Page 1 BLADE 250 SERVICE MANUAL...
Page 2 “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, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.
Page 3 HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for BLADE 250 ATV. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
Page 4 Homepage CONTENTS Page Content Index 1-1 ~ 1-18 GENERAL INFORMATION 2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION 3-1 ~ 3-8 LUBRICATION SYSTEM 4-1 ~ 4-12 FUEL SYSTEM 5-1 ~ 5-6 ENGINE REMOVAL 6-1 ~ 6-16 CYLINDER HEAD/VALVE 7-1 ~ 7-8 CYLINDER/PISTON 8-1 ~ 8-14 “V”...
Page 5 Home page Contents SERIAL NUMBER Frame number Engine number...
Page 6: Table Of Contents
Homepage Contents 1. GENERAL INFORMATION Symbols and Marks......1-1 Specifications........1-10 General Safety ........1-2 Torque Values ........1-11 Service Precautions ......1-3 Troubles Diagnosis......1-13 Specifications ........1-9 Lubrication Points ......1-18 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.
Page 7: General Safety
To this chapter contents 1. GENERAL INFORMATION General Safety Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have •...
Page 8 To this chapter contents 1. GENERAL INFORMATION Service Precautions ● Always use with SANYANG genuine parts and ● Never bend or twist a control cable to prevent recommended oils. Using non-designed parts for unsmooth control and premature worn out. SANYANG ATV may damage the ATV. ●...
Page 9 To this chapter contents 1. GENERAL INFORMATION ● The length of bolts and screws for assemblies, ● Remove residues of the old gasket or sealant cover plates or boxes is different from one another, before reinstallation, grind with a grindstone if be sure they are correctly installed.
Page 10 To this chapter contents 1. GENERAL INFORMATION ● Lubricate the rotation face with specified ● After service completed, make sure all lubricant on the lubrication points before connection points is secured. assembling. Battery positive (+) cable should be connected firstly. ●...
Page 11 To this chapter contents 1. GENERAL INFORMATION ● ● Insert the terminal completely. When separating a connector, it locker has to be unlocked firstly. Then, conduct the service Check if the terminal is covered by the boot. operation. Do not let boot open facing up. ●...
Page 12 To this chapter contents 1. GENERAL INFORMATION ● Do not let the wire harness contact with rotating, ● Protect wires or wire harnesses with electrical moving or vibrating components as routing the tape or tube if they contact a sharp edge or harness.
Page 13 To this chapter contents 1. GENERAL INFORMATION ● Do not let the wire harness been twisted as ● With sand paper to clean rust on connector installation. pins/terminals if found. And then conduct connection operation later. Clean rust ● 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.
Page 14: Lubrication System
To this chapter contents 1. GENERAL INFORMATION Specifications MAKER MODEL UA25A Overall Length 2160 mm Suspension Front Double arm System Overall Width 1160 mm Rear Unit Swing Overall Height 1175 mm Front AT22x7-10 (on road) Tire Specifications Wheel Base 1300 mm Rear AT22x10-10 (on road) Front...
Page 15: Specifications
To this chapter contents 1. GENERAL INFORMATION Specifications MAKER MODEL UA25C Overall Length 2160 mm Suspension Front Double arm System Overall Width 1160 mm Rear Unit Swing Overall Height 1205 mm Front AT25x8-12 (on road) Tire Specifications Wheel Base 1300 mm Rear AT25x10-12 (on road) Front...
Page 16: Torque Values
To this chapter contents 1. GENERAL INFORMATION 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 Type Tighten Torque Type Tighten Torque 5 mm bolt、nut...
Page 17 To this chapter contents 1. GENERAL INFORMATION Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks 2.40 Handlebar upper holder bolt 5.00 Steering shaft nut 5.00 Steering tie-rod nut 5.00 Knuckle nut 3.40 Steering shaft holder bolt 3.60 Tie rod lock nut 4.00 Handlebar under holder nut...
Page 18: Troubles Diagnosis
To this chapter contents 1. GENERAL INFORMATION Troubles Diagnosis A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline inside ● No fuel in fuel tank the carburetor ●...
Page 19 To this chapter contents 1. GENERAL INFORMATION B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed ● Air cleaner clogged ● Poor fuel supply Engine speed can be Engine speed can not be ●...
Page 20 To this chapter contents 1. GENERAL INFORMATION C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) ● Normal Abnormal Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the air screw of carburetor Good...
Page 21 To this chapter contents 1. GENERAL INFORMATION E. Clutch, driving and driving pulley FAULT CONDITIONS PROBABLE CAUSES ● Drive belt worn out or deformation ● Ramp plate of movable drive face damaged Engine can be started but ● Driving pulley spring broken motorcycle can not be moved.
