PGO ALLORO 125 Service Manual Download

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(D)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)

Limit of use.(mm)

thickness of frt pad

M2-50

5.3 3.3

thickness of frt pad

M2-125/150/200/250

8.3 5.3

Disk of frt brake

M2-50

3.5 3.0

Disk of frt brake

M2-125/150/200/250

4.0 3.5

thickness of REAR pad

M2-125/150/200/250

10.0 7.0

Swingness of frt/rr
wheel

M2-50/125/150/200/250

- 2.0

The lining of rr Brake

M2-50

4.0 2.0

Summary of Contents for ALLORO 125

Page 1: ...Manufactured by Motive Power Industry Co Ltd ...

Page 2: ...placement 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 procedu...

Page 3: ...n 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 re...

Page 4: ...ar 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 ...

Page 5: ...R DRUM REAR 133 KG SPEEDOMETER 80 km hr WEIGHT TOTAL TOTAL 215 KG HEAD HI LO 12V 35W 35W TOP SPEED 60 km hr REAR 12V 5W FUEL CONSUMPTION 45 km l BRAKE 12V 21W PERFORMAN GRADIENT 19 LIGGHT SIGNAL 12V 10W 4 ENGINE MODEL P2 HORN DC 12V FUEL 92 UNLEADED SILENCER DIFFUSER STROKE 2T AIR FORCED PARTICLE BELOW 15 BORE φ40 0 mm CO BELOW 4 5 STROKE 39 2 mm EXHAUS HC BELOW 7000 ppm CYLINDE CYLINDER SINGLE EX...

Page 6: ... REAR 146 KG SPEEDOMETER 140 km hr WEIGHT TOTAL TOTAL 230 KG HEAD HI LO 12V 35W 35W TOP SPEED 84 km hr REAR 12V 5W FUEL CONSUMPTION 40 km l BRAKE 12V 21W PERFORMAN GRADIENT 21 LIGGHT SIGNAL 12V 10W 4 ENGINE MODEL C1M HORN DC 12V FUEL 92 UNLEADED SILENCER DIFFUSER STROKE 4T AIR FORCED PARTICLE BELOW 15 BORE φ51 5 mm CO BELOW 4 5 STROKE 60 0 mm EXHAUS HC BELOW 7000 ppm CYLINDE CYLINDER SINGLE EXHAUS...

Page 7: ... REAR 147 KG SPEEDOMETER 140 km hr WEIGHT TOTAL TOTAL 242 KG HEAD HI LO 12V 35W 35W TOP SPEED 87 km hr REAR 12V 5W FUEL CONSUMPTION 40 km l BRAKE 12V 21W PERFORMAN GRADIENT 24 LIGGHT SIGNAL 12V 10W 4 ENGINE MODEL C5M HORN DC 12V FUEL 92 UNLEADED SILENCER DIFFUSER STROKE 4T AIR FORCED PARTICLE BELOW 15 BORE φ57 5 mm CO BELOW 4 5 STROKE 58 6 mm EXHAUS HC BELOW 7000 ppm CYLINDE CYLINDER SINGLE EXHAUS...

Page 8: ...EAR 151 KG SPEEDOMETER 160 km hr WEIGHT TOTAL TOTAL 250 KG HEAD HI LO 12V 55W 60W TOP SPEED 108 km hr REAR 12V 5W FUEL CONSUMPTION 40 km l BRAKE 12V 21W PERFORMAN GRADIENT 25 LIGGHT SIGNAL 12V 10W 4 ENGINE MODEL C7 HORN DC 12V FUEL 92 UNLEADED SILENCER DIFFUSER STROKE 4T AIR FORCED PARTICLE BELOW 15 BORE φ65 0 mm CO BELOW 4 5 STROKE 60 0 mm EXHAUS HC BELOW 7000 ppm CYLINDE CYLINDER SINGLE EXHAUST ...

Page 9: ...4 KG HEAD LAMP 12V 60W 55W TOP SPEED 110 km hr TAIL LAMP 12V 5W FUELCONSUMPTION 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 FORCEAIR OILCOOL 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 RIGH...

Page 10: ... 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 EXHAU...

Page 11: ... 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 abno...

Page 12: ...fter dismantling please clean all parts involved or used for checking and grease all contact surfaces when reassembling 5 Use grease recommended by PGO 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 conf...

Page 13: ...1 0 1 2 8 Left crankcase 6 1 0 1 2 9 Draining and filler bolt 8 1 8 When the engine is cold 10 Inlet pipe 6 1 0 1 2 11 Flywheel magneto stator 6 1 0 1 2 12 Cooling fan 6 1 0 1 2 13 Muffler nut on cylinder head 6 1 0 1 2 When the engine is cold 14 Starting motor 6 1 0 1 4 When the engine is cold 15 Bracket between eng and Rubber pad of central stand 6 1 0 1 2 16 Spark plug 14 2 5 3 0 17 Fan cover 6...

Page 14: ...er 2 6 0 9 1 1 6 Cylinder head bolt B Exhaust 2 8 2 0 2 3 7 Flange nut cam shaft holder 4 8 2 0 2 3 8 Gear oil drain bolt 1 8 1 7 2 0 9 Spark plug 1 10 1 2 1 3 10 Nut of fly wheel 1 12 5 0 6 0 11 Fixing nut clutch outer 1 12 5 0 6 0 12 Nut driving plate 1 12 5 0 6 0 13 Bolt of engine oil drain 1 12 2 5 3 0 14 Bolt of 2nd oil filter 1 12 0 8 15 Nut LH thread one way clutch 1 22 9 0 10 0 16 Cap coar...

Page 15: ...gine hanger bracket 2 10 4 5 5 0 11 Engine bolt engine hanger bracket 1 10 3 0 4 0 12 Hose bolt master cyl caliper 2 10 2 5 3 0 13 Front axle nut 1 12 4 5 5 5 14 Nut swing arm connecting rod 1 14 4 5 5 5 14 Rear axle nut 1 16 10 0 11 0 3 Chassis 4 Other parts standard torque values No Item Torque kg m 1 5mm bolt and nut 0 45 0 6 2 6mm bolt and nut 0 8 1 2 3 8mm bolt and nut 1 8 2 5 4 10mm bolt and...

Page 16: ...arts Clean grease 3 B 4T Engine 125 150 200 220cc NO Lubrication location Oil type Remarks 1 Crankcase rotating part Sliding part 2 Cylinder rotating part Sliding part premium 4 stroke motorcycle oil or SAE15W40 Auto Separated Lubrication M2 125 150 Total 900 c c Replacement 800c c M2 200 220 Total 1400 c c Replacement 1000c c 3 1 Drive gear box M2 125 150 SAE85 140 Total 110 c c Replacement 90c c...

Page 17: ...C Chassis appearance 1 Apply oil 1 2 2 Apply grease 3 4 5 6 7 8 1 2 3 4 5 6 7 8 ...

Page 18: ...D Wheel bearing Final transmission mechanism gear oil Speedometer gear clean grease ...

Page 19: ... I I Wheel bearing ALL Fasten tightly if loosen I I I I I I Front fork ALL Leaking and function check I I I I Steering head bearing ALL Check looseness Adjust it if required A A A Rear absorber ALL Leaking and function check I I I Main Side Stand ALL Function check or replace it if required I L I L I L Nuts bolts fasteners ALL Tighten it if required I I I I I I Battery ALL Recharge the battery it ...

