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blade 300
Service Manual
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TGB blade 300 Service Manual

BLADE 250/300
SERVICE MANUAL
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This service manual contains the technical data of each component inspection and repair for the
BLADE
250/300 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,
BLADE
250/300, 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.
Homepage Contents
HOW TO USE THIS MANUAL
This service manual describes basic information of different system parts and system inspection & service for 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.
BLADE
250/300 ATV. In addition,
Homepage
CONTENTS
Page Content Index
1-1 ~ 1-19 2-1 ~ 2-14 3-1 ~ 3-8 4-1 ~ 4-12 5-1 ~ 5-6 6-1 ~ 6-16
7-1 ~ 7-8 8-1 ~ 8-14
9-1 ~ 9-12 10-1 ~ 10-10 ALTERNATOR 11-1 ~ 11-8 13-1 ~ 13-9 14-1 ~ 14-14 FRONT BRAKE AND FRONT WHEEL
15-1 ~ 15-10 STEERING/FRONT SUSPENSION 16-1 ~ 16-18 REAR BRAKE/REAR WHEEL/REAR CUSHION
17-1 ~ 17-22 ELECTRICAL EQUIPMENT 18-1 ~ 18-2
GENERAL INFORMATION SERVICE MAINTENANCE INFORMATION LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL CYLINDER HEAD/VALVE
CYLINDER/PISTON
“V” TYPE BELT DRIVING SYSTEM/KICK-STARTER
FINAL DRIVING MECHANISM
CRANKSHAFT/ CRANKCASE BODY COVER
ELECTRICAL DIAGRAM
1 2 3 4 5 6
7 8
9 10 11 13 14
15 16
17 18
SERIAL NUMBER
Frame number
Home page
Contents
Engine number
1. GENERAL INFORMATION
Homepage Contents
Symbols and Marks............................. 1-1
General Safety ..................................... 1-2
Service Precautions ............................ 1-3
Specifications ...................................... 1-9
Symbols and Marks
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
Gear oil
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-30 API SG class oil. Warranty will not cover the
damage that caused by not apply with the limited engine oil.
(Recommended oil: KING MATE G-3 oil) King Mate G-3 is recommended. King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL
# 140)
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 DOT3 or WELLRUN brake fluid.
Special tools
Correct
Special tools
Meaning correct installation.
Wrong
Meaning wrong installation.
Specifications..................................... 1-10
Torque Values .................................... 1-11
Troubles Diagnosis............................ 1-13
Lubrication Points ............................. 1-18
1
Directions
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.
To this chapter contents
Service Precautions
●
Always use with SANYANG genuine parts and recommended oils. Using non-designed parts for SANYANG 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.
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
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
To this chapter c
ontents
1. GENERAL INFORMATION
●
When separating a connector, it locker has to be
unlocked firstly. operation.
Then, conduct the service
●
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
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
To this chapter contents
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
Specifications
To this chapter contents
1. GENERAL INFORMATION
MAKER
Overall Length 2160 mm Front Double arm Overall Width 1160 mm Overall Height 1175 mm Front AT22x7-10 (on road) Wheel Base 1300 mm
Wheel tread
Curb Weight
Passengers/ weight Two / 150 kg
Weight Dimension
Total Weight
Type 4-Stroke Engine Clutch Centrifugal, dry type Installation and arrangement
Front 940 mm Rim Aluminum Rear 890 mm Front Front 137 kg Rear 118 kg Max. Speed Above 86 km/hr Total 255 kg
Front 179 kg Rear 244 kg Total 423 kg
Vertical, below center, incline
TGB
Suspension System
Tire Specifications
Brake System
Performance
Reduction
MODEL
Rear Unit Swing
Rear AT22x10-10 (on road)
Disk (Ø 180mm)
Rear
Climb Ability Below 25ﾟ Primary
Reduction Secondary
Reduction
Transmission
Disk (Ø 220mm)
Belt
Gear / Sprocket
C.V.T., auto speed change
UA25A
Fuel Used Above 92 unleaded Speedometer 0 ~ 300 km/hr Cycle/Cooling 4-stroke/Water cooled Horn 93 ~ 112dB/A
Bore
Stroke
Cylinder
Number/
Engine
Arrangement Displacement Compression Ratio Max. HP Max. Torque Ignition Starting System
Air filtration
Ø71 mm
63 mm
Single Cylinder
249.4 cc
10.5 : 1
14.7kw / 6500rpm
23.5Nm / 5500rpm C.D.I. Electrical starter
Sponge
Muffler Exhaust Pipe Position
and Direction Lubrication System
Exhaust
E.E.C. P.C.V.