Page 22 To this chapter contents 1. GENERAL INFORMATION G. Loss power Check and adjustment Fault condition Probable causes Raise wheels off ground and spin by hand ● Brake dragging ● Spin freely Abnormal Drive chain too tight ● Damaged wheel bearing ●...
Page 23: Lubrication Points
To this chapter contents 1. GENERAL INFORMATION Lubrication Points Drive chain Acceleration cable/ Front & rear brake lever pivot Speedometer gear Wheel bearing 1-18...
Page 24: Maintenance Information
Home page Contents 2. MAINTENANCE INFORMATION Precautions in Operation ···················· 2-1 Drive Chain ··········································· 2-7 Periodical Maintenance Schedule ······ 2-2 Brake System (Disk Brake) ················· 2-8 Fuel Lines ············································· 2-3 Brake Light Switch/Starting Inhibitor Switch ··················································· 2-9 Acceleration Operation ······················· 2-3 Headlight Beam Distance ····················...
Page 25: Periodical Maintenance Schedule
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.
Page 26: Fuel Lines
To this chapter contents 2. MAINTENANCE INFORMATION Fuel Lines Fuel tank 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 Fuel hose Warning Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.
Page 27: Valve Clearance
To this chapter contents 2. MAINTENANCE INFORMATION Valve Clearance Timing mark Caution Checks and adjustment must be performed when the engine temperature is below 35℃. Remove front fender, fuel tank cover and fuel tank. 2 bolts Remove cylinder head cover. Remove cylinder head side cover.
Page 28: Carburetor Idle Speed Adjustment
To this chapter contents 2. MAINTENANCE INFORMATION Carburetor Idle Speed Adjustment Ignition cable 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.
Page 29: Ignition System
To this chapter contents 2. MAINTENANCE INFORMATION 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.
Page 30: Drive Belt
To this chapter contents 2. MAINTENANCE INFORMATION Drive Belt Clamp strips Loosen the 2 clamp strips of left crankcase cover, and then remove the left crankcase cover vapor hose. Remove 9 bolts of the engine left side cover and the cover. 9 bolts Check if the belt is crack or worn out.
Page 31: Brake System (Disk Brake)
To this chapter contents 2. MAINTENANCE INFORMATION Brake System (Disk Brake) Brake System Hose Make sure the brake hoses for corrosion or leaking oil. Brake Fluid Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit.
Page 32: Brake Light Switch/Starting Inhibitor
To this chapter contents 2. MAINTENANCE INFORMATION Brake Lining Wear Front brake The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear limit mark Lining closed to the edge of brake disc. Caution ●...
Page 33: Headlight Beam Distance
To this chapter contents 2. MAINTENANCE INFORMATION Headlight Beam Distance Turn on main switch Headlight beam adjustment. Turn the headlight adjustment screw to adjust headlight beam high. Caution ● To adjust the headlight beam follows related regulations. ● Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting.
Page 34: Steering Handle
To this chapter contents 2. MAINTENANCE INFORMATION Steering Handle Caution Check all wires and cables if they are interfered with the rotation of steering handle bar. Lift the front wheel out of ground. Turn handle from right to left alternative and check if turning is smoothly.
Page 35: Special Tools List
2. MAINTENANCE INFORMATION Special Tools List PARTS NO. : 440629 PARTS NO. : 440626 PARTS NAME : DRIVESHAFT&OIL PARTS NAME : ACG FLYWHEEL PULLER SEAL INSTALLER PARTS NO. : 440627 PARTS NO. : 440630 PARTS NAME : HMA COUNTER SHIFT PARTS NAME : L.
Page 36 2. MAINTENANCE INFORMATION PARTS NO. : 440636 PARTS NO. : 440633 PARTS NAME : 6205 BEARING PARTS NAME : L. CRANK CASE COVER REMOVER(AIR WRENCH) 6006 BEARING INSTALLER PARTS NO. : 440637 PARTS NO. : 440634 PARTS NAME : TAPPET PIN REMOVER PARTS NAME : R.
Page 37 2. MAINTENANCE INFORMATION PARTS NO. : 440643 PARTS NO. : 440640 PARTS NAME : CLUTCH FIXING NUT PARTS NAME : WATER PUMP 6901 SLEEVE 46” BEARING INSTALLER PARTS NO. : 440647 PARTS NO. : 440644 PARTS NAME : 6204 BEARING PARTS NAME : ENGINE VALVE REMOVER INSTALLER PARTS NO.
Page 38: Lubrication System
Home page Contents 3. LUBRICATION SYSTEM Mechanism Diagram ······························ 3-1 Engine Oil Strainer Clean ······················ 3-3 Precautions in Operation ······················ 3-2 Oil Pump ················································· 3-4 Troubleshooting ···································· 3-2 Gear Oil ··················································· 3-7 Engine Oil ··············································· 3-3 Mechanism Diagram Valve Rocker Arm Press-In Lubrication Cam Shaft Oil Route...
