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e Contents
FORWARD
This service manual contains the technical data of each component inspection and
repair for the 525 ATV.The manual is shown with illustrations and focused on
“Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that
provides technician with service guidelines.
If the style and construction of the ATV 525, are different from that of the photos,
pictures shown in this manual, the actual vehicle shall prevail. Specifications are
subject to change without notice.
Service Department
TAIWAN GOLDEN BEE CO., LTD.
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Homepage Contents
HOW TO USE THIS MANUAL
This service manual describes basic information of different system parts and
system inspection & service for 525 ATV.
In addition, please refer to the manual contents in detailed for the model you
serviced in inspection and adjustment.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance information and special tools
manual.
The third to the 11th chapters cover engine and driving systems.
The 12th chapter is cooling system.
The 13th to the 16th chapter is contained the parts set of assembly frame body.
The 17th chapter is electrical equipment.
The 18th chapter is wiring diagram.
Please see index of content for quick having the special parts and system
information.
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Symbols and marks are used in this manual to indicate what and where the special service are needed, in
case supplemental information is procedures needed for these symbols and marks, explanations will be
added to the text instead of using the symbols or marks.
Warning
Caution
Engine oil
Locking sealant
Oil seal
Brake fluid
Grease
Renew
Means that serious injury or even death may result if procedures are not
followed.
Means that equipment damages may result if procedures are not followed.
Limits to use SAE 10W-40 API SG class oil. Warranty will not cover the
damage that caused by not apply with the limited engine oil.
King Mate G-3 is recommended.
Apply sealant; medium strength sealant should be used unless otherwise
specified.
Apply with lubricant.。
Replace with a new part before installation.
Use recommended brake fluid DOT4 or WELLRUN brake fluid.
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Indication
Indication of components.
Indicates position and operation directions
Components assembly directions each other.
Indicates where the bolt installation direction, --- means that bolt
cross through the component (invisibility)
1-1
1. GENERAL INFORMATION
To this chapter contents
General Safety
Carbon monoxide
If you must run your engine, ensure the place is
well ventilated. Never run your engine in a closed
area. Run your engine in an open area, if you have
to run your engine in a closed area, be sure to use
an extractor.
Caution
Exhaust contains toxic gas which may cause one
to lose consciousness and even result in death.
Gasoline
Gasoline is a low ignition point and explosive
material. Work in a well-ventilated place, no flame
or spark should be allowed in the work place or
where gasoline is being stored.
Caution
Gasoline is highly flammable, and may explode
under some conditions, keep it away from
children.
Used engine oil
Caution
Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer although it
might not be verified.
We recommend that you wash your hands with
soap and water right after contacting. Keep the
used oil beyond reach of children.
Hot components
Caution
Components of the engine and exhaust system
can become extremely hot after engine running.
They remain very hot even after the engine has
been stopped for some time. When performing
service work on these parts, wear insulated
gloves and wait until cooling off.
1-2
Battery
Caution
‧
Battery emits explosive gases; flame is strictly
prohibited. Keeps the place well ventilated
when charging the battery.
‧
Battery contains sulfuric acid (electrolyte)
which can cause serious burns so be careful
do not be spray on your eyes or skin. If you
get battery acid on your skin, flush it off
immediately with water. If you get battery acid
in your eyes, flush it off immediately with water
and then go to hospital to see an
ophthalmologist.
‧
If you swallow it by mistake, drink a lot of
water or milk, and take some laxative such as
castor oil or vegetable oil and then go to see a
‧
doctor.
Keep electrolyte beyond reach of children.
Brake shoe
Do not use an air hose or a dry brush to clean
components of the brake system; use a vacuum
cleaner or the equivalent to avoid dust flying.
Caution
Inhaling brake shoe or pad ash may cause
disorders and cancer of the breathing system
Brake fluid
Caution
Spilling brake fluid on painted, plastic, or rubber
parts may cause damage to the parts. Place a
clean towel on the above-mentioned parts for
protection when servicing the brake system.
Keep the brake fluid beyond reach of children.
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To this chapter contents
Service Precautions
●
Always use with TGB genuine parts and
recommended oils. Using non-designed parts for
TGB ATV may damage the ATV.
●
Special tools are designed for remove and
install of components without damaging the
parts being worked on. Using wrong tools may
result in parts damaged.
●
When servicing this ATV, use only metric tools.
Metric bolts, nuts, and screws are not
interchangeable with the English system, using
wrong tools and fasteners may damage this
vehicle.
●
Clean the outside of the parts or the cover before
removing it from the ATV. Otherwise, dirt and
deposit accumulated on the part's surface may fall
into the engine, chassis, or brake system to cause
damage.
●
Wash and clean parts with high ignition point
solvent, and blow dry with compressed air. Pay
special attention to O-rings or oil seals because
most cleaning agents have an adverse effect on
them.