Catalytic reaction control system
Solid Particulate CO HC
Concentration
Nox
Expansion & Pulse Type Left side, and Backward Forced circulation & splashing
Below 7.0 g/ km Below 1.5g/ km Below 0.4g/ km
─
─
─
1-9
1. GENERAL INFORMATION
To this chapter contents
Specifications
MAKER
Overall Length 2160 mm Front Double arm Overall Width 1160 mm Overall Height 1205 mm Front AT25x8-12 (on road) Wheel Base 1300 mm
Wheel tread
Curb Weight
Passengers/ weight Two / 150 kg
Weight Dimension
Total Weight
Type 4-Stroke Engine Clutch Centrifugal, dry type Installation and arrangement
Front 940 mm Rim Aluminum Rear 890 mm Front Front 145 kg Rear 129 kg Max. Speed Above 86 km/hr Total 274 kg
Front 186 kg Rear 256 kg Total 442 kg
Vertical, below center, incline
TGB
Suspension System
Tire Specifications
Brake System
Performance
Reduction
MODEL
Rear Unit Swing
Rear AT25x10-12 (on road)
Disk (Ø 180mm)
Rear
Climb Ability Below 25ﾟ Primary
Reduction Secondary
Reduction
Transmission
Disk (Ø 220mm)
Belt
Gear / Sprocket
C.V.T., auto speed change
UA25C
1-10
Fuel Used Above 92 unleaded Speedometer 0 ~ 300 km/hr Cycle/Cooling 4-stroke/Water cooled Horn 93 ~ 112dB/A
Bore
Stroke
Cylinder
Number/
Engine
Arrangement Displacement Compression Ratio Max. HP Max. Torque Ignition Starting System
Air filtration
Ø71 mm
63 mm
Single Cylinder
249.4 cc
10.5 : 1
14.7kw / 6500rpm
23.5Nm / 5500rpm C.D.I. Electrical starter
Sponge
Muffler Exhaust Pipe Position
and Direction Lubrication System
E.E.C. P.C.V.
Catalytic reaction control system
Solid Particulate CO HC
Exhaust
Concentration
Nox
Expansion & Pulse Type Left side, and Backward Forced circulation & splashing
Below 7.0 g/ km Below 1.5g/ km Below 0.4g/ km
─
─
─
1. GENERAL INFORMATION
Specifications
MAKER
Overall Length 2155 mm Front Double arm Overall Width 1170 mm
Overall Height 1175 mm Front
Wheel Base 1300 mm
Wheel tread
Curb Weight
Weight Dimension
Passengers/ weight Two / 150 kg
Total Weight
Front 890 mm Rim Aluminum Rear 940 mm Front Front 156 kg Rear 129 kg Max. Speed Above 86 km/hr Total 285 kg
Front 190kg Rear 260 kg Total 450 kg
TGB
Suspension System
Tire Specifications
Brake System
Performance
Reduction
MODEL
Rear Unit Swing
AT22x7-10 AT25x8-12 AT23x8-12 AT22x10-10
Rear
Rear
Climb Ability Below 25ﾟ Primary
Reduction Secondary
Reduction
AT25x10-12 AT23x10-10
Disk (Ø 180mm) Disk (Ø 220mm)
Belt
Gear / Sprocket
ATV300C.C.
Type 4-Stroke Engine Clutch Centrifugal, dry type Installation and arrangement
Fuel Used Above 92 unleaded Speedometer 0 ~ 300 km/hr Cycle/Cooling 4-stroke/Water cooled Horn 93 ~ 112dB/A
Bore
Stroke
Cylinder
Number/
Engine
Arrangement Displacement Compression Ratio Max. HP Max. Torque Ignition Starting System
Air filtration
Vertical, below center, incline
Ø75 mm
65 mm
Single Cylinder
287.2 cc
8.8 : 1 15kw / 6500rpm
24.7Nm / 5500rpm C.D.I. Electrical starter
Sponge
Transmission
Muffler Exhaust Pipe Position
and Direction Lubrication System
E.E.C. P.C.V.