Page 39: Precautions In Operation
SAE 10W-30 (Recommended King serial oils) Gear oil Disassembly: 750c.c. Change: 650c.c. Gear oil viscosity SAE 140 (Recommended TGB Hypoid gear oils) Units:mm Items Standard (mm) Limit (mm) Inner rotor clearance 0.15 0.20 Oil pump Clearance between outer rotor and body 0.15~0.20...
Page 40: Engine Oil
To this chapter contents 3. LUBRICATION SYSTEM Engine Oil Turn off engine, and park the ATV in flat surface Check oil level with oil dipstick. So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.
Page 41: Oil Pump
To this chapter contents 3. LUBRICATION SYSTEM Oil Pump Oil Pump Removal Remove generator and starting gear. (Refer to chapter 10) 。 Clip Remove cir clip and take out oil pump driving chain and sprocket. Make sure that pump shaft can be rotated freely. Remove 2 screws on the oil pump, and then remove oil pump.
Page 42 this chapter contents 3. LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance between inner and outer rotors. Limit: 0.20 mm Check clearance between rotor side face and pump body Limit: 0.12 mm Pins Oil Pump Re-assembly...
Page 43 To this chapter contents 3. LUBRICATION SYSTEM Tighten the oil pump screw. 1 screw Roller Oil Pump Installation Install the oil pump, and then tighten screws. Torque value：0.1~0.3kgf-m Make sure that oil pump shaft can be rotated freely. 2 screws Install oil pump drive chain and sprocket, and Clip then install cir clip onto oil pump shaft.
Page 44: Gear Oil
To this chapter contents 3. LUBRICATION SYSTEM Gear Oil Gear oil join bolt Gear Oil Change Remove oil join bolt. Remove drain bolt and drain gear oil out. Install the drain bolt after drained. Torque value: 1.1~1.5kgf-m Make sure that the drain bolt washer can be re-used.
Page 45 To this chapter contents 3. LUBRICATION SYSTEM Notes:...
Page 46: Fuel System
Home page Contents 4. FUEL SYSTEM Mechanism Diagram ......4-1 Throttle Valve ........4-6 Precautions in Operation..... 4-2 Float Chamber........4-7 Trouble Diagnosis ........ 4-3 Adjustment of Idle Speed ....4-9 Carburetor Remove / Install ....4-4 Fuel Tank ..........4-10 Air Cleaner..........4-11 Air Cut-Off Valve ........4-5 Mechanism Diagram Fuel tank cap Fuel unit...
Page 47: Precautions In Operation
To this chapter contents 4. FUEL SYSTEM Precautions in Operation General Information Warning Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Cautions ● Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability. ●...
Page 48: Trouble Diagnosis
To this chapter contents 4. FUEL SYSTEM Trouble Diagnosis Poor engine start Mixture too lean ● Clogged fuel injector No fuel in fuel tank y ● Vacuum piston stick and closed Clogged fuel tube ● Malfunction of float valve ● Too much fuel in cylinder ●...
Page 49: Carburetor Remove / Install
To this chapter contents 4. FUEL SYSTEM Carburetor Remove / Install Removal Drain out fuel in the float chamber. Drain bolt Loosen the choke cable fixed iron sheet screw 1 screw from plate. Remove the choke cable. Choke cable Vacuum pipe Fuel pipe Disconnect the fuel hose.
Page 50: Air Cut-Off Valve
To this chapter contents 4. FUEL SYSTEM Air Cut-Off Valve 2 screws Disassembly Remove 2 screws. Remove air cut-off valve cover, spring and valve. O-ring Spring Air cut-off valve Cover Inspection Check the valve is in normal. If the valve is in normal, it will restrict air-flow. If air-flow is no restricting, replace carburetor assembly.
Page 51: Throttle Valve
To this chapter contents 4. FUEL SYSTEM Throttle Valve Disassembly Remove carburetor upper parts, and then remove throttle valve and throttle cable. Throttle valve Disconnect the throttle cable from the throttle valve and remove the valve spring. Remove the fuel needle clamp and fuel needle. Spring Assembly Place the fuel needle onto the throttle valve and...
Page 52: Float Chamber
To this chapter contents 4. FUEL SYSTEM Float Chamber Disassembly Remove 3 mounting screws and remove float chamber cover. 3 Screws Remove the fuel level plate, float pin, float and Float Float valve float valve. Fuel level plate Inspection Check float valve and valve seat for damage, blocking.