Page 20: ...liper do change the new fluid 2 Check the fluid level often Refill if necessary 3 Change the oil seal of main cylinder and caliper every two years 4 Change the brake fluid hose every four years NOTE 3 Available for M2 250 water cooled engine only 1 Check the clamping and hoses of radiator system initially 1 000 kilometers and per 10 000 kilometers for anti leaking proof 2 Replace the engine coolan...

Page 21: ... auto choke dair trapped in intake manifold ewrong ignition timing fbad adjustment of carburetor s fuel adjusting screw ccarburetor fuel level too high dmalfunction of auto choke ethrottle valve open too largely Check and adjust Trouble condition The reason Loose carburetor draining Screw check if in side of Carburetor have fuel or not The fuel supply in carburetors Is enough or smooth No fuel sup...

Page 22: ...he carburetor cclean the dirt dspecification is not correct Check and Adjust Trouble condition The reason Start engine and open throttle Gradually check and inspect Engine can rotate up Engine can t rotate Up completely Check ignition timing check With ignition timing lamp Timing is correct Timing is not correct Check cylinder Compression pressure use cylinder compression pressure gauge Pressure i...

Page 23: ...he combustion room gignition timing is too early ctoo much carbon in the combustion room dbad quality of the fuel eclutch slip fmixture is too lean gignition timing is too early Check the oil level in crankcase Is too much or dirty Oil level is normal Oil level is Not normal Check the lubrication of cylinder head Normal Abnormal Check engine overheat Or not Not overheat overheat Running accelerate...

Page 24: ...fignition coil faulty gH V coil disconnect or short circuit hmain switch is abnormal cA C generator malfanction dhose is damaged eair pipe is blocked or damaged Check and adjust Trouble condition The reason Check ignition timing Correct Not correct Adjust carburetor air screw Good adjustment Faulty Not correct Check if there is air Leakage on carburetor gasket No leakage leakage Good sparking Spar...

Page 25: ...l level is too low dfuel pipe fuel filter is blocked efuel pump faulty cclean and wash it Check and adjust Trouble condition The reason Check ignition timing correct Not correct Check fuel pump Fuel supply system good unsmoothly Check carburetor Is blocked or not No blocked blocked ...

Page 26: ...n out distorted or slipping dweight roller worn out edriving plate worn out fdriving plate spring distorted gdriving pulley shaft worn out cdriving belt worn out or slipping dweight roller worn out edriving pulley shaft worn out cadherent grease on driving belt pulley ddriving belt worn out edriven plate spring distorted fdriving pulley shaft worn out Trouble condition The reason Engine can start ...

Page 27: ...over cracked 8 Brake disorder adjustment according to standard procedure cbrake lining worn out dbake lining cam worn out ebrake cam worn out fbrake hub worn out cbrake lining worn out dunknown materials attached on brake lining eContact surface of the wheel hub becomes rough cbrake cable over stretching or moving unsmoothly dbrake contacting surface with brake lining does not contact 100 ewater o...

Page 28: ...ic plug is loose or drop off dmain wiring disconnected ewrong wire connection cfloat faulty doil gauge switch disconnected or short circuit Float upward lamp Extinguishes coil tank distorted Float downward lamp dsome impure material Turns on dropping in Check and adjust Trouble condition The reason Turn the signal lamp On Check wiring Of battey Normal Lamp dims light does Not flash no light Remove...

Page 29: ...ection ewire broken or short circuit Check and adjust Trouble condition The reason Turn the signal lamp On check wiring of battery normal Lamp dims light Not flash not light Remove the fuel gauge Moving float up and Down to check The needle movement Indicator moves Indicator no motion Do the short and opening Circuit test on the fuel Gauge plug which connect To wire harness Check the indicator mov...

Page 30: ...l inside the fuel gauge celectric plug drop off or loose dwire broken or short circuit Check and adjust Trouble condition The reason Turn signal lamp on Check wiring of battery normal No motion Indicator moves good No movement Move needle up and Down quickly I move Second check the Needle s movement Check electric plug Connecting condition good abnormal Remove the float Inside the tank Move up and...

Page 31: ...n brush worn out dcoil broken or short circuit estarting motor wire broken fcircuit plug is loose drop off main wiring broken Check and adjust Trouble condition The reason Check brake switch Turn signal lamp No to check wiring Of battery Brake lamp Lights up Brake lamp no light normal Lamp does not Flashing no light Push starting switch And check the function Of start relay normal No function Conn...

Page 32: ...can t return dstart relay capacitor melted or short circuit Check and adjust Trouble condition The reason Turn signal lamp On to check wi ring of battery normal Lamp dims no Flashing no light Starting Connect motor to the starting motor to Battery directly Running normal Runing slowly Kick the kickstarter lever Easy to kick Difficult to kick Check and adjust Trouble condition The reason Main switc...

Page 33: ...nition coil Check and adjust Trouble condition The reason Replace new spark Plug then check again Good sparking Weak sparking Or no sparking Check spark plug cap And H V cable is Loose or not Check the CDI plug Is loose or not good loosen Check the connection Between CDI plug and Each terminals check The resistivity of Each terminals good abnormal Check relative parts good abnormal good abnormal C...

Page 34: ...oltage then start engine Voltage remain The same Voltage goes up To normal value But after engine Stop the voltage Goes down again Check voltage rectifier Plug is loose or not good loosen Check the voltage Between chassisΘand The red cable of Voltage rectifier good No voltage Check the resistivity Of A C generator coil normal abnormal Start engine connect green cable to Chassis then measure the vo...

Page 35: ...g 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 ...

Page 36: ...Lever b movement of brake loose or damage Brake cable Change brake cable every 2 years Brake cam worn out a clearance between hub and lining b brake shoe and brake lining worn out Brake Wheel hub and brake shor c wheel hub worn and damaged standard dia rear 110 0mm limit of use rear 111 0mm For M2 50 only Front wheel axle damaged or distorsion Rear wheel axle damaged or distorsion unit kg c 1 driv...

Page 37: ...m Looseness on Connecting Part Oil leakage Damaged Condition Rear Damper Absorber Loose on ass y part Function Clutch and Shift mec hanism Gear oil leakage LH crank case Transmission Gear oil Change gear oil M2 200 220 110C C replace 130C C total M2 125 150 90C C replace 110C C total Ignition Spark plug Clearance 0 6 0 7mm NGK BP7HS NGK C7HSA NGK C7E NGK CR7E M2 50 M2 125 M2 150 M2 200 M2 220 Star...

Page 38: ...y1inder head inlet pipe locking Condition Locking torque Cylinder head cold 1 0 1 2KG m Cam holder nut 2 0 2 3kg m M2 50 M2125 150 200 220 Compression Pressure G MAX 50 6kg c 600rpm Using starting motor Compression Pressure G MAX 125 12kg c 750rpm Using starting motor Engine parts Compression Pressure G MAX 150 200 220 11kg c 650rpm Using starting motor Oil leakage Oil quantity Dirty Oil quantity ...