Catalytic reaction control system
Solid Particulate CO HC
Exhaust
Concentration
Nox
C.V.T., auto speed change
Expansion & Pulse Type Left side, and Backward Forced circulation & splashing
Below 7.0 g/ km Below 1.5g/ km Below 0.4g/ km
─
─
─
1. GENERAL INFORMATION
To this chapter contents
Torque Values
The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table.
Standard Torque Values for Reference
5 mm bolt、nut 6 mm bolt、nut 8 mm bolt、nut 10 mm bolt、nut 12 mm bolt、nut
Type
Engine Torque Values
Cylinder stud bolt Cylinder head nut Cylinder head right bolt Cylinder head side cover bolt Cylinder head cover bolt Cylinder head stud bolt (inlet pipe) 2 Cylinder head stud bolt (EX. pipe) Air inject pipe bolt Air inject reed valve bolt Tappet adjustment screw nut Spark plug Tensioner lifter bolt Carburetor insulator bolt Oil pump screw Water pump impeller Engine left cover bolt Engine oil draining bolt Engine oil strainer cap Mission draining bolt Mission filling bolt Shift drum fixing bolt Clutch driving plate nut Clutch outer nut Drive face nut ACG. Flywheel nut Crankcase bolts Mission case bolt
Item
Tighten Torque
0.45~0.6kgf-m 5 mm screw
0.8~1.2kgf-m 6 mm screw、SH nut
1.8~2.5kgf-m 6 mm bolt、nut
3.0~4.0kgf-m 8 mm bolt、nut
5.0~6.0kgf-m 10 mm bolt、nut
Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
4 4 2 2 4
2 4 2 4 1 2 2 2 1 9 1 1 1 1 1 1 1 1 1 7 7
10
8 8 6 6 6 8 6 3 5
10
6 6 3 7
6 12 30
8 12 14 28 14 14 14
6
8
Type
1.0~1.4
3.6~4.0
2.0~2.4
1.0~1.4
1.0~1.4
1.0~1.4
2.4~3.0
1.0~1.4
0.07~0.09
0.7~1.1
1.0~1.2
1.0~1.4
0.7~1.1
0.1~0.3
1.0~1.4
1.1~1.5
3.5~4.5
1.3~1.7
1.1~1.5
3.5~4.5
3.5~4.5
5.0~6.0
5.0~6.0
8.5~10.5
5.0~6.0
0.8~1.2
2.6~3.0
Tighten Torque
0.35~0.5kgf-m
0.7~ 1.1kgf-m
1.0 ~1.4kgf-m
2.4 ~3.0kgf-m
3.5~4.5kgf-m
Apply oil to thread
1-12
1. GENERAL INFORMATION
To this chapter contents
Frame Torque Values
Handlebar upper holder bolt Steering shaft nut Steering tie-rod nut Knuckle nut Steering shaft holder bolt Tie rod lock nut Handlebar under holder nut Front wheel nut Front axle castle nut Rear axle castle nut Rear wheel nut Engine hanger nut Rear axle holder bolt Drive gear bolt Driven gear nut Swing arm pivot bolt
Front suspension arm nut Front
/ Rear cushion mounting bolt Brake lever nut Brake hose bolt Brake caliper bolt Brake disk mounting bolt Air-bleed valve Exhaust muffler mounting bolt Exhaust muffler connection nut
Item
Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
4
6
1
10
4
10
2
10
2
8
4
10
2
8
8
10
2
14
2
14
8
10
4
12
4
12
2
10
4
10
1
14
4
6
2
6
13
10
6
6
11
8
3
5
2
8
2
7
10 10
1-13
2.40
5.00
5.00
5.00
3.40
3.60
4.00
2.40
5.00
5.00
2.40
8.50
9.20
4.6
4.6
9.20
5.00
4.60
1.00
3.50
3.25
4.25
0.50
3.00
1.20
To this chapter contents
Troubles Diagnosis
A. Engine hard to start or can not be started
Check and adjustment
Loosen carburetor drain bolt to check if there is gasoline inside the carburetor
Fuel supplied tom carburetor sufficient
Remove spark plug, install it into spark plug cap, and perform a spark test against engine ground.
