TGB Xmotion 125, Xmotion 250 Owner's Manual

Xmotion 125/250

OWNER-MANUAl

MAINTENANCE HANDBOOK

TAIWAN GOLDEN BEE CO.,LTD.

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TABLE OF CONTENT

1. REGULAR INSPECTION

1-1 Delivery Introduction -----------------------------------------------------2 1-2 Inspection Before Running ---------------------------------------------4 1-3 Regular Maintenance Schedule -------------------------------------- 5 1-4 General Inspection -------------------------------------------------------6 1-5 Notes for Inspection ----------------------------------------------------- 7

2. MAINTENANCE INFORMATION

2-1 Specification Sheet -----------------------------------------------------8 2-2 Safety Precautions--------------------------------------------------------10 2-3 Special Tools --------------------------------------------------------------11 2-4 List of Grease & Oil Adopted ----------------------------------------- 24 2-5 Circuit Drawings --------------------------------------------------------- 25 2-6 Troubleshooting ----------------------------------------------------------27 2-7 Tighting Torque of Screws --------------------------------------------27 2-8 Troubleshooting ----------------------------------------------------------30

3. DESCRIPTION OF PARTS AND COMPONENTS

3-1 Engine ---------------------------------------------------------------------39 3-2 Electric System ---------------------------------------------------------- 126

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4. DISASSEMBLY REPAIRMENT

4-1 Notice for Disassembly Repairment ----------------------------- 137 4-2 Removal and lnstallation of Engine -------------------------------138 4-3 Removal and Inspection of Electric Items -----------------------199 4-4 Removal and Inspection of Body Parts ----------------------------206 4-5 Brake System ----------------------------------------------------------- 214

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CHAPTER I

REGULAR INSPECTION

1-1 Delivery Introduction 1-4 General Inspection 1-2 Inspection Before Running 1-5 Notes for Inspection 1-3 Regular Maintenance Schedule _______________________

1-1 Delivery Introduction

To inform customers of correct methods to use: To practically and correctly

ride a scooter according to the Instruction of Manual and Maintenance Handbook. Customers should also try in person according to this manual.

1. Starting:

A. Turn the power switch to "ON." B. Hold the front or rear brake and press the "START" button. C. If the scooter is not started, release the "START" button and try again after a few minutes. Each start should be less than five seconds to avoid battery consumption. Note: This is an AUTO-CHOKE scooter, thus there is no choke lever. The fuel is controlled only by throttle grip. The accelerator has to return to its original place when the scooter is not in use.

D. If the scooter can not be started by the "START" button, try the kick starter.

2. Fuel:

Inform customers to refill the fuel to no more than 80% of the tank capacity only.

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1-1 Delivery Introduction 3

. Lubricant Adopted:

A. WARNING : The engine oil must be refilled when the oil warning lamp lights, otherwise the engine will be burned-out due to insufficient lubrication. Recommended oil : TGB Genuine EXTRA 4X OIL.

B. Genuine TGB HYPOID GEAR OIL(or SAE85W-140) will be adopted as gear oil to be changed on a periodical basis. Gear oil and engine oil are different in their nature. Attention should be paid to avoid mistake when used.

4. Regular Inspection and Maintenance:

Inform customers of the importance of inspection before running and regular inspection. A. Inspection Before Running: Riders should perform nspection by themselves before running. B. Regular Inspection: Regular inspection should be performed after the first month and the sixth month and every six months afterwards.

5. Description of Warranty System:

Clearly identify the content of warranty in accordance with the warranty paper. A. Content and term of warranty. B. Maintenance items not guaranteed. C. Items should be followed by customers. Instruct customers to carry the OWNER'S Manual with them when they come for regular inspection and maintenance. It is because such inspection should be recorded onto the Manual.

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1-2 Inspection Before Running

Items to be Inspected Before Running by Customers:

ITEM

CONTENT

GUIDELINE

1. Starter

Is the oil volume proper?

1 .Check Oil Warning Lamp to see if the oil volume is proper?

2 .Fuel

Is the fuel volume sufficient?

1 .Check fuel volume to see if it is enough to the destination.

3. Lamp & Direction Indicator

Is the lamp condition well? Is there any dirt?

1 .Check if the lighting condition of head lamp, tail lamp, licence lamp, brake lamp, direction indicator and other lamp is well.

2. Lamps should be kept clean and undamaged.

4. Back Mirror

Is the reflecting image well?

1. Look at the back mirror from the seat to check if the rear view is clear.

5. License Plate & Reflector

No dirt and damage should appear.

1. License plate should be installed, letters and numbers should be kept clear and clean. 2. Dirt and damage should not appear on the reflector.

6 . Brake

Check the distance of brake handle lever and the brake effect.