Page 53 To this chapter contents 4. FUEL SYSTEM Remove main jet, needle jet holder, needle jet, slow jet and air adjustment screw. Needle jet holder Main jet Caution Take care not to damage jets and adjust screw. y Before removing adjustment screw, turn it all the way down and note the number of turns.
Page 54: Adjustment Of Idle Speed
To this chapter contents 4. FUEL SYSTEM Adjustment of Idle Speed Parking brake Caution ● Air screw was set at factory, so no adjustment is needed. Note the number of turns it takes to screw it all the way in for ease of installation. ●...
Page 55: Fuel Tank
To this chapter contents 4. FUEL SYSTEM Fuel Tank 4 bolts Fuel unit removal Open the seat. Remove the front cover and fuel tank. Remove the side covers and lower side covers. Remove the front fender. (Covers remove please refer chapter Disconnect fuel unit coupler.
Page 56: Air Cleaner
To this chapter contents 4. FUEL SYSTEM Air Cleaner Clamp Removal Loosen the clamp strip of air cleaner and carburetor, and then remove the vapor hose. Loosen the clamp strip of air cleaner, and then remove the air cleaner vapor hose. Remove the air cleaner (2 bolts).
Page 57 To this chapter contents 4. FUEL SYSTEM Notes: 4-12...
Page 58: Engine Removal
Home page Contents 5. ENGINE REMOVAL Precautions in Operation ..... 5-1 Engine Installation ........ 5-6 Removal of Engine ....... 5-2 Precautions in Operation General Information ● The engine has to be supported with special service tools that can be lifted or adjustable. ●...
Page 59: Removal Of Engine
To this chapter contents 5. ENGINE REMOVAL Removal of Engine Negative Remove the seat. Remove battery negative post (-). Remove battery positive (+) post. Remove front fender and the footrest (refer chapter 13). Positive Remove starter motor wire. Starter motor wire Remove the spark plug cap.
Page 60 To this chapter contents 5. ENGINE REMOVAL Remove muffler protect (2 bolts). 2 bolts Loosen muffler front side bolt. 2 bolts Remove 2 bolts, and then remove the exhaust muffler. 2 bolts Remove 2 nuts, and then remove exhaust pipe. 2 nuts...
Page 61 To this chapter contents 5. ENGINE REMOVAL Loosen 1 screw and disconnect the choke cable. 1 screw Choke cable Remove fuel pipe and vacuum pipe Vacuum pipe Fuel pipe Release the clamp strip of air cleaner duct. Clamp Disconnect the carburetor upper parts and cable. Release the 2 nuts of carburetor insulator, and then remove the carburetor.
Page 62 To this chapter contents 5. ENGINE REMOVAL Remove coolant drain bolt, and drain out coolant. Water hoses clamp Remove coolant inlet hoses from water pump. Drain bolt Remove the thermo-sensor wire, by-pass pipe and By-pass pipe Outlet hose coolant outlet hose. Thermo-sensor wire Remove gear change lever (1 bolt).
Page 63: Engine Installation
5. ENGINE REMOVAL Loosen speedometer cable mounting nut, and Speedometer cable then remove the cable. Remove 3 bolts and remove drive chain protector. Turn the socket bolt clockwise, and then remove 3 bolts speedometer gear box. Caution The socket bolt is provided with left turn thread.
Page 64: Cylinder Head/Valve
Home page Contents 6. CYLINDER HEAD/VALVE Mechanism Diagram ··························· 6-1 Valve Stem Replacement··················· 6-10 Precautions in Operation ··················· 6-2 Valve Seat Inspection and Service ··· 6-11 Cylinder Head Reassembly ··············· 6-13 Troubleshooting·································· 6-3 Cylinder Head Removal ······················ 6-4 Cylinder Head Installation ················· 6-14 Cylinder Head Inspection ···················...
Page 65: Precautions In Operation
To this chapter contents 6. CYLINDER HEAD/VALVE Precautions in Operation General Information ● This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. ● Cylinder head service can be carried out when engine is in frame. Specification Item Standard...
Page 66: Troubleshooting
To this chapter contents 6. CYLINDER HEAD/VALVE Troubleshooting Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1.
Page 67: Cylinder Head Removal
To this chapter contents 6. CYLINDER HEAD/VALVE Cylinder Head Removal 2 nuts Remove engine. (Refer to chapter 5) Remove the inlet pipe (2 nuts). Remove 1 bolt of thermostat and then remove the Thermostat bolts thermostat. Remove hole bolt and spring for the cam chain tensioner.
Page 68 To this chapter contents 6. CYLINDER HEAD/VALVE Remove left crankcase cover, and turn the Timing mark Turn the drive face, and align the timing mark on the sprocket with that of cylinder head, piston is at TDC position. Remove cam sprocket bolts and then remove the sprocket by prying chain out.
