cover about its wearing Condition and inner diameter measurement.

Limit of use: 50cc:Change it when above 117.5mm

b. Check the clutch lining wearing condition and measure the lining thickness limit of use:change it below 2.5mm.

c. Check driven spring free length: standard: 87.9mm Limit of use:change it as it Is below 82.5mm(50cc)

d. Check wearing condition of driving plate set. Outer diameter measurement: Limit of use:change it as it Is above 33.950mm e. Check wearing condition of slide driven plate. Inner diameter measurement: Limit of use:change it as it Is above 34.070mm f. Check is there any wearing occur to the ditch. g. Check wearing condition of seal location, if necessary change a new one.

(5)Cylinder and piston: A. Troubleshooting.

a. compression pressure is too low, difficult to start engine and 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 defective. b. compression pressure is too high, engine overheating or abnormal noise. 1.piston tip has too much carbon piled up. 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 engine. 2.The connect surface of gasket must be clean. 3.Dismantle the cylinder and the cylinder head by screw driver. Do not scratch the contact surface. 4.Cylinder inner surface and piston outer surface cant be scratched. The contact surface should be lubricated by specified oil.

C. PISTON & CYLINDER DATAS:

Part name/description Cylinder head cylinder Piston/ Piston ring Flatness Bore Clearance b/w Piston ring piston and Standard Value (mm) 39.995~40.015 Lst ring 2nd ring Piston outer diameter Measuring location of piston outer dia. (12mm from the lower end of skirt) Clearance b/w piston and cylinder Piston pin hole inner dia Piston pin hole inner diameter Piston pin outer diamerer Clearance between piston and piston pin Connecting rod small end inner dia 0.05~0.06 0.05~0.06 39.950~39.970 Limit of use (mm) 0.100 40.050 0.10 0.10 39.895

0.045~0.065 13.022~13.013 10.002~10.008 9.994~10.000 0.004~0.018 13.996~14.007

0.10 13.045 10.025 9.970 0.030 14.025

D. cylinder head, cylinder, and piston dismantling.

1.Remove the engine. 2.Screwing out the two M6-bolt of cooling cowl. 3.Screwing out the two M6-blot of fan cover.

4.Remove the cooling cowl and fan cover.

5.Remove the spark plug. 6.Remove the two M6 nuts on the muffler and cylinder. Also remove the two M8-bolt of crankcase. 7.Remove muffler.

8.Remove the four M7-nut on the cylinder head, then remove the cylinder head and cylinder head gasket.

9.Remove the Cylinder and the gasket.

10.Remove the c type clip on the piston and piston pins by the nipper. Take off piston. 11.Dismatling of the piston ring Take off the first piston ring then the second ring. 12.When assembling please reverse the procedures of dismantling. Locking torque: M7:1.0-1.4kg-m M6:1.0-1.2kg-m

Opening end of piston ring

(6)A.C. Generator, Flyweel

A. Dismantling AC generator 1.Remove fan cowl. 2.Remove the M6 screws(4) 3.Remove Screws of flywheel magneto 4.Remove the AC flywheel magneto by special tool.

5.Remove the flywheel.

6.Remove the electric plug of AC Flywheel magneto. Take out the magneto.

B. Install AC generator
To install, please reverse the dismantling procedures. Locking torgue: M6: 1.0~1.2kg-m M10: 3.2~4.0kg-m

(7)Final Transmission Mechanism

A. Trouble shooting Engine can be started, but vehicle doesnt move. 1.Gear worn-out or cracked. 2.Gear burnt out. Noise occurs when running. 1.Gear worn out, burnt or gear surface damaged. 2.Bearing worn out or 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 off the oil in the gear box.

3.Remove the 6 bolt in gear box cover 4.Take off the gear box. 5.Take out the final reduction gear and idle gear shaft.

6.Clean up the gear box

C. Check the final transmission mechanism 1.Check the wearing condition of the driving shaft and gears.

2.Check the wearing condition of the idle gear shaft and idle gears.

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 procedures Of disassembling. After locking the drain bolt, refill 90c.c of gear oil, SAE 85W/140. Locking torque: M6: 1.0~1.2 kg-m M10: 3.5~4.0 kg-m Drain bolt: M8: 1.8 kg-m

E. Check for the flatness of cylinder head & cylinder.

Check the flatness of contact surface of cylinder head & cylinder. Limit of use: If it exceeds 0.1mm Change a new one.