Page 39: ...udgement standard Remark Function Lamp system Dirty or broken Horn signal Lamp reflector Function lock Function Rear view mirror Dirty or broken License plate Dirty or damaged Dashboard Function Losseness or Damage on Ass y part Muffler silencer Function chassis Loose or Damaged The previous Abnormal case Confirm it does Not happen Again Chassis Lubrication others Decarbonate on Combustion room An...

Page 40: ...w the opposite procedure of disassembling after recharging Note A The battery is totally sealed do not remove seal bolts when recharging B It s 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 4A 30min G MAX125 150 Standard recharging 0 7A 5 10 hr or rapid recharging 3A 60min...

Page 41: ...ner cover 2 Take out the air cleaner filter 3 Clean the filter by the compressor air 4 Assemble the air cleaner by the opposite procedure Note Do not start the engine when the air cleaner is Not installed G MAX50 G MAX125 150 M2 200 220 M2 250 ...

Page 42: ...heck 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 G MAX200 C7E NGK or equivalent spec G MAX220 CR7E NGK or equivalent spec G MAX250 DPR7EA NGK or equivalent spec Gap of spark plug 0 6 0 7mm general 0 9mm M2 250 Ele...

Page 43: ...uously measure the compression pressure 5 Compression pressure 50cc 6 kg c 600rpm 125cc 12 kg c 750rpm 150 200 220 cc 11 kg c 650rpm 250 cc see engine chapter 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 cham...

Page 44: ...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 can t be adjusted This scooter is using CDI set it is no need to adjust ignition timing If ignition timing is not correct check the CDI sets and AC magneto change it if ...

Page 45: ...front brake adjustment 1 check the clearance of front brake lever Clearance 10 20mm 2 if the clearance is beyond standard check whether a The air mix into the pipe caliper b The oil brake system is leaking 3 check the fluid level a Refill the brake fluid when the level is under the LOWER line b Brake fluid specification SAE J 1703F DOT3 DOT4 Note a To prevent the fluid splitting onto the parts or ...

Page 46: ...the tire 5 Check the depth of tire Thread a Depth front rear According to mark of tire to change a new tire Note When the arrow of rear brake indicator align with the arrow of left crankcase change the brake lining 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 fo...

Page 47: ... 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 ...

Page 48: ...t 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 ...

Page 49: ...en 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 ...

Page 50: ...he 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 ...

Page 51: ... 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 ...

Page 52: ... 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 ...

Page 53: ...apping 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 ...

Page 54: ...antle 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 ...

Page 55: ...justment 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...

Page 56: ...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 Clean the oil pump and Crank case before operation ...

Page 57: ...ng check if there is still air trapped in the oil pipe After assembling check the following a the adjustment of control cables b Is there air in oil pipe c oil leakage at any location 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 O ring o...

Page 58: ...retor pipe engine flywheel shelf s 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 Re...

Page 59: ...late abnormal B CVT parts measurement data Item Standard value mm Limit of use mm Model 50cc 50cc The inner dia of Slide driving plate 20 035 20 085 20 123 The outer dia of boss movable Driving plate 19 960 19 974 19 911 Belt width 18 0 19 0 17 0 Clutch lining thickness 3 1 5 Clutch outer diameter 117 0 117 2 117 5 Driving plate spring free length 87 9 82 5 The outer diameter of driven plate sets ...

Page 60: ...C Driving pulley 1 Take off the 10 screws of left Cover remove the left cover 2 Take off the left cover ...

Page 61: ...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 ...

Page 62: ...7 Remove the start idle gear fixing plate 8 Take off the idle gear ...

Page 63: ...emove 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 plate s gasket 3 Check the wearing condition for driving pulley surface 4 Check the outer diameter of the driving plate s boss Locking torque 1 Nut ...

Page 64: ... 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 ...

Page 65: ...r 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 cMake sure that on end of the torsion spring is hooked on the gro...

Page 66: ...ocedure of dismantling 3 Checking the clutch a Check the clutch driven face Check the clutch cover about its wearing Condition and inner diameter measurement b Check the clutch lining wearing condition and measure the lining thickness limit of use change it below 2 5mm Locking torque M10 3 5 4 0kg m Dismantling the clutch needs the special Tool please contact your dealers Limit of use 50cc Change ...

Page 67: ...iving 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 ...

Page 68: ...ect 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 can t be scratched The contact surface should be lubricated by specified oil C PISTON CYLINDER DATAS Part name description Standard Value mm Limit of use mm Cylinder head Flatness 0 100 cylinder Bore 39 995 40 015 40...

Page 69: ...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 ...

Page 70: ...k 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 ...

Page 71: ...iston 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 ...

Page 72: ...contact surface of cylinder head cylinder F Combustion chamber cleaning zClean out the carbon piled up in combustion chamber zDo not scratch the combustion chamber and contact surface of the cylinder during cleaning operation Limit of use If it exceeds 0 1mm Change a new one ...

Page 73: ... of the cylinder and piston 2 Clean out the carbon on the cylinder exhausting port 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 Be careful not to scratch the inner Surface of cylinder ...

Page 74: ...m 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 5 Inner diameter measurement of the piston pin hole Limit of use change it when over 14 032mm Limit of use change it when over 0 100mm ...

Page 75: ...n 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 ...

Page 76: ...e 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...

Page 77: ... 5 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 ...

Page 78: ...ve 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 ...

Page 79: ...ear worn out or cracked 2 Gear burnt out zNoise occurs when running 1 Gear worn out burnt or gear surface damaged 2 Bearing worn out or loosen zOil 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 ...

Page 80: ...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 ...

Page 81: ...dle 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 ...

Page 82: ... 7 Crankcase Crankshaft A Disassembling diagram ...

Page 83: ...earing is loose 3 The bearing of gear box is loose C Data Measuring Item Standard value Limit of use mm Clearance of connecting rod big end Parallel direction to rod 0 20 0 50 0 71 50cc Clearance of connecting rod big end Perpendicular direction to rod 0 04 Swingness of the crank shaft neck 0 03 0 10 ...

Page 84: ...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 ...

Page 85: ...4 Remove the carburetor 5 Remove the intake manifold and reed valve 6 Remove the oil pump fan cowl and fan itself ...

Page 86: ...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 ...

Page 87: ...ween crank shaft and co rod big end Parallel direction to rod 2 check the looseness on X Y axis of the connecting rod big end Perpendicular directions to rod Limit of use Replace a new when above 0 71mm Limit of use Replace a new one when above 0 04mm ...

Page 88: ...en Above 0 1mm 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 60mm A B ...

Page 89: ...SET 14 MAIN JET 03 SPG COMP 15 FLOAT VALVE SET 04 PLATE SET 16 PIN ARM 05 TUBE SET 17 FLOAT SET 06 JET NEEDLE 18 FLOAT CHAMBER SET 07 THROTTLE VALVE 19 TUBE SET 08 SCREW SET 20 SCREW WASHER 09 SCREW SET A S 21 CAP HOLDER 10 O RING 22 AUTO BYSTARTER SET 11 NEEDLE JET 23 SCREW WASHER 12 SLOW JET 24 PLATE SET ...

Page 90: ...ure 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...

Page 91: ...etor 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 ...

Page 92: ...ve 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 ...

Page 93: ...and assembling operation 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 ...

Page 94: ... 1 Lubrication System ...

Page 95: ... 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 ...

Page 96: ...aft 3 Install the lock pin 4 Match the lock pin hole to the pump cover and install the oil pump cover 5 Put on the screws and tighten them 6 After installing turn the shaft lightly to assure installation 7 Place the oil pump into the crankcase 8 Tighten the oil pump after installation Note The notch of the oil pump shaft should comply With the notch of the inner gear Note When installing the arrow...

Page 97: ...0 045 0 10 0 12 Oil pump Clearance between gear end and Oil pump body 0 045 0 10 0 12 Troubleshooting Reduction in fuel oil volume a Natural consumption b Leakage of fuel c Piston loop seizes or improperly install ation d Worn out of valve s 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 ...

Page 98: ...otor 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 3 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 follow...

Page 99: ... 4 Drive pulley starter clutch driven pulley A Troubleshooting B Measurement data C Driving pulley D Starter E Clutch driven pulley ...

Page 100: ...rty Note No grease and oil should be distributed over driving belt and driving plate B Measurement data Item Standard value mm Limit of use mm The inner dia Of slide driving plate 24 011 24 052 24 10 The outer dia Of boss movable Driving plate 23 960 23 974 23 940 Belt width 20 0 21 0 19 0 Clutch lining thickness 3 1 5 Clutch outer inner diameter 125 0 125 2 125 5 Driven plate spring free length 1...

Page 101: ... 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 ...

Page 102: ...on level ground increase the engine s speed slowly and notice the RPM at which the motorcycle begins to move forward Specified Engagement RPM 3100 300 rpm 6 Clutch LOCK UP inspection Apply the rear brake as firm as possible Briefly open the throttle fully and notice the maximum engine RPM sustained during the test cycle Specified Clutch LOCK UP RPM 5200 400 rpm ...

Page 103: ... 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 Locking torque 1 Nut of driving pulley M12 4 0 5 5kg m 2 Locking nut of clutch...

Page 104: ...ndition 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 ...

Page 105: ...ck the wearing condition of the outer diameter of spindle comp and the inner diameter of bush and gear b Check the wearing condition of shaft of driven gear comp Gear sets and ratchet 9 Assembling the starter Assemble the starter follows the Opposite procedure of dismantling Locking torque M6 1 0 1 2kg m Note cMake sure one end of the torsion spring is hooked on the groove of driven gear and anoth...

Page 106: ...the clutch follows the opposite procedure of dismantling 3 Checking clutch dismantling tool a Check clutch driving face Check clutch cover about its wearing condition And inner diameter measurement zlimit of use change it above 125 5mm b Check clutch lining wearing condition and Measure the lining thickness zlimit of use change it below 1 5mm Locking torque M12 4 0 5 5kg m ...

Page 107: ... driving plate sets And measure outer diameter zlimit of use change it above 33 95mm e Check wearing condition of slide driven plate And measure its Inner diameter zlimit 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 ...

Page 108: ... 23 HEXAGON NUT 6 VALVE INLET 24 SHAFT EX ROCKER ARM 7 GASKET HEAD CYL 25 LOCK PIN 8 LOCK PIN D10 14L 26 CAMSHAFT HOLDER 9 HEXAGON FLANGE BOLT 27 PLAIN WASHER 10 STUD BOLT 28 HEXAGON FLANGE NUT 11 STUD BOLT 29 CYL HEAD COVER COMP 12 INSULATOR CARB GASKET 30 CYL HEAD COVER 13 INSULATOR CARB 31 PACKING CYL HEAD COVER 14 IGNITION PLUG CR7HSA 32 HEXAGON FLANGE BOLT 15 PLAIN WASHER 33 VALVE SEAL 16 SPR...

Page 109: ...igh 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 stem s oil seal is damaged B The operation data information Description IN EX Standard Value mm Limit of use mm IN 0 08 Clearance between adjuster tapped Screw and valve stem Before warm up EX 0 08 Compression pressure thrott...

Page 110: ...over 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 ...

Page 111: ...head are at parallel position convex part of cam shaft points upwards then install the cam shaft on the cylinder head 3 Install the cam chain onto the cam shaft gear 4 Install the locking pin 5 Install the camshaft holder washer and nuts on the cylinder head 6 Lock tightly the cylinder head nuts Locking torque Cam shaft holder nuts 2 0kg m 7 Adjust the valves clearance Limit of Use IN replace it b...

Page 112: ...ad gasket 8 Remove cam chain guide Further dismantling Use the valve contracting tool to remove valve pin supporter the vlave spring collar valve spring and valve stem oil seal Notice Not to injure the contact Surface of the cylinder Avoid any object dropping info the engine Notice Valve Spring has to be operated by the valve spring contractor To assemble the cylinder head please follow the opposi...

Page 113: ...and Piston ring 2nd ring 0 02 0 06 0 10 lst ring 0 10 0 25 0 50 2nd ring 0 10 0 25 0 50 Clearance of cutting section side ring 0 2 0 7 Piston outer diameter 57 470 57 490 57 400 Measuring location of piston outer dia Down to 5 mm from the piston skirt Clearance b w piston and cylinder 0 025 0 035 0 10 Piston Piston ring Piston pin hole inner dia 15 006 15 012 15 030 Piston pin outer diameter 14 99...

Page 114: ...ket 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 can t be injured Contact Surface should lubricate by specified oil C Data 125CC Part name description Standard value mm Limit of use mm Bore 51 490 51 510 51 60 Curve 0 005 Cylindrility 0 005 Cylinder Roundness 0 005 lst ring 0 03 0 07 0 10 Clear...

Page 115: ...Measuring location Perpendicular to the piston pin hole down to 7mm 125CC or 5mm 150CC form the piston skirt 2 The clearance between the piston and piston pin 3 Checking any wearing damage inside the cylinder Vertical to piston pin and in X Y direction to measure cylinder bore from the upper middle and lower location 4 The maximum clearance between the cylinder and piston pin Dot drop the clip int...

Page 116: ...ion of the inner dia in X or Y direction d Checking the flatness of cylinder contact surface e Connecting rod small end inner diameter measurement Limit of use Roundness change it when above 0 005mm Cylindrility change it when above 0 005mm Limit of use change it when above 0 05mm Limit of use change a new one when above 13 06mm 125CC 15 06mm 150CC ...

Page 117: ...ton piston pin and piston pin clip b Installing piston 1 Fix the lock pin and gasket on the crankcase 2 Lubricate the Cylinder inner surface piston and piston rings by Motor Oil 3 Install the piston ring into the cylinder carefully NOTICE Do not drop other objects into the crankcase NOTICE a The mark IN on the piston tip should face to the INLET side b Do not drop the piston pin clip into the cran...

Page 118: ... 7 A C Generator A Dismantling AC generator B Installing AC generator ...

Page 119: ...mantle 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 ...

Page 120: ...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 ...

Page 121: ...ssion mechanism D Assemble the final transmission mechanism A Troubleshooting zEngine can be started but the vehicle doesn t move 1 Gear worn out or cracked 2 Gear burnt out zNoise occur when running 1 Gear worn out burnt or gear surface 2 Bearing worn out of loosen zOil leakage 1 Too much oil 2 Seal worn out or damaged ...

Page 122: ...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 ...

Page 123: ...move 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 ...

Page 124: ...ng 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 ...

Page 125: ... 9 Crankcase Crankshaft A Disassembling diagram B Troubleshooting C Data D Remove crankcase and crankshaft E Check crankshaft F Assemble the crankcase ...

Page 126: ...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 ...

Page 127: ...nd vertical direction 0 04 Swingness of the crank shaft journal 0 03 0 10 D Remove the crankcase and crankshaft by the following procedures 1 Remove the engine 2 Remove the muffler 3 The carburetor 4 Engine corer 5 Cylinder head 6 Cylinder 7 The driving plate 8 AC flywheel magneto 9 The starter clutch 10 Oil pump 11 Bolts of left right crankcase ...

Page 128: ... Change it when above 0 1mm Change it when above 0 1mm 3 Check the looseness of crankshaft bearing If it is loosen replace to a new one F Assemble crankcase 1 assemble crankcase according to the opposite procedure of disassembling 2 The locking torque of bolts and nuts are described in previous chapter please refer Limit of use replace it when above 0 04mm A B ...

Page 129: ...ATIONS ITEM SPECIFICATION SPECIFICATION Model M2 125 M2 150 Carburetor type KEIHIN CVK24 KEIHIN CVK24 Bore size 24mm 24 mm I D NO 013 046 Idle r min 1700 100 1700 100 Float height 18 0 0 5 mm 18 0 0 5 mm Main jet 102 102 Jet needle 4HGGN 4HLGL Needle jet P O P O Pilot jet 35 35 Pilot screw PRE OPENING 2 1 4 turns out 1 1 2 turns out ...

Page 130: ...present on the downstream side of the venturi A Negative pressure is admitted into the diaphragm chamber d through an orifice e provided in the piston valvec Rising negative pressure overcomes the spring f force causing the piston valve c to rise into the diaphragm chamber and prevent the air velocity from increasing Thus air velocity in the venturi passage is kept relatively constant for improved...

Page 131: ...tered by the pilot screw g and sprayed into the main bore through the pilot outlet port i COASTING ENRICHMENT SYSTEM The coasting enrichment system is included in the slow system At the normal running operation Joining of the air from upper part of then carburetor inlet side to pilot air passage j which obtains proper fuel air mixture ratio But if the throttle valve is closed suddenly a large nega...

Page 132: ......

Page 133: ...s the needle jet g mixes with the air admitted through the main air jet h and forms an emulsion The emulsified fuel then passes through the clearance between the needle jet g and jet needle i and is discharged into the venturi A where it meets the main air stream being drawn by the engine Mixture proportioning is accomplished in the needle jet g The clearance through which the emulsified fuel must...

Page 134: ...l content reaches upper part of The fuel pipe and mixes again with the air coming through a passage extending from main bore h The two succesive mixings of fuel with air are such that proper fuel air mixture for starting is produced when the mixture is sprayed out through outlet port i into the main bore NOTE An enrichener is operated almost the same way as a choke When the engine is cold The auto...

Page 135: ... valve d pushes up against the valve seat When this occurs no fuel enters the float chambere As the fuel level falls the float clowers and the needle valve d unseats itself admitting fuel into the float chamber e In this manner the needle valve d admits and shuts off fuel to maintain the appropriate fuel level inside the float chamber e ...

Page 136: ...hen the rider open the throttle grip quickly the intaken air volume becomes large and air velocity at the bottom of the throttle valve piston valve is slow and sucking volume of fuel is less The throttle valve lever c pulls lever d with the cable and lever e turns and pushes rod f The rod f pushes plunger g This plunger pushes out the fuel through outlet pipe h spraying fuel into the main bore ...

Page 137: ... circuits in the carburetor body with a spray type cleaner and allow each circuit to soak if necessary to loosen dirt and varnish Blow the body dry using compressed air CAUTION y after cleaning reassemble the carburetor with new seals and gaskets Some carburetor cleaning chemicals especially diptype soaking solutions are very corrosive and must be handled carefully Always follow the chemi cal manu...

Page 138: ...attery has been connected NOTE To inspect the function check for change of temperature from the cold condition CAUTION FLOAT HEIGHT ADJUSTMENT To check the float height turn the carburetor upside down Measure the float height A while the float arm is just con tacting the needle valve using vernier calipers Bend the tongue as necessary to bring the float height A To the specified level Float height...

Page 139: ... cleaner blocked 2 Mixed air is too dilute in the idle system zSparking unsteady while increasing speed 1 Ignition system malfunction 2 Air mixture is too dilute zDifficult 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 vol...

Page 140: ...t main jet and fuel adjusting screws zAssemble the float valve float and float pin 4 Checking fuel level Note When the valve is too dirty or severely worn not the Valve base will not close completely thus will result In increasing of fuel level and fuel leakage problem A new replacement is needed Note zAvoid any damage on the jets and the fuel adjusting screws zBefore dismantling record the number...

Page 141: ... 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 Limit of use mm thickness of frt pad M2 50 5 3...

Page 142: ...ut 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 ...

Page 143: ...s 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 8 Before assembling please add grease on each cable Locking Torque M6 1 0 1 2kg m M10 3 0 4 0kg m ...

Page 144: ...nt 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 ...

Page 145: ...ing 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 zHorizontal direction Change a new one when above 2 0mm zVertical direction Change a new one when above 2 0mm ...

Page 146: ...t 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 125 150 200 250 NOTE If the guide rod is crooked it should be replaced by a new one or repaired ...

Page 147: ... 3 0kgm 6 Checking the front brake disk Standard thickness of disk 3 5 mm M2 50 4 0 mm M2 125 150 200 220 250 Limit of usage change it when below 3 0 mm M2 50 3 5 mm M2 125 150 200 220 250 7 Checking the front brake PAD a standard thickness 5 3mm M2 50 8 3mm M2 125 150 200 220 250 limit of use As the thickness is below using limit change it Note No grease on the lining M2 125 150 200 220 250 M2 50...

Page 148: ...of fuel volume adjusting screws 1 After the engine is warm up adjust the stopping screw throttle of throttle valve to the standard rpm Idle rpm 1 700 100rpm 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 th...

Page 149: ...g 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 Model Standard value mm Limit of use mm The swingness of rear wheel G MAX 2 0 Wheel hub inner diameter M2 50 110 0 111 0 Thickness of brake lining M2 50 4 0 2 0 Brake disc thickness M2 125 150 2...

Page 150: ... of the rear wheel 3 Remove the rear wheel 4 To assemble the rear wheel please reverse the dismantling procedure 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 Locking torque M6 0 7 1 1kg m M14 8 0 10 0kg m ...

Page 151: ...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 125 150 200 220 250 ...

Page 152: ...84 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 M2 50 125 150 200 220 M2 250 ...

Page 153: ... is blocked c Auto cock and filter is blocked d The membrane of fuel pump is over swell 2 The membrance of auto cock is over extended a Fuel tank cover s ventilation hole is blocked b Fuel pipe is crooked squeezed or blocked c fuel pump and fuel filter is dirty B Fuel supply system diagram ...

Page 154: ... 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 ...

Page 155: ...e 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 ...

Page 156: ...tem 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 ...

Page 157: ...der 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 yCurrency 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 yAbnormal recharge system 1 The plug connection is not good wi...

Page 158: ...y 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 125 150 200 220 250 ...

Page 159: ...ing current and time Standard 0 4A 4 10Hr or Rapid 3A 60min 50cc Standard 0 7A 5 10Hr or Rapid 3A 60min 125 150cc Standard 0 9A 5 10Hr or Rapid 3A 60min 200 220 250cc NOTICE This battery is totally sealed Do not remove seal bolt when recharging Notice yKeep away from fire when recharging yThe ON or OFF of recharging currency must be operated by the switch of recharge It will cause spark or explosi...

Page 160: ...ting Then increase the rpm slowly Assume the battery is fully charged situation Head Lamp Switch Recharging rpm 2 500rpm 6 000prm OFF DAY Under2 000rpm 0 6A MIN 1 5A MIN ON NIGHT Under2 000rpm 0 6A MIN 1 5A MIN e If the testing result does not match the standard value check the regulator While testing the red wire cable must not touch the frame yThis test needs to be done when the battery is fully...

Page 161: ...s produced at the positive electrode will immediately react With an active material lead at the negative electrode to turn back to water thus preventing water from losing PRECAUTION WHEN HANDLING BATTERY ELECTROLYTE y Take most care so as not to cause battery acid to contact a person and the vehicle y If battery acid has contacted the skin clothes or vehicle immediately flush with plenty of water ...

Page 162: ... of electrolyte in even one cell will result in deteriorated performance and shortened life INSERTING CAP SEALING PLUG CAUTION To install the cap temporarily fit the cap to all the cells Lightly thereafter press the cap little by little into each filler Hole evenly and horizontally Inserting the cap at once in one cell and then in the next Cell will cause the cap to deform resulting in poor sealin...

Page 163: ...the battery voltage If the voltage reading is less than the 12 0V recharge the battery with a battery charger y When recharging the battery remove the battery from the motorcycle y Practice the standard charging unless otherwise necessary y After recharging wait for more than 30 minutes and check the battery voltage with a pocket tester y If the battery voltage is less than the 12 5V recharge the ...

Page 164: ... 3 Recharge system A Recharge system diagram for M2 50 ...

Page 165: ...B Recharge system diagram for M2 125 150 ...

Page 166: ...box b Measure the resistance value of terminals 3 Check regulator Measure the resistance value between each terminal It should be in the specified range otherwise change a new one Yellow V S black 0 1 1 0 White V S black 0 2 2 0 ACG inside M2 50 M2 125 150 200 220 250 ...

Page 167: ...gnition 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 ...

Page 168: ... 5 The starting system 1 The wiring of starting 2 Make sure the Engine RUN OFF switch is in Run position 3 Check the safety switch by operating the brake lever and the brake lamps shall light on ...

Page 169: ...unction 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 yCheck 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 over 5 s...

Page 170: ...46 Wiring diagram for M2 50 ...

Page 171: ...47 Wiring diagram for M2 125 150 ...

Page 172: ...48 Wiring diagram for M2 150 4V ...

Page 173: ...49 Wiring diagram for M2 200 ...

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Page 175: ......

Page 176: ...50 Wiring diagram for M2 250 ...

Page 177: ...0 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 ...

Page 178: ...ngine assembly Front section muffler 1 dismantle 2 castle nuts 2 take off front section oil cooler 1 loosen 2 bolts remark there are 2 washers 2 dismantle the oil cooler Second Air Injection SAI 1 dismantle 1 bolt 2 take off the SAI Fan cover 1 dismantle 2 bolts 2 dismantle 2 screws 3 take off the fan cover ...

Page 179: ...PGO 200 220 engine dismantle Cooling cowl 1 dismantle 3 tapping screws 2 dismantle 1 upper hexagon bolt 3 take off upper cooling cowl 4 dismantle 1 lower hexagon bolt 5 take off lower cooling cowl ...

Page 180: ... 2 dismantle cylinder head cover Chain tensioner 1 loosen the middle bolt 2 dismantle the spring 3 loosen 2 bolts of the body 4 dismantle the chain tensioner body 5 take off the packing Recover the chain tensioner 1 dismantle the bolt spring 2 push the lock 3 push back to the body ...

Page 181: ... 4 1 2 3 Camshaft holder 1 loosen 4 nuts washers 2 dismantle the holder 3 dismantle 2 lock pins 4 dismantle the camshaft Cylinder head 1 loosen 2 hexagon bolts 2 dismantle cylinder head 3 dismantle 2 lock pins 4 take off the gasket 1 2 ...

Page 182: ... take off the cylinder 3 dismantle 2 lock pins 4 take off the packing Piston 1 dismantle 2 clips 2 dismantle piston pin 3 take off the piston Attention To prevent clip falling down the crankcase use clothes to cover the crankcase Engine lower hanger 1 loosen left 2 hexagon bolts ...

Page 183: ...lts 3 dismantle the engine lower hanger Cooling fan 1 loosen 4 bolts 2 dismantle the fan Generator outer 1 Loosen 1 nut washer 2 use special tool turn the outer counterclockwise lock the inner bolt clockwise 3 dismantle the outer ACG special tool S620505G01 ...

Page 184: ...e dismantle 1 2 3 4 Generator stator 1 loosen 2 bolts washers of pulser 2 dismantle the bracket of pulser 3 loosen 3 socket bolt 3 dismantle the stator Starting motor 1 loosen 2 hexagon bolts 2 dismantle starting motor ...

Page 185: ... pins 4 dismantle the packing Attention Be careful of the surface don t defect it to avoid oil leaking Starting idle gear 1 dismantle the shaft 2 dismantle the body One way Clutch 1 loosen the nut washer with special tool 2 dismantle the one way clutch Attention 1 the thread of nut is left hand direction clockwise to loosen ...

Page 186: ...ockwise to lock 2 use the compressed air wrench to loosen nut or use the tool to fix the crankshaft Special tool one way clutch S620504G01 Sprocket of oil pump 1 dismantle E clip washer 2 dismantle the sprocket chain 3 dismantle the sprocket of crankshaft ...

Page 187: ... miss it Right crankcase 1 loosen 2 bolts 2 dismantle the right crankcase 3 dismantle 2 lock pins 4 take off the packing Attention Be careful of the surface don t defect it to avoid oil leaking Crankshaft 1 dismantle the crankshaft assembly including a ball bearing in the left side 2 take off the timing chain Attention Be careful to take off the ...

Page 188: ...PGO 200 220 engine dismantle crankshaft from the left crankcase don t damage the oil impact the crankshaft ...

Page 189: ...meter of valve stem EX 4 955 4 970 4 900 IN 5 000 5 012 5 30 Inner diameter of valve guide EX 5 000 5 012 5 30 IN 0 010 0 037 0 08 Clearance between valve stem and Valve guide EX 0 030 0 057 0 10 The inner dia Of slide drivingplat 27 011 27 021 27 10 The outer dia Of boss movable Driving 26 970 26 990 26 95 Belt width 18 7 19 3 17 70 Clutch lining thickness 3 1 50 Clutch outer inner diameter 130 0...