1 .Operate the handle lever slowly to the brake begin to effect in order to inspect the moving distance. 2.Test the brake with low speed running to see the brake effect of front and rear brakes.

1.Is the air pressure proper?

1 .Check if the air pressure of tire is sufficient with a gauge or by sight.

2.Groove should be deep enough.

1 .Check if the groove of tires is enough.

3.Unusual wear is not desired.

1 .Check landing flat of tire to see if any unusual wear appears.

4.Breaking and damage are not desired.

1 .Check landing flat and side to see if any breaking or damage appear.

7. Tire

5.Metal, stone and other articles are not desired.

1 .Cneck if any cracking, stone or any other article sticks into the tire.

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1-3 Regular Maintenance Schedule

The chart below lists the recommended intervals for all the returned periodic service work necessarily to keep the motorcycle operating at peak performance and utmost efficiency. Mileages are expressed in terms of kilometers and months. These intervals judged by odometer reading or month whichever comes first.

\~^^^^ Maintenance N, ^^\ kilometer

300KM

Every

1000KM

Every

3000KM

Every

6000KM

Every

12000KM

Item

^^ Maintenance Interval

Check Items \

NEW

1 Month 2 Month 3 Month 4 Month

Remarks

01 Air cleaner element(Remark)

02 Oil filter(Screen)

03 Engine oil

Replacement for every 3000KM

04 Tire, pressure

05 Battery

06 Spark plug

07 Carburetor(idle speed)

08 Steering bearing and handles

09 Check Transmission for leakage

10 Check crankcase for leakage

11 Transmission oil

Replacement for every 5000KM (5 Month)

12 Drive Belt/roller

13 Fuel tank switch and lines

14 Throttle valve operation and cable

15 Engine bolts and nuts

16 Cylinder head, cylinder, and piston

17 Exhaust system/cleaning carbon

18 Cam chain/ignition time

19 Valve clearance

20 Shock absorbers

21 Front/rear suspension

22 Main/side stands

I/L

23 Crankcase Blow - by system(PCV)

24 Coolant

25 Cooling fan, lines

26 Clutch disk

27 Brake mechanism/brake lining(pad)

28 Bolts/nuts for each components

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*The above maintenance schedule is established by taking the monthy 1000 kilometers as areference which ever comes first. Code : I ~ Inspection, cleaning, and adjustment R ~ Replacement

C ~ Cleaning(replaced if necessary) L ~ Lubrication

Remark : 1. Clean or replace the air cleanr element more often whe the scooter is operated on

dusty roads or in the Heavily - polluted environment.

2. Maintenance should be performed more often if the scooter is frequently operated

in high speed and after the scooter has accumulated a higher mileage.

1-4 General Inspection General Inspection and Adjustment

* means adjustable. Note: The ignition of this scooter by the use of crank-shaft which is 4 ignitions/revolution.

Special attention should be paid while setting the turning speed of Engine by Tachometer.

Brake Disc

Tail Light/Turn Signal Light

Gear Oil

Spark Plug

Raer Brake

Brake Disc

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Fuses

Head Light

Tire

Air Filter

Head Lig

Tail Light/Turn Signal Light

Raer

1-5 Notes for Inspection

ITEM

INSPECTION DETAILS

Be aware of smoke and fire while performing maintenance.

New Packing, Gasket, O Ring, locking pin should be used while assembling.

Only designated TGB oils should be used on spare parts.

Clean the vehicle before maintenance to avoid dirt or mud on disconnected parts.

The locking sequence of Bolt and Nut should be from inside to outside, or in diagonal step. Reverse the sequence to loose.

Special tools should be used when necessary.

Attention should be paid to avoid damage or loss of disconnected parts. Clean and grease properly before the assembly. No grease on Bolt's Thread.

Reconfirm each function after the assembly.

Special attention should be paid to the battery's electrolyte and brake oil which will stam clothes.

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CHAPTER 2 MAINTENANCE INFORMATION

2-1 Specification Sheet

CU8 (X-Motion 125)

Air Filter

Paper Type

Length (mm)

2130

Fuel Capacity

11 L

Wi dth (mm)

840

Type

CVK164

Dimen

Height (mm)

1380

Venturi (mm)

sion

Wheelbase (mm)

1500

Front

Fuel

System

Carburetion

Rear

Unload

mass

Total

150

Type

C.D.I.

Ma s

Front

102

Spark

CR8E

Rear

198

Ignition

Pointgap (mm) 0.8+0.1

Total mass

2 person/

150 kg

Total

300

Electric

system

Battery Type

GTX14-BS

Front

120/70-14

type

Automatic

Tire

Rear

140/60-13

Clutch type

Centrifugal type

Engine Type

4 Stroke 4V electroplated

ceramic cylinders engine

Transmission type

CVT

Fuel Type

Petrol

Type

Automatic

Number of Cylinder

Single cylinder

0.79~2.72

Bore X Stroke (mm )

57 X 48.8

Gear Box

Gear

Ratio

9.67

Cylinder Capacity

124.5 c.c.