F. Combustion chamber cleaning

Clean out the carbon piled up in combustion chamber. Do not scratch the combustion chamber and contact surface of the cylinder during cleaning operation

G. Check cylinder and piston:

1.Check the wearing and damage condition on the contact surface of the cylinder and piston. 2.Clean out the carbon on the cylinder exhausting port. Be careful not to scratch the inner Surface of cylinder.

3.Cylinder bore measurement: (1)Measure each point (A)(B)(C) orderly, and in X.Y. axis to find the smallest value. (2)Limit of use: 50cc-change it when over 40.050mm

4.Piston outer diameter measurement: (1)Measure at the skirt area where is 12 mm from the skirt lower end of skirt. (2)Limit of use: 50cc-change if when below 39.895mm

(3)Calculate the clearance between the cylinder and piston. Limit of use: change it when over 0.100mm

5.Inner diameter measurement of the piston pin hole Limit of use: change it when over 14.032mm

6.Outer diameter measurement of the piston pin limit of use: change it when under 9.970mm(G-MAX 50cc)

7.Check piston ring: Measure piston ring gap: Limit of use: change new ones when the first ring and second ring are over 0.4mm Push the piston ring into the cylinder By piston, the measure the gap

8.Check connecting rod small end (1)lnstall piston pin, bearing onto the connecting rod small end, then check the looseness of the piston pin. (2)Measure the inner diameter of the connecting rod small end.

Limit of use: replace a new one when over 14.025mm.(G-MAX 50cc)

H. Installing cylinder and piston

1.Place the piston ring into the second ring ditch first, then install the piston ring into the first ditch. 2 a. Piston ring should be installed into piston ring ditch by even force b. After assembling, be sure that the piston ring sliding surface is at the same height as the piston outer surface. c. If the piston ring can not fit into the ditch, please clean up the carbon in the piston ring ditch or piston ring itself. 3. a. Piston ring must be installed in the correct location. b. After installing the piston ring, it should be able to rotate freely. c. If it is necessary to change the new piston ring, it must change the whole set. 4. a. The location of the piston ring gap and the lock pin must be in opposite side. b. The mark on the piston tip must be pointing to the exhausting port. c. Lubricate the piston pin before installation. 5.Please follow the opposite procedure of dismantling to install cylinder and cylinder head.

(8)Crankcase, Crankshaft:
A. Disassembling diagram

B. Troubleshooting. Engine noise: 1.The bearing of final transmission mechanism is loose. 2.Crank pin bearing is loose. 3.The bearing of gear box is loose.

C. Data Measuring Item Clearance of connecting rod big end (Parallel direction to rod) Clearance of connecting rod big end (Perpendicular direction to rod) Swingness of the crank shaft neck Standard value 0.20-0.50 0.03 Limit of use.(mm) 0.71(50cc) 0.04 0.10

D. Dismantle the crankcase and crankshaft please follow the following procedures: 1.Remove the engine.

2.Remove the left crank case, the driving pulley (driving plate) clutch and belt. 3.Remove the air cleaner.

4.Remove the carburetor.

5.Remove the intake manifold and reed valve.

6.Remove the oil pump, fan cowl and fan itself.

7.Remove the AC flywheel magneto.

8.Dismantle the right and left crankcase. There are all together 7 bolts.

9.Remove center stand, left and right crankcase and take out the crankshaft.

E. Check the crankshaft: 1.measure the clearance between crank shaft and co-rod big end.(Parallel direction to rod)

Limit of use: Replace a new when above 0.71mm

2.check the looseness on X.Y. axis of the connecting rod big end(Perpendicular directions to rod)

Limit of use: Replace a new one when above 0.04mm

3.measure the swingness of crank shaft neck. Limit of use A B Change it when Change it when Above 0.1mm Above 0.1mm

60mm

4.check the slackness of crankshaft bearing, if it is slack, change a new one.

F. Assemble the crankcase. 1.To assemble the crankcase, please reverse the procedures of disaseembling. 2.The locking torque value for bolts and nuts are all described in the previous chapters Please refer.