1. GENERAL INFORMATION
●
Never bend or twist a control cable to prevent
unsmooth control and premature worn out.
●
Rubber parts may become deteriorated when old,
and prone to be damaged by solvent and oil.
Check these parts before installation to make sure
that they are in good condition, replace if
necessary.
●
When loosening a component which has
different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.
●
Store complex components such as
transmission parts in the proper assemble order
and tie them together with a wire for ease of
installation later.
●
Note the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
●
Components not to be reused should be
replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.
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1-3
To this chapter contents
1. GENERAL INFORMATION
●
The length of bolts and screws for assemblies,
cover plates or boxes is different from one another,
be sure they are correctly installed. In case of
confusion, Insert the bolt into the hole to compare
its length with other bolts, if its length out side the
hole is the same with other bolts, it is a correct
bolt. Bolts for the same assembly should have the
same length.
●
Remove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.
●
Tighten assemblies with different dimension
fasteners as follows: Tighten all the fasteners
with fingers, then tighten the big ones with
special tool first diagonally from inside toward
outside, important components should be
tightened 2 to 3 times with appropriate
increments to avoid warp unless otherwise
indicated. Bolts and fasteners should be kept
clean and dry. Do not apply oil to the threads.
●
When oil seal is installed, fill the groove with
grease, install the oil seal with the name of the
manufacturer facing outside, and check the shaft
on which the oil seal is to be installed for
smoothness and for burrs that may damage the
oil seal.
Manufacturer's name
1-4
●
The ends of rubber hoses (for fuel, vacuum, or
coolant) should be pushed as far as they can go
to their connections so that there is enough room
below the enlarged ends for tightening the
clamps.
Groove
Clamp
Connector
●
Rubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
●
The tool should be pressed against two (inner
and outer) bearing races when removing a ball
bearing. Damage may result if the tool is pressed
against only one race (either inner race or outer
race). In this case, the bearing should be
replaced. To avoid damaging the bearing, use
equal force on both races.
Both of these examples can result in
bearing damage.
Boots
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To this chapter contents
●
Lubricate the rotation face with specified
lubricant on the lubrication points before
assembling.
1. GENERAL INFORMATION
●
After service completed, make sure all
connection points is secured.
Battery positive (+) cable should be connected
firstly.
●
And the two posts of battery have to be greased
after connected the cables.
●
Check if positions and operation for installed
parts is in correct and properly.
●
Make sure service safety each other when
conducting by two persons.
●
Note that do not let parts fall down.
●
Before battery removal operation, it has to
remove the battery negative (-) cable firstly. Notre
tools like open-end wrench do not contact with
body to prevent from circuit short and create
spark.
●
Make sure that the battery post caps are
located in properly after the battery posts had
been serviced.
●
If fuse burned, it has to find out the cause and
solved it. And then replace with specified
capacity fuse.
Capacity
verification
1-5
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To this chapter c
ontents
1. GENERAL INFORMATION
●
When separating a connector, it locker has to be
unlocked firstly. Then, conduct the service
operation.
●
Insert the terminal completely.
Check if the terminal is covered by the boot.
Do not let boot open facing up.
●
Do not pull the wires as removing a connector
or wires. Hold the connector body.
●
Make sure if the connector pins are bent,
extruded or loosen.
●
Insert the connector completely.
If there are two lockers on two connector sides,
make sure the lockers are locked in properly.
Check if any wire loose.
●
Secure wires and wire harnesses to the frame
with respective wire bands at the designated
locations. Tighten the bands so that only the
insulated surfaces contact the wires or wire
harnesses.
●
Wire band and wire harness have to be
clamped secured properly.
●
Do not squeeze wires against the weld or its
clamp.
●
Check if the connector is covered by the twin
connector boot completely and secured
properly.
●
Before terminal connection, check if the boot is
crack or the terminal is loose.
1-6
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To this chapter contents
●
Do not let the wire harness contact with rotating,
moving or vibrating components as routing the
harness.
1. GENERAL INFORMATION
●
Protect wires or wire harnesses with electrical
tape or tube if they contact a sharp edge or
corner. Thoroughly clean the surface where
tape is to be applied.
●
Keep wire harnesses far away from the hot
parts.
●
Route wire harnesses to avoid sharp edges or
Never Touch
corners and also avoid the projected ends of
bolts and screws.
●
Route harnesses so that they neither pull too
tight nor have excessive slack.
Never too tight
●
Secure the rubber boot firmly as applying it on
wire harness.
●
Never use wires or harnesses which insulation
has been broken. Wrap electrical tape around
the damaged parts or replace them.
●
Never clamp or squeeze the wire harness as
installing other components.
Never clamp or
squeeze the wire
harness
1-7
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1. GENERAL INFORMATION
●
Do not let the wire harness been twisted as
installation.
●
Wire harnesses routed along the handlebar
should not be pulled too tight or have excessive
slack, be rubbed against or interfere with adjacent
or surrounding parts in all steering positions.
●
Before operating a test instrument, operator
should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.
Do you know how to set the
instrument to its
measurement position and
the insert locations of its
two probes?
1-8
●
With sand paper to clean rust on connector
pins/terminals if found. And then conduct
connection operation later.
Clean rust
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Specifications
MAKER
To this chapter contents
1. GENERAL INFORMATION
TGB
MODEL
VSG 500c.c.
Overall Length 2080 mm Front Double Arm
Overall Width 1240 mm
Overall Height 1320 mm Front AT23X7-10
Wheel Base 1290 mm
Wheel tread
Curb Weight
Passengers/ weight Two / 150 kg
Weight Dimension
Total Weight
Type 4-Stroke Engine
Installation and
arrangement
Fuel Used Above 92 unleaded Speedometer 0 ~ 300 km/hr
Front 1050 mm Rim Aluminum / Steel
Rear 975mm Front
Front 154 kg
Rear 161 kg Performance Max. Speed Above 92 km/hr
Front 197 kg
Rear 293 kg
Total 490kg
Vertical, below center,
incline
Suspension
System
Tire Specifications
Brake System
Transmission
devices
Rear Unit Swing
Rear AT22X11-10
Disk (Ø 180mm)
Rear
Transfer Shaft drive
Shift lever L, H, N, R
Shift Manual lever
Clutch type Wet multi-plate
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2. MAINTENANCE INFORMATION
Periodical Maintenance Schedule
INTERVAL
ITEM
Muffler Bolts and Exhaust Pipe
Nuts
Valve Clearance I - I I
Air Cleaner - C C R
Engine Idle RPM I I I I
Spark Plus
Engine Oil R - R R
Oil Filter R - R R
Front Differential Set Oil
Final Gear Oil
C.V.T Belt - - I I
Fuel Tube
Throttle Cable Play I I I I
Brakes I I I I
Brake Hose
Brake Fluid
Tires - I I I
Suspensions - - I I
Steering System I I I I
Chassis Bolts and Nuts T T T T
General Lubrications - L L L
Code: C ~ Cleaning (replaced if necessary) I ~ Inspection, cleaning, and adjustment
L ~ Lubrication R ~ Replacement T ~ Tighten
Have your ATV checked, adjusted, and recorded maintenance data periodically by your TGB Authorized Dealer to
maintain the ATV at the optimum condition
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever
comes first.
Remarks: 1. Clean or replace the air cleaner element more often when the ATV is operated on dusty roads or in
2. Maintenance should be performed more often if the ATV is frequently operated in high speed and
3. Preventive maintenance
MONTHS 1 3 6 12
Kms INITIAL 200 EVERY 1000 EVERY 2000 EVERY 4000
MILES INITIAL 120 EVERY 600 EVERY 1200 EVERY 2400
Replace Every 6000KM (4000 MILES)
Replace Every 6000KM or Every 6 Months
Replace Every 6000KM or Every 6 Months
Replace Every 4 Years
Replace Every 4 Years
Replace Every 2 Years
the Heavily- polluted environment.
after the ATV has accumulated a higher mileage.
a. Ignition system-Perform maintenance and check when continuous abnormal ignition, misfire,
after-burn, overheating occur.
b. Carbon deposit removal-Remove carbon deposits in cylinder head, piston heads, exhaust system
when power is obviously lower than normal.
T T T T
- - I I
R - R R
R - R R
- I I I
- - I I
- I I I
2-2
To this chapter contents
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Throttle
adjustment
screw
Fuel Lines
Remove the seat .Loosen 2 screws and 2 bolts
Remove the tank cover
Check all lines, and replace it when they are
deterioration, damage or leaking
Warning
To this chapter contents
Gasoline is a low ignition material so any kind of
fire is strictly prohibited as dealing it.
Acceleration Operation
Have a wide open of throttle valve as handle in any
position and release it to let back original (full
closed) position.
Check handle if its operation is smooth.
Check acceleration cable and replace it if
deteriorated, twisted or damaged.
Lubricate the cable if operation is not smooth.
Measure the throttle lever free play in its flange
part.
Remove rubber boot, loosen fixing nut, and then
adjust it by turning the adjustment screw. Tighten
the fixing nut, and check acceleration operation
condition.
Free play: 1~3 mm.
Air Cleaner
Remove seat.
loosen 4 hooks from the air cleaner cover and
then remove the cover.
Loosen the clamp strip and 1 screw of air cleaner
element, and then remove the air cleaner element.
Clean the element with non-flammable or
high-flash point solvent and then squeeze it for
dry.