Page 69 To this chapter contents 6. CYLINDER HEAD/VALVE Remove the 2 cylinder head mounting bolts from 4 Nuts cylinder head right side, and then remove 4 nuts and washers from cylinder head upper side. Remove the cylinder head. 2 bolts Gasket Remove cylinder head gasket and 2 dowel pins.
Page 70: Cylinder Head Inspection
To this chapter contents 6. CYLINDER HEAD/VALVE Remove valve stem seals. Valve stem seals Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface. Caution Do not damage the matching surface of cylinder head. Cylinder Head Inspection Check if spark plug and valve holes are cracked.
Page 71 To this chapter contents 6. CYLINDER HEAD/VALVE Rocker Arm Measure the cam rocker arm I.D., and wear or damage, oil hole clogged? Service Limit: Replace when it is less than 12.080 mm. Rocker Arm Shaft Measure the active O.D. of the cam rocker arm shaft and cam rocker arm.
Page 72 To this chapter contents 6. CYLINDER HEAD/VALVE Valve guide Caution 5.0 mm valve guide reamer Before measuring the valve guide, clean carbon deposits with reamer. Tool: 5.0 mm valve guide reamer Measure and record each valve guide inner diameters. Service limit: 5.03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve...
Page 73: Valve Stem Replacement
To this chapter contents 6. CYLINDER HEAD/VALVE Valve Stem Replacement Heat up cylinder head to 100~150 ℃ with heated Valve guide driver plate or toaster. 5.0mm Caution ● Do not let torch heat cylinder head directly. Otherwise, the cylinder head may be deformed as heating it.
Page 74: Valve Seat Inspection And Service
To this chapter contents 6. CYLINDER HEAD/VALVE Valve Seat Inspection and Service Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution ●...
Page 75 To this chapter contents 6. CYLINDER HEAD/VALVE Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width.
Page 76 To this chapter contents 6. CYLINDER HEAD/VALVE After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground. Cylinder Head Reassembly Lubricate Valve spring retainer valve stem with engine oil, and then insert the Valve stem seal...
Page 77: Cylinder Head Installation
To this chapter contents 6. CYLINDER HEAD/VALVE Cylinder Head Installation Gasket Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head. Install chain guide, dowel pins and a new cylinder head gasket onto the cylinder. Caution Do not damage the matching surfaces of cylinder and cylinder head.
Page 78 To this chapter contents 6. CYLINDER HEAD/VALVE Install cam chain on to sprocket and align the Timing mark timing mark on the sprocket with that of cylinder head. Align sprocket bolt hole with camshaft bolt hole. Tighten the sprocket mounting bolts. Caution 2 bolts Make sure timing marks are matched.
Page 79: Valve Clearance Adjustment
To this chapter contents 6. CYLINDER HEAD/VALVE Install Air Injection system (AI) pipe. (4 bolts) 4 bolts Spark plug Install inlet pipe onto cylinder Install and tighten spark plug Torque value: 1.0~2.0kgf-m Caution This model is equipped with more precision 4-valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinder head deformation, engine noise...
Page 80: Cylinder/Piston
7. CYLINDER/PISTON Mechanism Diagram ···························· 7-1 Piston Ring Installation ··················· 7-6 Precautions in Operation ···················· 7-2 Piston Installation ···························· 7-7 Cylinder Installation ························· 7-7 Trouble Diagnosis································ 7-2 Cylinder and Piston Removal ············· 7-3 Mechanism Diagram...
Page 81 7. CYLINDER/PISTON Precautions in Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. UA25A Specification Unit：mm Item Standard Limit 70.995~71.015 71.100 Cylinder Bend 0.050 Top ring 0.015~0.050 0.090 Clearance between piston rings ring 0.015~0.050 0.090...
Page 82 To this chapter contents 7. CYLINDER/PISTON Cylinder and Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Coolant hose Cover the holes of crankcase and cam chain with a piece of cloth. Remove piston pin clip, and then remove piston pin and piston.
Page 83 To this chapter contents 7. CYLINDER/PISTON Check cylinder if warp. Service limit: 0.05 mm Measure clearance between piston rings and grooves. Service Limit: Top ring: 0.09 mm ring: 0.09 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn.
Page 84 To this chapter contents 7. CYLINDER/PISTON Measure the outer diameter of piston pin. Service Limit: 16.96 mm Measure the inner diameter of connecting rod small end. Service Limit: 17.064 mm Measure the inner diameter of piston pin hole. Service Limit: 17.02 mm Calculate clearance between piston pin and its hole.
Page 85: Piston Ring Installation
To this chapter contents 7. CYLINDER/PISTON Piston Ring Installation Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown. Caution ● Do not damage piston and piston rings as installation. ●...