Page 190: ...ween piston and piston pin 0 020 0 017 0 025 Connecting rod small end inner dia 16 010 16 016 16 060 Piston Cylinder inspection 220CC Part name description Standard value mm Limit of use mm Bore 67 485 67 505 67 595 Curve 0 005 Cylindrility 0 005 Cylinder Roundness 0 005 lst ring 0 04 0 08 0 15 Clearance b w Piston and Piston ring 2nd ring 0 02 0 06 0 15 lst ring 0 10 0 25 0 50 2nd ring 0 30 0 45 ...

Page 191: ...Standard value mm Limit of use mm Clearance of connecting rod big end axle direction 0 005 0 013 0 05 Clearance of connecting rod big end vertical direction 0 10 0 40 0 8 Swingness of the crank shaft journal 0 03 0 10 ...

Page 192: ...1 6 3 Electric system Carburetor model electric General maintenance Engine Management System ...

Page 193: ...What is transistor ignition Transistor Ignition System z Transistor a kind of semi conductor that can control electric current has the switch function z Apply transistor to engine ignition control called transistor ignition ...

Page 194: ...ion controller z Ignition coil z DC generator with longer pulse flange z TPS Throttle Position Sensor optional part of Carburetor Digital ignition controller ACG Ignition coil TPS Major components of Transistor ignition ...

Page 195: ...aditional C D I CDI Digital controller longer More coils Transistor ignition 5 4 3 2 1 item longer shorter ACG flange no yes CDI More coils Less coils Ignition coil yes no Digital controller yes no TPS G MAX 200 220 transistor Traditional CDI parts ...

Page 196: ...lamp choke RPM 1000 OFF ON Control timing relay Headlamp switch 12V from battery Digital controller Green black fuse Headlamp choke carburetor diagram zWhen engine speed 1000rpm the digital controller permits the relay to conduct the circuit ...

Page 197: ...6 3 phase DC generator Regula tor yellow yellow yellow battery ground ground Charging to battery Battery feedback voltage Charging system diagram ...

Page 198: ...7 Fuse wire white white Main fuse layout relay fuse layout reserved fuse layout Red white Red Red white Red black ...

Page 199: ...8 G MAX 200 220 Electric parts battery relay fuse 15A Seat lamp controller Digital controller diode Remarks If dismantle the battery engine will cease fire ...

Page 200: ... oil Replace 1000cc Total 1400cc Replace 800cc Total 1000cc Gear oil Replace 110cc Total 130cc Replace 90cc Total 110cc Oil filter 2 nd filter 2 nd filter Air element Wet paper bigger Wet paper CVT sponge Circle shape Oval shape headlamp H4 55W 60W HS1 35W 35W ...

Page 201: ...10 G MAX 200 220 Specified engine oil synthetic 1000ml ...

Page 202: ...11 Engine oil gear oil Drain of engine oil drain of gear oil Gear oil filling Replace 110cc total 130cc ...

Page 203: ...e oil filling gauge replacement 1000cc total 1400cc Check the oil level 1 park in flat area 2 keep in idle for 3 minutes 3 cold down 3 minutes 4 take off the gauge 5 when lower the lowest limit add oil to upper limit upper lowest ...

Page 204: ...13 Replace the 2nd oil filter 1 dismantle the right lower cover 2 replace the filter keep the surface clean apply grease to the O ring before installing ...

Page 205: ...14 Air element 1 loosen 8 screws 2 dismantle the cover Take off the element Don t forget to install the black rubber packing back to the element ...

Page 206: ...15 CVT sponge Clean with compressed air or replace a new one 1 loosen 3 bolts 2 take off the sponge ...

Page 207: ...16 CVT dismantle 1 loosen the outer bolts 2 dismantle the cover 3 loosen 2 hexagon nuts Don t miss the lock pin falling into the crankcase ...

Page 208: ...17 CVT install notes 1 keep the words of belt facing to operator 2 push the belt to bottom 3 lock the nuts Rotation direction ...

Page 209: ...18 Spark plug Dismantle the right lower cover Loosen with the special tool Spark plug C7E carburetor or CR7E EMS model ...

Page 210: ...19 Ignition coil Dismantle the right lower cover You can see the ignition coil clearly ...

Page 211: ...20 Front brake system Service data tire pressure 2 0 kg cm2 using limit of Disk thickness 3 5mm using limit of pad thickness to groove bottom ...

Page 212: ...21 Replace the front pads dismantle 1 dismantle clip 2 take off the pin 3 take off the yoke 4 dismantle the pads install reverse procedure of dismantle 2 1 3 ...

Page 213: ...22 Front brake system Service data tire pressure 2 0 kg cm2 using limit of Disk thickness 3 5mm using limit of pad thickness to groove bottom ...

Page 214: ...23 Replace the rear pads dismantle 1 dismantle clip 2 take off the pin 3 take off the yoke 4 dismantle the pads install reverse procedure of dismantle 1 2 3 ...

Page 215: ...1 6 5 Engine Management System EMS ...

Page 216: ...2 EMS index PGO 2nd stage EMS structure EMS units EMS diagnostic ...

Page 217: ...3 Feature of PGO 2nd stage EMS feature 1 small light 2 integrity 3 accuracy 4 simple ...

Page 218: ...ure A ECU Control unit injector coil Fuel supply ignition Engine temperature sensor Throttle position sensor Intake pressure sensor Crank speed sensor 5 sensors Oxygen sensor ISC Idle speed control 2nd air control ...

Page 219: ...5 EMS structure B ECU Oxygen sensor Engine temperature sensor Throttle position sensor Intake pressure sensor injector ISC coil Spark plug Crank speed sensor Electric control unit ...

Page 220: ...6 EMS units ...

Page 221: ...7 噴油嘴 Throttle position sensor Intake pressure sensor injector Idle Speed Controller ...

Page 222: ...8 crank speed sensor Fuel pump Assy Transistor ignition coil comp Oxygen sensor Engine temperature sensor ...

Page 223: ...9 ECU Electronic Control Unit Topple snsor Second air solenoid ...

Page 224: ...10 Important PIN no of ECU ECU PIN 1 PIN 18 PIN 19 PIN 36 PIN ...

Page 225: ...f ECU Important PIN no of ECU PIN NO function 11 Control pole of fuel pump 12 Control pole of headlamp relay 13 supply 5V voltage to sensors 16 Control pole of injector 18 Control pole of coil 19 Input voltage from battery ...

Page 226: ...12 Function of Crank speed sensor function induct the engine speed tell ECU to control inject fuel ignition theory calculate the interval time of each flange on the outer ...

Page 227: ...13 Engine temperature sensor function induct engine oil temperature then ECU knows engine is cold or hot theory different temperature vary resistence ...

Page 228: ...14 Measure engine temperature sensor T resistance KΩ 20 18 800 KΩ 40 1 136 KΩ 100 0 155 KΩ usually 1 5 5 5 KΩ ...

Page 229: ...15 Throttle position sensor TPS function induct throttle angle provides the road load condition to ECU theory angle changes resistance changes ...

Page 230: ...16 Throttle position sensor TPS Lb output Pu power 5V Gr ground Lb Gr throttle output V close 0 6 0 02V WOT 3 8 0 10V ...

Page 231: ...17 Intake pressure sensor function induct intake air pressure ECU judge intake or compress stroke to decide injection ignition theory different pressure outputs diferent resistance ...

Page 232: ...18 壓力特性 0 0 1 0 2 0 3 0 4 0 5 0 0 50 100 150 絕對壓力 kPa 輸出電壓 Vcc V Intake pressure sensor Pu output 5V G B output Gr ground G B Gr press KPa output V 13 3KPa 0 5V 120 KPa 3 4V ...

Page 233: ...19 Intake pressure sensor average resistance in ambient wire R KΩ Pu Gr 2 4KΩ G B Gr 2 4KΩ Pu output 5V G B output Gr ground ...

Page 234: ...20 Oxygen sensor function induct the A F ratio feedback to ECU and decide the injection time modify to the best 14 7 ratio others there is heater inside help it reach the working temperature quickly ...

Page 235: ...21 Oxygen sensor W heater 12V 2 couple 8Ω Gr ground B output ...

Page 236: ...22 injector function inject the gas mixed with air theory control the opening time interval to decide the gas amount ...

Page 237: ...23 injector time msec Gas amou nt feeding injecting R B output 12V Br W output 12V each terminal virus ground is 12V ...

Page 238: ...24 Draining cap of injector bleed the air Used when replace the fuel pump pipe etc drain the gas The gas inside the pipe may become poor quality after storage drain it before start the engine ...

Page 239: ...25 Fuel pump function pumping the gas to injector and keep the constant pressure as 3kgf cm2 theory the regulator keeps constant pressure regulator filter pump ...

Page 240: ...26 Fuel pump R B output 12V B ground R B B voltage 12V resistance 1KΩ ...

Page 241: ... Fall down sensor function when vehicle fall down more than 65degree then EMS cut off the power and cease the engine theory there is ball mechanism inside the sensor act by gravity and conduct the wiring ...

Page 242: ...28 Fall down sensor power degree output ground OFF any OFF ON 65 ON ON 65 OFF to recover the sensor function after fall down 1 turn OFF the key 2 turn ON the key O input 12V Bl W output B grounding ...

Page 243: ...29 ISC Idle Speed Control W ISC A R B ISC B G ISC B Gr ISC A ISC unit R A A 80Ω B B 80Ω ...

Page 244: ...fer the sensors and decide how much air is required then tell the ISC to act forward or backward sample when cold engine ECU tell ISC enrich the by pass air to increase the engine speed After warm up ECU tell ISC reduce the by pass air to decrease the engine speed ISC Idle Speed Control ...

Page 245: ...31 ISC Step motor ISC By pass air Throttle body engine Throttle valve Air flow ISC Idle Speed Control ...

Page 246: ...ISC initialization timing timing when used scooter occur 1 Hard to start the engine 2 Engine Idle speed is unstable 3 Other unstable situation To initialize the ISC then the ISC reset to control zero point ...

Page 247: ...ug quick diagnostic 2 wide open throttle turn on the key the ISC sounds da da 3 release the throttle after the ISC stop acting 4 turn off the key finish initialization Wide open ISC act Key ON throttle Main key ISC Release throttle Key OFF ISC off ...

Page 248: ...34 EMS fuses 7 5A 10A 5A 1A 10A 15A ...

Page 249: ... 5A 7 5A 10A 15A protect the units when extra current occurs 1A Y G B protect the ECU 5A R W G B protect fuel pump injector 7 5A O G B protect ignition wiring EMS 10A O Dg protect EMS system wiring 15A R W R W protect whole vehicle wiring ...

Page 250: ...36 6 6 EMS diagnostic ...

Page 251: ...37 part no S320840G01 name quick diagnostic Quick diagnostic ...

Page 252: ...Prepare quick diagnostic 2 Open the rubber cover beside the battery 3 Plug in the quick diagnostic How to use quick diagnostic 4 turn on the key 5 wait for about 8 seconds 6 observe the EMS led on dash board ...

Page 253: ...39 PC diagnostic PC software KEIHIN adapter connect cable PGO vehicle RS232 or USB PC diagnostic assy S320891G01 S320838G01 software adapter connect cable ...

Page 254: ...40 part number S320891G01 name software adapter PC diagnostic software adapter ...

Page 255: ...41 part number S320838G01 name connect cable PC diagnostic ...

Page 256: ...r 6 long 6 short Crankshaft position sensor Always on ECU Always off System is all right 1 long 1 short Engine temperature sensor 3 long 3 short injector 0 long 9 short Intake manifold pressure sensor 0 long 6 short Throttle position sensor 1 long 7 short Oxygen sensor 3 long 7 short Ignition coil Defect code part ...

Page 257: ...e seat 2 wide open the throttle turn on the key 3 after the EMS led off release the throttle 4 don t turn off the key until EMS led on again 5 turn on the key to confirm again wot EMS led on Key ON EMS led on throttle key EMS check EMS led off Release throttle Key OFF ...

Page 258: ...44 6 7 EMS system Repairing tool ...

Page 259: ...45 pocket tester wiring pocket tester wiring part no S905310005 ...

Page 260: ...46 Ignition gauge connect minimum distance 6mm Plug cap ground ...

Page 261: ...47 Fuel pressure gauge fuel pressure gauge part no S905330008 ...

Page 262: ...48 Connect to the vehicle measure the fuel pressure standard 3kgf cm2 usage 1 dismantle the hose to injector 2 connect the gauge assembly to the pipe 3 turn on the key 4 read the pressure ...

Page 263: ...49 6 8 General Electric units ...

Page 264: ...50 G MAX 220 made in electric diode Storage light controler fuse relay Fuel pump Assy fuel jet relay ...

Page 265: ...51 Signal flasher relay LED within the leg shield cover dismantle the leg shield cover first ...

Page 266: ...52 regulator within the right body cover dismantle 1 luggage comp 2 rear rack 3 body cover ...

Page 267: ...53 Fuel gauge below the middle cover dismantle 1 middle cover ...

Page 268: ...54 Measure the fuel gauge gray output black ground gray black F 4 10Ω E 80 90Ω ...

Page 269: ...55 Starting relay within the right body cover dismantle 1 luggage comp 2 middle cover 3 rear rack 4 body cover ...

Page 270: ...he 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 d Lock and unlock the screw several times to release the bubbles e Operate slowly the brake lever several times f Clamp the brake lever to the end g Loose the drain screw then open the lever completely h Locking the drain screw and th...

Page 271: ...56 EMS relays within the right body cover dismantle 1 luggage comp 2 middle cover 3 rear rack 4 body cover ...

Page 272: ...57 EMS relays wiring A EMS system Dg O Gr B Bl W B fuel pump injector R W R W R B Db C headlamp O O Y W Y A B C ...

Page 273: ...58 Control of relays Relay 15A theory use small current to control big current Usage fuel pump injector EMS whole system headlamp Small current ECU Big current ...

Page 274: ...59 Measure the relays use the pocket tester 1 find the control coil 2 fit 12V to the control coil 3 the relay sounds ka 4 measure the resistance disconnect NG connected OK Ω Ω DC 12V 1 2 4 ...

Page 275: ......

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