PGO G-MAX 50 User 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.
 G-MAX 200: abbreviated as “M2-200” is 4 stroke engine
(4T), 200cc displacement.
 G-MAX 220: abbreviated as “M2-220” is 4 stroke engine
(4T), 220cc displacement.
 G-MAX 250: abbreviated as “M2-250” is 4 stroke engine
(4T), liquid cooled, 250cc displacement.
At every section, we illustrate each important point by assembling
procedures, explosive diagrams and photographs.
Although we have tried our best to make this manual as perfect as
possible, please kindly inform us if any fault needs to be corrected
in this manual.
Thank you for purchasing our PGO scooters.
FACTORY
Motive Power Industry Co.,Ltd.

CONTENTS：Page
Ⅰ.The specification of G-MAX (ALLORO)
Ⅱ.Service information
(1)The operation notice
(2)Locking torque value
(3)Lubrication instruction
(4)Periodical maintenance table
(5)Troubleshooting
Ⅲ.Checking and adjustment
(1)Regular checking table
(2)Battery
(3)Cleaning air cleaner
(4)The final reduction mechanism oil
(5)Spark plug
(6)Compression pressure measurement
(7)Ignition timing
(8)Throttle cables adjustment
(9)Idle adjustment
(10)Front brake adjustment
(11)Rear brake adjustment
(12)Tire
Ⅳ.Dismantling, maintaining, repairing and assembling operation
A. Plastic parts
B. G-MAX 50 Engine dismantling
(1)Lubrication system
(2)Engine dismantling
(3)Drive pulley, starter, clutch,
(4)Cylinder and, piston
(5)AC Generator
(6)Final transmission mechanism
(7)Crankcase, crankshaft.
(8)Carburetor, reed valve
C. G-MAX 125/150 Engine dismantling
(1) Lubrication system
(2) Engine dismantling
(3) Install Engine
(4) Drive pulley, starter, clutch, driven pulley
(5) Cylinder head and valve

(6) Cylinder and piston
(7) AC generator
(8) Final transmission mechanism
(9) Crankcase, crank shaft
(10) Carburetor
(D)Steering column, front wheel, front brake comp, front fork
(E)Rear wheel, rear brake, rear damper
(F)Fuel supply
Ⅴ.Electric equipment
(1)Troubleshooting
(2)Battery
(3)Recharge system
(4)Ignition system
(5)Starting system
(6)Switch operation
(7)Wiring diagram
ⅤI. GMAX-200/220 characteristics , dismantle & inspection
(1) Engine dismantling
(2) engine inspection
(3) Electric system
(4) Maintenance
(5)Engine Management System(EMS)
(6)EMS diagnostic
(7)EMS system Repairing tool
(8)EMS General Electric units

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

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

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

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

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

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