Page 86: Cylinder Installation
To this chapter contents 7. CYLINDER/PISTON Clean up all residues and foreign materials on the matching surface of crankcase. attention to not let these residues and foreign materials fall into crankcase. Caution Soap the residues into solvent so that the residues can be removed more easily.
Page 87 To this chapter contents 7. CYLINDER/PISTON Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation. Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged.。...
Page 88 Home page Contents 8. V-BELT DRIVING SYSTEM Mechanism Diagram ··························· 8-1 Drive Belt ·············································· 8-5 Maintenance Description ···················· 8-2 Drive Face············································· 8-7 Trouble Diagnosis ······························· 8-2 Clutch Outer/Driven Pulley·················· 8-10 Left Crankcase Cover ························· 8-3 Mechanism Diagram 5.0~6.0kgf-m 8.5~10.5kgf-m 5.0~6.0kgf-m...
Page 89: Maintenance Description
Torque value Special Service Tools ● Drive face nut: 8.5~10.5kgf-m Clutch spring compressor: ● Clutch outer nut: 5.0~6.0kgf-m Inner bearing puller: TGB-440645 ● Drive plate nut: 5.0~6.0kgf-m Clutch nut wrench 39 x 41 mm: TGB-440629 Universal holder: TGB-440646 Bearing driver:...
Page 90: Left Crankcase Cover
To this chapter contents 8. V-BELT DRIVING SYSTEM Left Crankcase Cover Clamp strips Left crankcase cover removal Release the 2 clamp strips of left crankcase cover ducts, and then remove the ducts. Remove left crankcase cover. (9 bolts) Remove 2 dowel pin and gasket. 9 bolts Left crankcase cover install Install left crankcase cover in the reverse...
Page 91 To this chapter contents 8. V-BELT DRIVING SYSTEM Left crankcase cover inspection 2 bolts Remove 2 bolts to remove left crankcase cover bearing setting plate. 9 bolts Check bearing on left crankcase cover. Rotate bearing’s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on cover tightly.
Page 92: Drive Belt
To this chapter contents 8. V-BELT DRIVING SYSTEM Drive Belt Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. Special Tool：universal holder Hold clutch outer with universal holder, and Bearing stay collar Universal holder remove nut, bearing stay collar and clutch outer.
Page 93 To this chapter contents 8. V-BELT DRIVING SYSTEM Installation Caution ● Pull out driven face to avoid it closing. Driven face ● Cannot oppress friction plate comp in order to avoid creates the distortion or the damage. Install drive belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft.
Page 94: Drive Face
To this chapter contents 8. V-BELT DRIVING SYSTEM Drive Face Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut. Remove drive face and drive belt. Remove movable drive face comp and drive face Movable drive face boss from crankshaft.
Page 95 To this chapter contents 8. V-BELT DRIVING SYSTEM Inspection Weight roller The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be affected. Check if rollers are worn or damaged.
Page 96 To this chapter contents 8. V-BELT DRIVING SYSTEM With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution The movable drive face surface has to be free of grease. Clean it with cleaning solvent. Drive face boss Movable drive face Drive face boss...
Page 97: Clutch Outer/Driven Pulley
To this chapter contents 8. V-BELT DRIVING SYSTEM Clutch Outer/Driven Pulley Clutch nut wrench Disassembly Remove drive belt, clutch outer and driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily. Caution Do not press the compressor too much.
Page 98 To this chapter contents 8. V-BELT DRIVING SYSTEM Clutch lining Clutch lining Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 3.0 mm Clutch weight Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 97.4 mm Free length Driven pulley...
Page 99 To this chapter contents 8. V-BELT DRIVING SYSTEM Clutch weight Replacement Remove snap ring and washer, and then remove Spring Driving plate clutch weight and spring from driving plate. Caution Some of models are equipped with one mounting plate instead of 3 snap rings. Check if spring is damage or insufficient elasticity.
Page 100 To this chapter contents 8. V-BELT DRIVING SYSTEM Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Outer bearing Remove inner bearing. Clipper Caution ● If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly.
Page 101 To this chapter contents 8. V-BELT DRIVING SYSTEM Installation of Clutch OUTER/Driven Pulley Oil seal Assembly Install new oil seal and O-ring onto movable driven face. Apply with specified grease to lubricate the inside of movable driven face. Specified grease O-ring Install the movable driven face onto driven face.
Page 102: Final Driving Mechanism
Home page Contents 9. FINAL DRIVING MECHANISM Inspection of Mission Mechanism ···· 9-6 Mechanism Diagram - transmission cover ······························································ 9-1 Bearing Replacement ························ 9-8 Precautions in operation ···················· 9-2 Re-assembly of Final Driving Mechanism Trouble Diagnosis ······························· 9-2 ····························································· 9-11 Disassembly of Transmission ············...