Caution
Never use gasoline or acid organized solvent to
clean the element.
Soap the element into cleaning engine oil and then
squeeze it out. Install the element onto the element
seat and then install the air cleaner cover.
Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold spark plug washer and install the spark plug
by screwing it.
Tighten the plug by turning 1/2 turn more with plug
socket after installed.
Tighten torque: 1.0~1.2kgf-m
2. MAINTENANCE INFORMATION
Vacuum hose
Cook Assy ;Fuel
Fuel tank
Fuel hose
Lock nut
Carbureto
Fuel filter
Clamp
Ground electrode
0.7~0.8mm
Central electrode
Element
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2. MAINTENANCE INFORMATION
Valve Clearance
Caution
To this chapter contents
Checks and adjustment must be performed when
the engine temperature is below 35℃.
Remove front fender, fuel tank cover and fuel tank.
Remove cylinder head cover.
Turn camshaft bolt in C.W. direction and let the “T”
mark on the camshaft sprocket align with cylinder
head mark so that piston is placed at TDC position in
compression stroke.
Caution
Do not turn the bolt in C.C.W. direction to prevent
from camshaft bolt looseness.
Valve clearance inspection and adjustment. Check
& adjust valve clearance with feeler gauge.
Standard Value: IN 0.10 ± 0.02 mm
EX 0.15 ± 0.02 mm
Loosen fixing nut and turn the adjustment nut for
adjustment.
Caution
Re-check the valve clearance after tightened the
fixing nut.
2-4
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Carburetor Idle Speed Adjustment
Caution
●
Inspection & adjustment for idle speed have to
be performed after all parts in engine that
needed adjustment have been adjusted.
●
Idle speed check and adjustment have to be
done after engine is being warm up. (It is
enough that operates engine from stop to
running for 10 minutes.)
Park the ATV with onto neutral and warm up
engine.
Connect tachometer (the wire clamp of tachometer is
connected to the high tension cable).
Turn the throttle valve stopper screw to specified
idle speed.
Specified idle speed: 1500 ± 100 rpm
Emission adjustment in idle speed
Warm up the engine for around 10 minutes and
then conduct this adjustment.
1. Connect the tachometer onto engine.
2. Adjust the throttle valve stopper screw and let
engine runs in 1500±100 rpm.
3. Insert the exhaust sampling pipe of exhaust
analyzer into the front section of exhaust pipe.
Adjust the air adjustment screw so that emission
value in idle speed is within standard.
4. Slightly accelerate the throttle valve and
release it immediately. Repeat this for 2~3
times.
5. Read engine RPM and value on the exhaust
analyzer. Repeat step 2 to step 4 procedures
until measured value within standard.
Emission standard CO: below 2.5~3.5%
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HC: below 2000ppm
2. MAINTENANCE INFORMATION
Air adjustment screw
Ignition cable
Stopper screw
Carburetor undersurface
2-5
2. MAINTENANCE INFORMATION
To this chapter contents
Ignition System
Caution
●
C.D.I ignition system is set by manufacturer so it
can not be adjusted.
●
Ignition timing check procedure is for checking
whether CDI function is in normal or not.
Connect tachometer and ignition light.
Start engine.
As engine in idle speed: 1500 rpm, aim at the mark
“F” with the ignition light. Then, it is means that
ignition timing is correct.
Increase engine speed to 6000 rpm to check
ignition advance degree. If indent is located within
the ignition advance degrees, it is means that the
ignition advance degree is in normal.
If ignition timing is incorrect, check CDI set, pulse
rotor and pulse generator. Replace it if malfunction
of these parts is found.
Cylinder Compression Pressure
Warm up engine.
Turn off the engine.
Remove the trunk.
Remove the central cover.
Remove spark plug cap and spark plug.
Install compression gauge.
Full open the throttle valve, and rotate the engine
by means of starter motor.
Caution
Rotate the engine until the reading in the gauge
no more increasing.
Usually, the highest pressure reading will be
obtained in 4~7 seconds.
Compression pressure: 10.6 ±0.3 Kg/cm²
Check following items if the pressure is too low:
●
Incorrect valve clearance.
●
Valve leaking.
●
Cylinder head leaking, piston, piston ring and
cylinder worn out.
If the pressure is too high, it means carbon
deposits in combustion chamber or piston head.
2-6
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14bolts
Clamp st
rips
Drive Belt
Loosen the 2 clamp strips of clutch cover, and then
remove the clutch cover vapor hose.
Remove 14 bolts of the clutch cover.
Check if the belt is crack or worn out.
Replace the belt if necessary or in accord with the
periodical maintenance schedule to replace it.
Width limit: 26.8 mm or above
To this chapter contents
2. MAINTENANCE INFORMATION
Teeth
Width
2-7
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