Transmis -

sion

Starter

Electric &Kick

raked angle ( ° )

Cooling System

Liquid

Front

Lubrication system

Forced circulation & splashing

Tire Pressure (psi)

Rear

Reference and setting range(IN )

0.12±0.02 mm

Left

Reference and setting range(EX)

0.12±0.02 mm

Motion

system

Turn angel ( ° )

Right

...

MaxSpeed (km/hr)

105 km/h

Front

Disk

Idle speed (rpm )

1800+100 rpm

Braking system

Rear

Disk

Max Power ( Kw/rpm )

9 kw/8750 rpm

Front

Hydraulic-pressed Spring type

Max Torque (Nm/rpm)

10.5Nm/8250rpm

Suspension

Rear

Hydraulic-pressed Spring type

Compression Ratio

10.5

Front

Hydraulic-pressed Spring

Oil Spec.

SAE 10W-30

Buffer

Rear

Hydraulic-pressed Spring

Oil Capacity ( L)

1 L

Frame Type

Welding Tube

Engine

Gear Oil Spec., Capacity

SAE 90, 0.11L

Front Lamp

35W/35W-12V

Rear Lamp

5W-12V

Brake Lamp

21W-12V

Lamp

Direction Lamp

21W-12V

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CUB (X-Motion 250)

Air Filter

Paper Type

Length (mm)

2130

Fuel Capacity

11 L

Width (mm)

840

Type

...

Height (mm)

1380

Venturi (mm)

...

Dimension

Wheelbase (mm)

1500

Front

Fuel

System

Carburetion

Rear

100

Unload mass

Total

160

Type

E.C.U.

Front

107

Spark

CR8E

Rear

203

Ignition

Point ga (mm) 0.8±0.1

Mass

Total mass 2

person/ 150 kg

Total

310

Electric system

Battery Type

GTX14-BS

Front

120/70-14

type

Automatic

Tire

Rear

140/60-13

Clutch type

Centrifugal type

Engine Type

4 Stroke

Transmission type

CVT

Fuel Type

Petrol

Type

Automatic

Number of Cylinder

Single cylinder

0.8~2.30

Bore X Stroke (mm )

71 X 63.3

Gear Box

Gear Ratio

7.42

Cylinder Capacity

249.4 c.c.

Transm -

ission

Starter

Electric

raked angle ( ° )

—

Cooling System

Liquid

Front

Lubrication system

Forced circulation & splashing

Tire Pressure (psi)

Rear

Reference and setting

range(IN)

0.1 ±0.02 mm

Left

—

Reference and setting

range(EX)

0.15±0.02 mm

Motion

system

Turn angel ( ° )

Right

—

Max Speed (km/hr)

128 km/h

Front

Disk

Idle speed (rpm )

1650±100 rpm

Braking system

Rear

Disk

Max Power ( Kw/rpm )

17.2kw/8750 rpm

Front

Hydraulic-pressed Spring type

Max Torque (Nm/rpm)

22.7Nm/8250rpm

Suspension

Rear

Hydraulic-pressed Spring type

Compression Ratio

10.8

Front

Hydraulic-pressed Spring

Oil Spec.

SAE 10W-30

Buffer

Rear

Hydraulic-pressed Spring

Oil Capacity (L)

1.4 L

Frame Type

Welding Tube

Engine

Gear Oil Spec.,Capacity

SAE 90, 0.18L

Front Lamp

35W/35W-12V

Rear Lamp

5W-12V

Brake Lamp

21W-12V

Lamp

Direction Lamp

21W-12V

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2-2 Safety Precautions

Warning: Engine Exhaust

Please keep good ventilation during engine operation. Do not operate engine in closed-room.

The toxic carbon-oxygen (CO) in exhaust may lead human to loss conscious and even death.

Warning: Gasoline

The gasoline is very easy to burn or explode. Forbid any fire during inspection of gasoline tank or gasoline leak.

Warning: Battery H2 and Battery Liquid

1. The battery liquid is toxic sodium liquid. Please do not contact the liquid with skin or eye. If any contact happens, please wash with massive clean water and contact with doctor.

2. The released H2 from battery is explosive. Please keep good ventilation during charging battery and forbid any fire.

Watch: Brake Fluid

The brake fluid can damage the painting on plastic. Please cover the plastic parts with towel or cloth during maintenance of brake disk. If the brake fluid is split on plastic component, please remove the fluid and wash the surface with water right away.

Watch: High Temperature of Engine

The engine cover, cylinder, and exhaust pipe have high temperature after starting of engine. Please wear glove in maintenance of parts during engine operation, or maintenance should be waited until engine is cooled.