Page 103: Precautions In Operation
Gear box cover 2.6~3.0kgf-m Gear oil drain bolt 1.1~1.5kgf-m Gear oil fill bolt 3.5~4.5kgf-m Tools Special tools Bearing driver (6204): TGB-440647 Bearing driver (6205LLU): TGB-440631 Bearing driver (6305): TGB-440639 Needle bearing driver (HK2016): TGB-440627 Drive shaft and oil seal driver: TGB-440629...
Page 104: Disassembly Of Transmission
To this chapter contents 9. FINAL DRIVING MECHANISM Disassembly of Transmission Remove gear change lever (1 bolt). 1 bolt Speedometer cable Loosen speedometer cable mounting nut, and then remove the cable. Remove 3 bolts and remove drive chain protector. Turn the socket bolt clockwise, and then remove speedometer gear box.
Page 105 To this chapter contents 9. TRANSMISSION Remove gear box cover bolts (9 bolts) and then 9 bolts remove the cover. Remove shift drum catch ball, spring and bolt. Shift drum fixed catch bolt Shift drum Remove shift spindle, shift fork shaft, shift fork and shift drum.
Page 106 To this chapter contents 9. FINAL DRIVING MECHANISM Remove drive shaft bearing setting plate (1 bolt). Bearing setting plate Remove the drive shaft. Special tool: Shaft protector Remove gasket and dowel pin. Caution ● If non- essential do not remove the drive shaft from the case upper side.
Page 107: Inspection Of Mission Mechanism
To this chapter contents 9. TRANSMISSION Inspection of Mission Mechanism Check if the shift spindle is wear or damage. Check if the shift drum is wear or damage. Check if the shift fork and shaft is wear or damage. Measure the outer diameter of shift fork shaft, and replace it if it exceed service limit.
Page 108 To this chapter contents 9. FINAL DRIVING MECHANISM Check if the reverse shaft is wear or damage. Check if the final shaft and gear are burn, wear or damage. Check bearings on gear box and gear box cover. Drive shaft bearing Gear box Rotate each bearing’s inner ring with fingers.
Page 109: Bearing Replacement
To this chapter contents 9. TRANSMISSION Bearing Replacement Inner bearing puller Caution ● Never install used bearings. Once bearing removed, it has to be replaced with new one. Crankcase side Remove drive shaft bearing setting plate, and then remove drive shaft bearing from left crankcase using following tools.
Page 110 To this chapter contents 9. FINAL DRIVING MECHANISM Install drive shaft. Drive shaft and Clutch nut wrench Special tool: Drive seal install bush shaft puller Drive shaft and oil seal install bush Clutch nut wrench Drive shaft puller Apply with grease onto new drive shaft oil seal lip, Drive shaft and seal install bush and then install the oil seal.
Page 111 To this chapter contents 9. TRANSMISSION Remove final shat out side bearing. Inner bearing puller Special tool: Inner bearing puller Remove oil seal from gear box cover and discard the seal Install new bearing and bearing driver into gear Universal box cover outer side.
Page 112: Re-Assembly Of Final Driving Mechanism
To this chapter contents 9. FINAL DRIVING MECHANISM Re-assembly of Final Driving Oil seal Mechanism Apply with grease onto the oil seal lip of final driving shaft. Reverse shaft Drive shaft Install counter shaft, reverse shaft and final shaft onto gear box. Final shaft Counter shaft Shift drum...
Page 113 To this chapter contents 9. TRANSMISSION Align the position mark on the shift spindle Position mark sprocket with that of shift drum, and then install shift spindle. Dowel pins Install dowel pins and new gasket. 9 bolts Install gear box cover and bolts, and tighten. Torque value: 1.0~1.4kgf-m Install the shift spindle bracket, drive chain protector, speedometer gear box and gear change lever.
Page 114: Alternator
Home page Contents 10. ALTERNATOR/STARTING CLUTCH Mechanism Diagram ··························· 10-1 Flywheel Removal ································ 10-4 Starting Clutch ····································· 10-5 Precautions in Operation···················· 10-2 Right Crankcase Cover Removal ······· 10-3 Flywheel Installation ···························· 10-7 A.C.G. Set Removal ····························· 10-3 A.C.G. Set Installation·························· 10-8 Right Cover Bearing····························...
Page 115: Precautions In Operation
25.026~25.045 25.050 OD of starting clutch gear 42.192~42.208 42.100 Torque value Flywheel nut 5.0~6.0kgf-m Starting clutch hexagon bolt 1.0~1.4kgf-m with adhesive 8 mm bolts 0.8~1.2kgf-m 12 mm bolts 1.0~1.4kgf-m Tools Special tools A.C.G. flywheel puller: TGB-440626 Universal holder: TGB-440646 10-2...