Check if sparks Weak sparks, no spark at
Perform cylinder compression pressure test.
Cylinder compression pressure normal
Re-start by following the starting procedures
No ignition There are some signs of
Remove the spark plug again and check it.
Dry spark plug Wet spark plug
Fault condition
No fuel is supplied to carburetor
all
Low compression pressure or no pressure
ignition; nut engine can not be started
Remove carburetor after 30 minutes and connect a hose onto fuel rich circuit. Then blow the hose with air
Blowing in normal Blowing clogged
1. GENERAL INFORMATION
Probable causes
●
No fuel in fuel tank
●
Check if the pipes, fuel tank to carburetor
and intake vacuum, are clogged.
●
Float valve clogged
●
Lines in fuel tank evaporation
system clogged
●
Malfunction of fuel pump
●
Loosen or damaged fuel pump
vacuum hose
●
Fuel filter clogged
●
Malfunction of spark plug
●
Spark plug foul
●
Malfunction of CDI set
●
Malfunction of AC generator
●
Ignition coil is in open or short circuit
●
Ignition coil leads open or short circuit
●
Malfunction of main switch
●
Piston ring seized
●
Malfunction of cylinder valves
●
Worn cylinder and piston ring
●
Cylinder gasket leak
●
Sand hole in compression parts
●
Malfunction of throttle valve operation
●
Air sucked into intake manifold
●
Incorrect ignition timing
●
Fuel level in carburetor too high
●
Malfunction of throttle valve operation
●
Throttle valve opening too wide
●
Malfunction of automatic by- starter
1-14
1. GENERAL INFORMATION
B. Engine run sluggish (Speed does not pick up, lack of power)
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Check and adjustment Fault condition Probable causes
Try gradual acceleration and check engine speed
Engine speed can be increased.
Check ignition timing (Using ignition lamp)
Ignition timing correct Incorrect ignition timing
Check cylinder compression pressure (using compression pressure gauge)
Compression pressure
Check if carburetor jet is clogged
Remove spark plug
Check if engine over heat
Continually drive in acceleration or high speed
correct
No clogged Clogged
No foul or discoloration Fouled and discoloration
Normal Engine overheat
No knock Knock
Engine speed can not be increased.
No compression pressure
●
Air cleaner clogged
●
Poor fuel supply
●
Lines in fuel tank evaporation
system clogged
●
Exhaust pipe clogged
●
Fuel nozzle clogged in carburetor.
●
Fuel nozzle clogged in carburetor.
●
Malfunction of CDI
●
Malfunction of AC alternator
●
Cylinder & piston ring worn out
●
Cylinder gasket leaked
●
Sand hole in compression parts
●
Valve deterioration
●
Seized piston ring
●
Remove foreign
●
Remove dirt
●
Incorrect spark plug heat range
●
Piston and cylinder worn out
●
Lean mixture
●
Poor fuel quality
●
Too much carbon deposited
in combustion chamber
●
Ignition timing too advanced
●
Poor circuit on the cooling system
●
Too much carbon deposited
in combustion chamber
●
Lean mixture
●
Poor fuel quality
●
Ignition timing too advanced
1-15
1. GENERAL INFORMATION
C. Engine runs sluggish (especially in low speed and idling)
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Check and adjustment
Fault condition
Check ignition timing (using ignition lamp)
Normal Abnormal
Adjust the air screw of carburetor
Good Poor
Air sucked through carburetor gasket
No air sucked Air sucked
Remove spark plug, install spark plug into spark plug cap and perform spark test against engine ground
Good spark Poor
D. Engine runs sluggish (High speed)
Check and adjustment
Check ignition timing
Fault condition
Normal Abnormal
Check for fuel supplying system in automatic fuel cup
Good Abnormal
Check if carburetor clogged
No clogged Clogged
Probable causes
●
Incorrect ignition timing (malfunction of
CDI or AC alternator)
●
Rich mixture (loosen the screw)
●
Lean mixture (tighten the screw)
●
Poor heat insulation gasket
●
Carburetor lock loose
●
Poor intake gasket
●
Poor carburetor O-ring
●
Vacuum hose crack
●
Spark plug fouled
●
Malfunction of CDI
●
Malfunction of AC generator
●
Malfunction of ignition coil
●
Open or short circuit in spark plug leads
●
Malfunction of main switch
Probable causes
●
Malfunction of CDI
●
Malfunction of AC alternator
●
Insufficient fuel in fuel tank
●
Fuel filter clogged
●
Restricted fuel tank vent
●
Cleaning
1-16
1. GENERAL INFORMATION
E. Clutch, driving and driving pulley
To this chapter contents
FAULT CONDITIONS
Engine can be started but motorcycle can not be moved.
Engine running and misfire as motorcycle initial forward moving or jumping suddenly (rear wheel rotating as engine in running)
Poor initial driving (Poor climbing performance)
F. Poor handling
FAULT CONDITIONS
Steering is heavy
One wheel is wobbling
Vehicle pulls to one side
1-17
PROBABLE CAUSES
●
Drive belt worn out or deformation
●
Ramp plate of movable drive face damaged
●
Driving pulley spring broken
●
Clutch weights broken
●
Drive slide-shaft gear groove broken
●
Transmission gear damaged
●
Clutch weights spring broken
●
Clutch outer stuck with clutch weights
●
Connection parts in clutch and shaft worn out or burned
●
Drive belt worn out or deformation
●
Weight roller worn out
●
Movable drive face shaft worn out
●
Driven pulley spring deformation
●
Driven pulley shaft worn out
●
Greased in drive belt and driven face.
PROBABLE CAUSES
●
Damaged steering bearing
●
Damaged steering shaft bushing
●
Bent rim
●
Improperly installed wheel hub
●
Excessive wheel bearing play
●
Bent swing arm
●
Bent frame
●
Swing arm pivot bushing excessively
●
Worn
●
Bent tie-rod
●
Incorrect tie-rod adjustment
●
Rear tie air pressure incorrect
●
Improper wheel alignment
●
Bent frame
G. Loss power
Check and adjustment
Raise wheels off ground and spin by hand
Spin freely Abnormal
Check tire pressure
Accelerate lightly, engine speed can be increase
Check ignition timing
Test cylinder compression
Check carburetor
Check spark plug
Check for engine overheating
Accelerate or run at high speed
Normal Abnormal
Normal Abnormal
Normal Abnormal
Normal Abnormal
Normal Clogged
Normal Fouled or discolored
Normal Overheating
Normal Knocks
To this chapter contents
1. GENERAL INFORMATION
Fault condition
●
●
●
●
Probable causes
Brake dragging
Drive chain too tight Damaged wheel bearing Wheel bearing needs lubrication
●
Punctured tire
●
Faulty tire valve
●
Fuel / air mixture ratio too rich or lean
●
Clogged in air cleaner
●
Clogged in muffler
●
Restricted fuel flow
●
Clogged fuel tank cap breather hole
●
Faulty pulse generator
●
Faulty CDI unit
●
Leaking head gasket
●
Worn cylinder and piston rings
●
Clean
●
Clean the spark plug
●
Spark plug is incorrect heat range
●
Excessive carbon deposited
in combustion chamber
●
Wrong type of fuel
●
Fuel / air mixture ratio is lean
●
Use of poor quality fuel
●
worn piston and cylinder
●
Fuel / air mixture ratio is lean
●
Wrong type of fuel
●
Ignition timing too advanced
●
Excessive carbon deposited
in combustion chamber
1-18
1. GENERAL INFORMATION
To this chapter contents
Lubrication Points
1-19
Drive chain
Speedometer gear
Acceleration cable/ Front & rear brake
lever pivot
Wheel bearing
Precautions in Operation ···················· 2-1
Home page Contents
Periodical Maintenance Schedule ······ 2-2 Fuel Lines ············································· 2-3 Acceleration Operation ······················· 2-3 Air Cleaner············································ 2-3 Spark Plug ············································ 2-3 Valve Clearance ··································· 2-4 Carburetor Idle Speed Adjustment····· 2-5 Ignition System ···································· 2-6 Cylinder Compression Pressure ········ 2-6 Drive Belt ·············································· 2-7
Precautions in Operation
Specification
Transmission Gear oil
Capacity of coolant
Fuel Tank Capacity
Engine Oil
Clearance of throttle valve
Spark plug
“F” Mark in idling speed
Full timing advanced
Idling speed
Cylinder compression pressure
Valve clearance
Tire dimension
Tire pressure (cold)
Battery
Capacity
Change
Capacity
Change
Engine + radiator
Reservoir upper
Type
Gap
Front
Rear
3 ±1 psi / 5 ±1 psi
2. MAINTENANCE INFORMATION
Drive Chain ··········································· 2-7 Brake System (Disk Brake) ················· 2-8 Brake Light Switch/Starting Inhibitor
Switch ··················································· 2-9 Headlight Beam Distance ···················· 2-10 Clutch Disc Wear ································· 2-10 Cushion················································· 2-10 Steering Handle···································· 2-11 Wheel/Tire············································· 2-11 Nuts, Bolts Tightness ·························· 2-11 Special Tools List ································ 2-12
BTDC 10º / 1700 rpm BTDC 27º / 4000 rpm
12.0 ±2 kgf/cm²
IN:0.10 ± 0.02 mm
12V12Ah (MF battery) type:
12000 c.c.