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2-3 Special Tools

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2-4 List of Grease & Oil Adopted:

TGB Supper Grease No.0

Apply in Oil Seal.

Supper Grease No.3

Apply in Axle Shaft, inside of Oil Seal.

1104 Sealing ThreeBond Apply on Right Hand Crank Surface.

TGB Gear Oil 85w-140

Transmission Gear Oil for Scooters.

TGB Genuine EXTRA 4X OIL

Engine Oil Apply in oil tank

Three-Bond 1322 Under M10 Screw (For medium fixing) for Flywheel Magneto.

TGB Supper Grease No. I

Apply in Oil Seal.

DOT-3 Brake Oil For Brake.

TGB Supper Grease No.2

Apply in Kick Starter.

TGB Supper Grease No.4

For Movable Drive Face Comp.

Cemedine 575 Apply in Handle Grip

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2-6 Troubleshooting

Complaint

Possible Reason

Remedy

No action for starter motor

1. Fuse breaks. 2. No power in battery. 3. Defective action of brake switch. 4 Short circuit of starter relay.

Replace Charging Replace Replace

No sparking or poor sparking

1. Defective spark plug. 2. Defective CDI & ignition coil unit. 3. Defective magneto stator coil. 4. Loose connection of lead wire.

Replace Replace Replace Connect

Unable or Difficult to start

Plug not sparking

1. Damaged spark plug or spark plug cap. 2. Dirty or wet spark plug. 3. Defective CDI &ignition coil unit or stator coil. 4.Open or short in high-tension cord. 5. Defective ignition switch. No fuel reaching the carburetor 1. No gasoline in fuel tank.

2.Clogged hole in the fuel tank cap.

3.Clogged or defective fuel cock. 4.Clogged fuel hose or defective vacuum hose. Compression too low 1. Excessively worn cylinder or piston rings. 2.Spark plug too loose. 3. Broken,cracked or otherwise failed piston.

Replace Clean & dry Replace Replace Replace Replace Clean Clean or replace Clean or replace Replace Tighten Replace

Noisy engine

1 . Piston or cylinder worn down. 2. Combustion chamber fouled with carbon. 3. Piston pin,bearing or piston pin worn. 4. Worn or burnt crankshaft bearings.

Replace Clean Replace Replace

Engine idles poorly

1. Stiff piston ring in place. 2. Excessively worn cylinder or piston rings. 3. Gas leaks from crankshaft oil seal. 4. Defective CDI & ignition coil unit. 5. Clogged jets in carburetor.

Replace Replace Replace Replace Clean or adjust

2-7 Tighting Torque of Screws

*Standard Torque Values of Bolts and Nuts *

Specification

Torque (kg-cm)

Specification

Torque (kg-cm)

5 mm Bolt and Nut

8 mm Bolt and Nut

220

5 mm Flange Bolt and Nut

8 mm Flange Bolt and Nut

270

6 mm Bolt and Nut

100

10 mm Bolt and Nut

350

6 mm Flange Bolt and Nut

120

10 mm Flange Bolt and Nut

400

6 mm SH Bolt and Nut

12 mm Bolt and Nut

550

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* Torque Values of Chassis Components *

No. Tightening Location

Specification

Torque

(kg-cm)

Front Wheel Axle Self-lock Nut

M12

500~600

Brake Disk Hex Bolt

180~280

Brake Clipper Tightening Bolt

M 8x35

210~250

Speed Meter Cable Nut

Front Fork Bearing Tightening Nut

M25x1.0

600~650

Rear Wheel Axle Self-lock Nut

M16x10

600~900

Rear Brake Connecting Rod Bolt

M16x32

50~80

Rear Brake Pin Self-lock Nut

250~270

Rear Upper Cushion Tightening Bolt

M10*46

200~300

Rear Lower Cushion Tightening Bolt

M8*35

200~300

* Torque Values of Engine components *

Tightening Location

Specification

Torque

Quantities

(kg-cm)

Cylinder Head Bolt

80~100

Cylinder Stud Bolt

M8x182.5

500~800

M8x195.5

Cylinder Intake Pipe Stud Bolt

M6x50

500~800

Muffler and Exhaust Pipe Tightening Screw

100~120

Muffler & Right Crankcase Upper Tightening Screw

M 8x42

300~400

Muffler & Right Crankcase Lower Tightening Screw

M 8x38

300~400

Spark Plug

M10

100~120

Valve Gap Adjust Lock Bolt

50~90

Fuel Filter Nut Cap

M30

150~200

Cooler Fan Lock CR

M6x18

500~800

Wire Assembly Lock Screw

M6x20

800~1000

Start Clutch Gear ightening Nut

M22 (R.T.)

800~1000

Driven Belt Pully Assembly

M12

400~600

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TGB Xmotion 125, Xmotion 250 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual