PGO G-MAX220 Manuals

Manuals and User Guides for PGO G-MAX220. We have 1 PGO G-MAX220 manual available for free PDF download: Service Manual

PGO G-MAX220 Service Manual (276 pages)

Brand: PGO | Category: Scooter | Size: 34.28 MB

Contents
3
G-Max 50 Specification
5
G-Max 125 Specification
6
G-Max 150 Specification
7
G-Max 200 Specification
8
G-Max 220 Specification
9
G-Max 250 Specification
10
Service Information
11
The Operation Notice
12
Locking Torque Value
13
4T Engine (125/150/200/220CC)
14
Chassis
15
Other Parts Standard Torque Values
15
Lubrication Instruction
16
Chassis Appearance
17
Wheel Bearing
18
Periodic Maintenance Table
19
Troubleshooting
21
Difficult Starting or Can’t Start
21
Weak Acceleration
22
Engine Running Unsmoothly (Low Speed and Idling)
24
Engine Running Unsmoothly (High Speed)
25
Clutch, Drive and Driven Pulley
26
Handlebar Steering Astrayed When Running
27
Front, Rear Damper Not in Balanced
27
Brake Disorder
27
Oil Indicator Malfunction
28
Fuel Indication Malfunction
29
The Starting Motor Abnormal
31
Starting Motor Running Slowly or no Pick-Up
32
Starting Motor Can Not Stop after Starting
32
No Sparking
33
Charging Abnormal(Battery over Charging or over Discharging)
34
Checking and Adjustment
35
Regular Checking Table
36
Battery: Recharge When Power Is out
40
Cleaning Air Cleaner
41
The Final Reduction Mechanism Oil
42
Spark Plug
42
Compression Pressure Measurement
43
Ignition Timing
44
Throttle Cables Adjustment
44
Idle Adjustment
45
Front Brake Adjustment
45
Rear Brake Adjustment (Drum Brake Only)
46
Tire
46
Plastic Part Dismantle Overview
47
Actual Dismantle Procedure
48
G-MAX 50 Engine Dismantle, Maintenance, Repair and Assembly
54
Lubrication System and Oil Pump
55
Lubrication System Diagram
55
Removing the Oil Pump
56
Check the Oil Pump
56
Assemble the Oil Pump
57
Releasing Air in the Oil Pump
57
Engine Dismantling
58
Drive Pulley, Starter & Clutch Troubleshooting
59
CVT Parts Measurement Data
59
Driving Pulley
60
Cylinder and Piston Troubleshooting
68
Piston & Cylinder Datas
68
Cylinder Head, Cylinder, and Piston Dismantling
69
Check for the Flatness of Cylinder Head & Cylinder
72
Combustion Chamber Cleaning
72
Check Cylinder and Piston
73
Installing Cylinder and Piston
76
A.C. Generator, Flyweel
77
Install AC Generator
78
Final Transmission Mechanism Troubleshooting
79
Disassemble the Final Transmission Mechanism
79
Check the Final Transmission Mechanism
81
Assemble the Final Transmission Mechanism
81
Crankcase, Crankshaft Disassembling Diagram
82
Crankcase, Crankshaft Troubleshooting
83
Crankcase, Crankshaft Data
83
Dismantle the Crankcase and Crankshaft
84
Check the Crankshaft
87
Assemble the Crankcase
88
Carburetor, Reed Valve
89
Carburetor Dismantling Diagram
89
Carburetor, Reed Valve Troubleshooting
90
Dismantling Carburetor
91
Dismantling Float, Nozzle
91
Dismantling Reed Valve
92
Checking for the Reed Valve
92
G-MAX 125/150 Engine Dismantling, Maintaining, Repairing and Assembling Operation
93
Lubrication System
94
Oil Pump Dismantling
95
Oil Pump Assembly
96
Measurement Data
97
Reduction in Fuel Oil Volume
97
Engine Burning-Out
97
Troubleshooting
97
Installing Engine
98
Drive Pulley, Starter Clutch. Driven Pulley
99
Drive Pulley, Starter Clutch. Driven Pulley Troubleshooting
100
Drive Pulley, Starter Clutch. Driven Pulley Measurement Data
100
Starter Dismantle
105
Clutch Driven Pulley
106
Cylinder Head and Valve
108
Cylinder Head and Valve Troubleshooting
109
The Operation Data Information
109
Dismantling and Installing the Camshaft
110
Check Camshaft
111
When Installing
111
Dismantling the Cylinder Head
112
Further Dismantling
112
Cylinder and Piston
113
Cylinder and Piston Operation Notice
114
Cylinder and Piston Data
114
Dismantling Cylinder
115
Dismantling Piston
115
Piston Outer Dia Measurement
115
Checking the Flatness of Cylinder Contact Surface
116
Connecting Rod Small End Inner Diameter Measurement
116
A.C. Generator
118
Dismantling AC Generator
119
Installing AC Generator
120
Final Transmission Mechanism
121
Crankcase, Crankshaft
125
Remove the Crankcase and Crankshaft
127
Check Crankshaft
128
Assemble Crankcase
128
Carburetor Specifications
129
General Theory
130
Diaphragm and Piston Operation
130
Slow System
131
Coasting Enrichment System
131
Main System
133
Auto-Enricher (Auto-Choke) System
134
Float System
135
Accelerator Pump System
136
Inspection
137
Carburetor Cleaning
137
Auto-Enrichener Inspection
138
Float Height Adjustment
138
The Float Nozzle
140
Handle Bar, Front Wheel, Front Brake and Front Fork
141
Change the Speedometer Cable
142
Steering Handlebar
143
Front Wheel
144
Dismantling the Carburetor
148
Adjustment of Fuel Volume Adjusting Screws
148
Rear Wheel, Rear Brake, Rear Damper
149
Fuel Supply Troubleshooting
153
Fuel Supply System Diagram
153
Dismantling and Assembling Fuel Tank
154
Oil Tank Disassembling Diagram
155
Dismantling and Assembling Oil Tank
155
Electric Equipment
156
Battery
158
Testing the Recharging Performance
160
Battery Construction
161
Electrolyte Filling
161
Inserting Cap (Sealing Plug)
162
Precaution for Handling Battery
163
Recharging
163
Battery Removal
163
Recharge System Diagram for M2-50
164
Recharge System Diagram for M2-125/150
165
Check A.C. Generator
166
Check Regulator
166
Ignition System
167
The Wiring of Ignition
167
The Starting System
168
Wiring Diagram for M2-50
170
Wiring Diagram for M2-125/150
171
Wiring Diagram for M2-150(4V)
172
Wiring Diagram for M2-200
173
Wiring Diagram for M2-22CEFI
174
Wiring Diagram for M2-22CEFI (ECU)
175
Wiring Diagram for M2-250
176
GMAX-200/220 Characteristics , Dismantle & Inspection
177
PGO-200/220 Engine Dismantle
178
Cooling Cowl
179
Cylinder Head Cover
180
Chain Tensioner
180
Recover the Chain Tensioner
180
Camshaft Holder
181
Cylinder Head
181
Cooling Fan
183
Generator Outer
183
Generator Stator
184
Starting Motor
184
Right Crankcase Cover
185
Starting Idle Gear
185
One Way Clutch
185
Sprocket of Oil Pump
186
Oil Pump
187
Right Crankcase
187
Crankshaft
187
Engine Inspection Data
189
Piston & Cylinder Inspection (200CC)
190
Electric System
192
What Is Transistor Ignition?
193
Electric System
193
Major Components of Transistor Ignition
194
Comparision of Transistor V.S. CDI Ignition
195
G-MAX 200/220 Electric System
196
Headlamp & Choke (Carburetor) Diagram
196
Charging System Diagram
197
Fuse Wire
198
G-MAX 200/220 Electric Parts
199
General Maintenance
200
G-MAX 200/220 Specified Engine Oil (Synthetic 1000Ml)
201
Engine Oil, Gear Oil
202
Engine Oil Filling & Gauge
203
Replace the 2Nd Oil Filter
204
Air Element
205
CVT Sponge
206
CVT Dismantle
207
CVT Install Notes
208
Spark Plug
209
Ignition Coil
210
Front Brake System
211
Replace the Front Pads
212
Replace the Rear Pads
214
Engine Management System (EMS)
215
EMS Index
216
Feature of PGO 2Nd-Stage EMS
217
EMS Structure (A)
218
EMS Structure (B)
219
EMS Units
220
Intake Pressure Sensor
221
Throttle Position
221
Important PIN No.# of ECU
224
Function of Crank Speed Sensor
226
Engine Temperature Sensor
227
Measure Engine Temperature Sensor
228
Throttle Position Sensor (TPS)
229
Oxygen Sensor
234
Injector
236
Draining Cap of Injector
238
Bleed the Air
238
Drain the Gas
238
Fuel Pump
239
Fall down Sensor
241
Isc(Idle Speed Control)
243
ISC Initialization Timing
246
Procedure of ISC Initialization
247
EMS Fuses
248
Main Purpose of EMS Fuses
249
EMS Diagnostic
250
Quick Diagnostic
251
PC Diagnostic
253
Quick Diagnostic Table
256
Clear the Defect Code Memory
257
EMS System Repairing Tool
258
Pocket Tester Wiring
259
Ignition Gauge
260
Fuel Pressure Gauge
261
Connect to the Vehicle
262
General Electric Units
263
Storage Light Controler
264
Signal Flasher Relay (LED)
265
Regulator
266
Fuel Gauge
267
Measure the Fuel Gauge
268
Starting Relay
269
Front Brake
270
EMS Relays
271
EMS Relays Wiring
272
Control of Relays
273
Measure the Relays
274

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PGO G-MAX220 Service Manual (276 pages)

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