(9)Carburetor, Reed Valve

A: Carburetor dismantling diagram

01 CARBURETOR ASSY. NEEDLE JET 02 TOP SET 03 SPG., COMP. VALVE SET 04 PLATE SET 05 TUBE SET SET 06 JET NEEDLE CHAMBER SET 07 THROTTLE VALVE 08 SCREW SET WASHER" 09 SCREW SETA S

13 14 15 16 17 18 19

HOLDER, MAIN JET FLOAT PIN, ARM FLOAT FLOAT

TUBE SET 20 "SCREW, 21 CAP

B. Troubleshooting: a. Engine can not be started. 1.No fuel in the fuel tank. 2.Fuel pipe is blocked. 3.There is too much fuel in the cylinder. 4.Air cleaner is blocked. b. Engine idling(RPM) unsteady, running not smoothly 1.Improper adjustment of the carburetor idling. 2.Ignition disorder. 3.Compression pressure is too low. 4.Air mixture is too thick. 5.Air mixture is too lean. 6.Air cleaner is blocked. 7.Air injection is not in good function. 8.Fuel is dirty. c. Air mixture is too lean. 1.Carburetor main jet is blocked 2.The ventilation hole of the fuel tank cover is blocked. 3.Fuel filter is blocked. 4.Fuel pipe bended, squeezed or blocked. 5.Float valve is abnormal. 6.Fuel level is too low. 7.Air pipe is blocked. d. Air mixture is too thick 1.Float valve is abnormal. 2.Fuel level is too high. 3.Air jet is blocked.

C. Dismantling carburetor 1.Remove the luggage box. 2.Loose the hose clamp between the carburetor and the air cleaner. Then remove the air cleaner. 3.Unscrew the fuel draining screw of the carburetor. Drain off the fuel inside the carburetor. 4.Remove the fuel pipe and the vacuum pipe on the carburetor. 5.Remove the oil pile on the carburetor. 6.Remove the bolts on the intake manifold and carburetor.

D. Dismantling float, nozzle Note: The auto choke has been properly adjusted already. Please do not adjust it further. When there is blockage in the carburetor, please clean it by air compressor.

E. Reed valve 1.Dismantling reed valve. (1)Take off the luggage box (2)Remove the air cleaner (3)Remove the carburetor. (4)Unscrew the locking screw of the intake manifold.

(5)Remove the intake manifold. (6)Remove the reed valve.

2.checking for the reed valve. change a new one when the reed valve is worn out or distorted. change a new one too when the base of the reed valve is cracked, injured or distorted.

4. G-MAX 125/150 engine Dismantling, Maintaining, Repairing and assembling operation (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. Note: The notch of the oil pump shaft should comply With the notch of the 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 to assure installation. 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 item Clearance between the inner gear And outer gear Clearance between the outer gear And oil pump body Clearance between gear end and Oil pump body ( mm ) _ 0.045-0.10 0.045-0.10 ( mm ) 0.12 0.12 0.12 Limit of use

Oil pump

Troubleshooting
Reduction in fuel oil volume a. Natural consumption b Leakage of fuel c.Piston loop seizes, or improperly installation 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

(1)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 Standard value ( mm ) Item ( mm ) The inner dia. Of slide driving plate The outer dia. Of boss, movable Driving plate Belt width Clutch lining thickness Clutch outer inner diameter Driven plate spring, free length The outer diameter of driven Plate sets The inner diameter of slide Driven plate The outer diameter of weight Roller set 17.920~18.080 17.40 34.000~34.025 34.06 20.0~21.0 3 125.0~125.2 151 33.965~34.025 19.0 1.5 125.5 127 33.95 24.011~24.052 23.960.~23.974 24.10 23.940 Limit of use

(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 400 rpm LOCK-UP RPM : 5200

5.To assemble the driving pulley, reverse the whole procdeure. Locking torque: 1.Nut of driving pulley 2.Locking nut of clutch

M12: 4.0-5.5kg/m. 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 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 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: Make 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.

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. 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. 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.

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. -Poor adjustment of valve clearance -Valve being burned out or bent -Valve timing is not correct -Valve spring is damaged. -Poor sealing of valve base. -Leakage in Cylinder head gasket. -Cylinder head twisted or cracked. -Spark plug is not properly installed. 3.Compression pressure is too high. 5.Abnormal noise -Poor adjustment of valve clearance -Valve burned or damaged spring -Camshaft is worn out. Chain adjuster is worn out. Camshaft, valve rocker arm is worn out.

-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 Clearance between adjuster tapped Screw and valve stem (Before warm up) Compression pressure(throttle open full)

IN/EX IN EX

Standard Value (mm) 0.08 0.08 12kg/750rpm 11kg/700rpm 26.3(125CC) 26.625(150CC) 26.3(125CC) 26.53(150CC) 10.00~10.015 10.00~10.015 9.972~9.987 9.972~9.987 1.0 4.975~4.900 4.955~4.970 5.000~5.012 5.000~5.012 0.010~0.037 0.030~0.057

Limit of use (mm) (125CC) (150CC) 25.9(125CC) 26.23(150CC) 25.9(125CC) 26.13(150CC) 10.10 10.10 9.91 9.91 1.8 4.90 4.90 5.30 5.30 0.08 0.10

IN
Height of the cams convex part

EX IN EX IN EX IN&EX IN EX IN EX IN EX

Inner diameter of rocker arm shaft Outer diameter of rocker arm shaft Valve base angle Outer diameter of valve stem Inner diameter of valve guide Clearance between valve stem and Valve guide

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. Limit of Use: IN :replace it below 25.90(125CC), 26.23mm(150CC) EX :replace it below 25.90(125CC), 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 on 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: Limit of use : replace it below 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. Install the exhaust rocker arm, the inlet rocker arm, and the rocket arm shaft. 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. 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: Not to injure the contact Surface of the cylinder. Avoid any object dropping info the engine.

Further dismantling
Use the valve contracting tool to remove valve pin, supporter, the vlave spring collar, valve spring and valve stem oil seal. 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 Bore Curve Cylindrility Roundness Clearance b/w Piston and lst ring Piston ring 2nd ring

Standard value
( mm )

Limit of use
( mm )

Cylinder

Clearance of cutting
Piston/ Piston ring section

lst ring 2nd ring side ring

Piston outer diameter Measuring location of piston outer dia.

56.990~57.010 0.03~0.07 0.02~0.06 0.10~0.25 0.10~0.25 0.2~0.7 56.975~56.990

Down to 5 mm from the piston skirt

Clearance b/w piston and cylinder Piston pin hole inner dia Piston pin outer diameter Clearance between piston and piston pin Connecting rod small end inner dia

0.025~0.035 15.006~15.012 14.990~14.992 0.020~0.017 15.010~15.028

57.100 0.005 0.005 0.005 0.10 0.10 0.50 0.50 --56.90 --0.10 15.030 14.96 0.025 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 Bore Curve Cylindrility Roundness Clearance b/w Piston and lst ring Piston ring 2nd ring

Standard value
( mm )

Limit of use
( mm )

Cylinder

Clearance of cutting
Piston/ Piston ring section

lst ring 2nd ring side ring

Piston outer diameter Measuring location of piston outer dia.

51.490~51.510 0.03~0.07 0.02~0.06 0.15~0.35 0.15~0.35 0.2~0.8 51.460~51.480

Down to 7mm from the piston skirt

Clearance b/w piston and cylinder Piston pin hole inner dia Piston pin outer diameter Clearance between piston and piston pin Connecting rod small end inner dia

0.025~0.035 13.022~13.013 12.996~13.00 0.02~0.017 13.015~13.028

51.60 0.005 0.005 0.005 0.10 0.10 0.50 0.50 51.40 0.10 13.045 12.96 0.025 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: 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: Dont 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 above 0.005m. 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.
Limit of use : Change it when above 51.6mm.( 125CC) 57.1mm(150CC)

4.The maximum clearance between the cylinder and piston pin. 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. Limit of use : 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.

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.

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 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: 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 Clearance of connecting rod big end 0.10~0.35 axle direction Clearance of connecting rod big end vertical direction. Swingness of the crank shaft journal. 0.03 0.10 0.04 0.55 Standard value(mm) Limit of use.(mm)

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

Limit of use : replace it when above 0.04mm.

2.Measure the swing ness of the crankshaft

journal. Limit of use A Change it when above 0.1mm B 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.

(10)Carburetor:
A.Troubleshooting. B.Dismantling the carburetor. C.Dismantling the float and nozzle. CARBURETOR SPECIFICATIONS:

ITEM Model Carburetor type Bore size I.D. NO Idle r/min Float height Main jet Jet needle Needle jet Pilot jet

SPECIFICATION M2-125 KEIHIN CVK24 24mm 013 1700 100 18.0 0.5 mm #102 4HGGN P-O #35

SPECIFICATION M2-150 KEIHIN CVK24 24 mm 046 1700 100 18.0 0.5 mm #102 4HLGL P-O #35 1 1/ 2 turns out

Pilot screw (PRE-OPENING) 2 1/4 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

78

(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 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 1,700100rpm 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.