1400 c.c.
1200 c.c.
750 c.c.
650 c.c. 850 c.c. 420 c.c. 1~3 mm
NGK CR8E
0.8 mm
1700±100 rpm
EX:0.15 ± 0.02 mm
AT22x7-10 / AT25x8-12
AT22x10-10 / AT25x10-12
2
2-1
2. MAINTENANCE INFORMATION
Periodical Maintenance Schedule
Maintenance
Code
1 Air cleaner I C R 2 Fuel filter I I R 3 Oil filter C C 4 Engine oil change R Check daily.Replace every 3000km or 3 months 5 Tire pressure/condition I Check daily 6 Battery inspection I I 7 Brake & free ply check I I 8 Steering handle check I I
9 Suspension operation check I I 10 All nut/bolts torque check I I 11 Gear oil check for leaking I I 12 Spark plug check or change I I R 13 Gear oil R Check monthly.Replace every 6000 km or 6 months 14 Frame lubrication L 15 Exhaust pipe I I 16 Ignition timing I I 17 Idling emission check A I 18 Throttle operation I I 19 Engine bolts torque check I I 20 CVT driving device(belt) I R 21 CVT driving device(rollers) C R 22 Drive chain I / L I / L C
23 24 Fuel lines I I
25 Cam chain I I 26 Valve clearance I A 27 Cooling hoses/connections I I 28 Coolant reservoir I I 29 Coolant I I R 30 Brake fluid I I Replace every 2 years
Code: I = Inspection, cleaning, and adjustment R = Replacement A = Adjustment
C ~ Cleaning (replaced if necessary) L = Lubrication
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
Lights/electrical equipment/multi-meters
the Heavily- polluted environment.
2. Maintenance should be performed more often if the ATV is frequently operated in high speed and after the ATV has accumulated a higher mileage.
3. Preventive maintenance 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 obvious lower. Than ever
Item
Inital
500KM
I Check daily
3 Month every
2-2
To this chapter contents
1,000KM
6 Month every
3,000KM
12 Month every
12,000KM
Loosen 2 screws and 2 bolts
Fuel Lines
Remove the seat
Remove the tank cover Check all lines, and replace it when they are deterioration, damage or leaking
Warning
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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.
Spark Plug
Recommended spark plug: CR8E Remove spark plug cap. Clean dirt around the spark plug hole. Remove spark plug. Measure spark plug gap.
Spark plug gap：0.8 mm
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
Throttle adjustment screw
Fuel tank
Clamp
Ground electrode
0.8~0.9mm
Central electrode
Fuel hose
Fuel filter
Lock nut
Element
2-3
2. MAINTENANCE INFORMATION
Valve Clearance
Caution
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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. Remove cylinder head side 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
2 bolts
Timing mark
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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 main stand 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(ATV250): 1700 ± 100 rpm
Specified idle speed(ATV300): 1600 ± 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 1600±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%
HC: below 2000ppm
2. MAINTENANCE INFORMATION
Ignition cable
Stopper screw
Air adjustment screw
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: 1600 rpm, aim at the mark “F” with the ignition light. that ignition timing is correct.
Then, it is means
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: 12 ± 2 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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