79

(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. 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. Remove the main jet, needle jet base, needle jet,

slow jet and fuel adjusting screws.

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. Use the detergent solution to clean the jets. Fuel adjusting

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
Assemble the slow jet, needle jet, main jet and fuel adjusting screws. Notice Record the number of turning loops before dismantling Assemble the float valve, float and float pin. 4.Checking fuel level Notice Check after the checking on the float valve and the float is done. Put the float gauge on the float chamber80 perpendicularly to the main jet for measurement.

(10)Handle bar, front wheel, front brake and front fork: A. Troubleshooting 1.steering handlebar is abnormal, too tight. a.steering mechanism; washer of conical bush locked too tightly. b.steering mechanism; steel ball is cracked. c.steering mechanism; steel ball base and washer of conical base is damaged. d. wheel pressure is too low. 2.steering handlebar is aslant. a. left and right damper are not even. b.Front fork is crooked. c. The axle of front fork is crooked or the wheel is aslant. 3.front wheel swings. a.wheel rim is distorted. b.bearing of front axle is loose. c.wheel spoke is distorted. d.Tire worn out. e. The wheel axle is improperly assembled. 4.front damper is too soft, or spring fatigue. 5.Noise in front damper. a.noise comes form the shock absorber tube. b.locking screw of damper is loose.

B. Data Item Model Standard value(mm) thickness of frt pad thickness of frt pad Disk of frt brake Disk of frt brake thickness of REAR pad Swingness of frt/rr wheel The lining of rr Brake M2-50 M2-125/150 M2-50 M2-125/150 M2-125/150 M2-50/125/150 M2-50 5.3 8.3 3.5 4.0 10.0 4.0 Limit of use.(mm) 3.3 5.3 3.0 3.5 7.0 2.0 2.0

C. Change the speedometer cable: 1.Remove the front handle cover.

2.Remove the nut of the speedometer cable.

3.Remove the fixed screw of the speedometer cable on the front wheel. 4.Pull out the damaged speedometer cable. 5.To assemble the new cable, please follow the opposite of dismantling procedures. Note: Put some grease onto the inner cable before assembling.

(D)Steering handlebar 1.Remove the LH/RH back mirrors. 2.Remove the upper handle cover. 3.Remove the nuts on front fork and handlebar. 4.Take off the fixing bolt. 5.Remove the nut and bolt of the front fork fixed on The handlebar. 6.Take off the handle bar.

7.When assembling, please follow the opposite procedures. Locking Torque: M6 : 1.0-1.2kg-m M10 : 3.0-4.0kg-m 8.Before assembling, please add grease on each cable.

(E)Front wheel
1.Remove the locking nut of the front wheel on the right side. 2.Draw out the axle of front wheel, remove the ring and take off the gear sets of speedometer. 3.Remove the front wheel assy. 4.Assemble the front wheel follows the opposite procedure of dismantling. Locking Torque: M10: 3.0-4.0kg-m Note: 1.Put the lock block of speedometer gear assy upon the extrusion of the front fork. 2.Put the grease onto the grease sets of speedometer before assembling. 5.Checking the front wheel axle a. Check the bending degree of the front axle. b. Take note of the bending degree on the middle of axle. c. Limit of use: Change it when above 0.2 mm.

6.Front wheel bearing checking Turn the tire. If the bearing is Loosen or any occurrence for noise, Please change a new one.

7.Front wheel rim checking (1)Check the swing of the front wheel rim. (2)Limit of use: Horizontal direction: Change a new one when above 2.0mm. Vertical direction: Change a new one when above 2.0mm.

(F)Front brake 1. Disassembling and assembling of the front brake comp. a. Remove two bolts fixed on the front brake comp and the front fork. b. Remove the front brake comp. c. Assemble the front brake comp. Follows the opposite procedure of dismantling. Locking Torque: M8: 2.0~3.0kg-m

2.Air releasing of the front brake comp The procedure of air releasing A .Fill the enough brake oil to the container b. Do not let the brake oil overflow from the master cylinder or container when assemble the master cylinder cover. c. Put the spanner upon the drain screw. a. Lock and unlock the screw several times to Release the bubbles. b. Operate slowly the brake lever several times. c. Clamp the brake lever to the end. d. Loose the drain screw, then open the lever completely. e. Locking the drain screw and then loose it when the lever is opened completely. f. Repeat above procedure until all the air in the brake system has been released Completely. Locking torque of leaking screw: 0.6 kg-m

1.Front fork checking: If it is bent or cracked, please replace with a new one. 4.Front shock absorber checking Check is there any unusual damage or worn-out condition, and whether the guide rod of the Front fork is crooked or not. Fork oil type: SAE 10W20 Capacity (each side): 84 CC (M2-50) Capacity (each side): 95 CC (M2-125/150)

NOTE: If the guide rod is crooked, it should be replaced by a new one or repaired.

Tube fixing screw Spring fixing bolt

5.Disassembling and assembling the front brake-disk. a. Remove the front wheel. b. Remove bolts on the disk. c. Remove the disk. d. Assemble the disk follows the disassembling procedure. Locking torque M8: 2.0~3.0kgm 6.Checking the front brake-disk. Standard thickness of disk: 3.5 mm (M2-50); 4.0 mm (M2-125/150) Limit of usage: change it when below 3.0 mm (M2-50); 3.5 mm (M2-125/150) 7.Checking the front brake-PAD. a. standard thickness: 5.3mm(M2-50); 8.3mm(M2-125/150). limit of use: As the thickness is below using limit, change it.

Note: No grease on the lining.

M2-125/150

M2-50

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

A. Troubleshooting. 1.Rear wheel swings. a. Wheel rim is distorted. b. Tire worn out. c. The wheel axle is improperly assembled. 2.rear damper is too soft. a. Spring fatigue. 3.Bad braking a. The adjustment of brake is not proper. b. The brake lining is dirty. c. The brake lining worn out. d. The cam of brake lining is worn out. e. The brake cam lever worn out. f. The wheel hub worn out or damage. g. The operation on the brake arm tooth is not good. B. Data Item The swingness of rear wheel Wheel hub (inner diameter) Thickness of brake lining Brake disc thickness Thickness of brake pad Model G-MAX M2-50 M2-50 M2-125/150 M2-125/150 Standard value(mm) Limit of use(mm) 110.0 4.0 4.0 8.3 2.0 111.0 2.0 3.5 5.3

C. Disassembling and assembling the rear wheel. 1.Remove the rear mudguard and the exhaust pipe. 2.Remove the locking nut of the rear wheel 3.Remove the rear wheel 4.To assemble the rear wheel please reverse the dismantling procedure. Locking torque: M6 : 0.7-1.1kg-m M14: 8.0-10.0kg-m

D. Checking the rear wheel a. check the swingness of rear wheel. b. vertical direction: change it when above 2.0mm c. horizontal direction: change it when above 2.0mm

E. Rear brake: (M2-50) 1.Rear brake disassembling diagram. (1)Checking the rear brake hub: a. measure the inner diameter of rear brake hub. b.Limit of use: change it when above 111.0mm

2.Checking the brake lining: (M2-50) a. measure the thickness of the rear brake lining. b.linit of use: As the thickness is less than 2.0 mm, change it.

3. Brake pad inspection for M2-125/150

F. Rear absorber 1. Check the locking torque of rear absorber at lower & upper. 2. Both locking torque is 3.5~4.5 kg-m. 3. Oil leakage check is always necessary.

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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 No 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: 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. between A.C. generator and CDI sets
between CDI sets and High Voltage coil.

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.
the wire or plug of wiring connection is not good.

between CDI sets and main switch. between 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.

main switch disconnects. 2.Ignition secondary circuit. Ignition coil is not in good function Spark plug is dead. H.V. coil is not in good function. The spark plug cap is not in good function. 3.Ignition timing A.C. generator is out of order. A.C. coil is not in good function. C.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 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.

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 OFF(DAY) ON(NIGHT)

Recharging rpm Under2,000rpm Under2,000rpm

2,500rpm 0.6A(MIN) 0.6A(MIN)

6,000prm 1.5A(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

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. 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.

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

1.Make sure the Engine RUN/OFF switch is in Run position. 2.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

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Wiring diagram for M2-125/150

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