Page 116: Right Crankcase Cover Removal
To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Right Crankcase Cover Removal 11 bolts Remove left footrest. Drain out the engine oil and coolant, and then remove coolant hoses. Remove water pump cover (4 bolts). Remove 11 bolts from the right crankcase cover. Remove the right crankcase cover.
Page 117: Flywheel Removal
To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Check the oil seal for wear or damage. Replace Oil seal it if necessary. Install a new one bearing (6201LU) by bearing driver. Special tool: Bearing driver Bearing driver Flywheel Removal Reduction gear Flywheel nut Remove right crankcase cover.
Page 118: Starting Clutch
To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Remove starter reduction gear and shaft. Pull flywheel puller out flywheel with A.C.G. flywheel puller. Special tool: A.C.G. Flywheel puller Remove flywheel and starting driven gear. Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear. Check the gear for wear or damage.
Page 119 To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Install starting clutch driven gear onto one way clutch. Hold flywheel and rotate starting clutch gear. The starting clutch gear should be rotated in C.C.W direction freely, but not C.W direction. (View as shown in this figure.) One way clutch removal Starting driven gear Remove starting driven gear.
Page 120: Flywheel Installation
To this chapter contents 10. ALTERNATOR/STARTING CLUTCH One way clutch Installation 3 socket bolts Install the components in the reverse procedures of removal. Caution Tape a tightening tape onto the thread of hexagon bolt. Torque value: 1.0~1.4kgf-m Starting driven gear Install starting driven gear.
Page 121: A.c.g. Set Installation
To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Install reduction gear shaft and reduction gear. Reduction gear A.C.G. Set Installation Wire 2 bolts Install the A.C.G. coil set onto right crankcase cover (3 screws). Install pulse generator (2 screws). Tie the wire harness securely onto the indent of crankcase.
Page 122 To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Install right crankcase cover (11 screws). 11 bolts Install the dowel pin, new gasket and water pump cover onto crankcase cover. Water pump cover bolts Connect water hoses to the right crankcase cover and water pump cover.
Page 123 To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Note: 10-10...
Page 124 Home page Contents 11. CRANKCASE / CRANK Mechanism Diagram ··························11-1 Disassembly of crankcase ················ 11-3 General information ···························11-2 Crankshaft Inspection ······················· 11-5 Trouble diagnosis ······························11-2 Assembly of crankcase ····················· 11-6 Mechanism Diagram 1.0~1.4kgf-m 0.8~1.2kgf-m 0.8~1.2kgf-m Eng. Oil drain bolt 3.5~4.5kgf-m 11-1...
Page 125: General Information
Engine oil drain bolt 3.5~4.5kgf-m Cylinder stud bolt 1.0~1.4kgf-m Tools Special tools L. crank shaft oil seal driver (27*42*7): TGB-440630 Trouble diagnosis Engine noise ● Loose crankshaft bearing ● Loose crankshaft pin bearing ● Worn out piston pin and pin hole 11-2...
Page 126: Disassembly Of Crankcase
To this chapter contents 11. CRANKCASE / CRANK Disassembly of crankcase Tensioner Remove the cam chain setting plate, and then remove cam chain. Loosen the pivot bolt and remove the tensioner. Cam chain setting plate Loosen 2 bolts on the right crankcase. 2 bolts Loosen 11 bolts on the left crankcase.
Page 127 To this chapter contents 11. CRANKCASE / CRANK Remove balance shaft from right crankcase. Balance shaft Remove crankshaft from right crankcase. Remove gasket and dowel pins. Scrape gasket residues off the crankcase contact surface. Caution Do not damage contact surface of the gasket. It is better to moisten the gasket residue for easy scrapping.
Page 128: Crankshaft Inspection
To this chapter contents 11. CRANKCASE / CRANK Crankshaft Inspection Use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit: 0.6 mm Measure point for the crank big end of the connecting rod. Measure the clearance of the big end at the vertical directions.
Page 129: Assembly Of Crankcase
To this chapter contents 11. CRANKCASE / CRANK Check balance shaft bearing Balance shaft bearings Check bearings on right and left crankcase. Rotate each bearings inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear tightly.
Page 130 To this chapter contents 11. CRANKCASE / CRANK Install 2 dowel pins and new gasket. Dowel pins Install the left crankcase onto the right crankcase. Tighten 11 bolts on the left crankcase. 11 bolts Torque value: 0.8~1.2kgf-m Tighten 2 bolts on the right crankcase. Torque value: 0.8~1.2kgf-m 2 bolts 11-7...
Page 131 To this chapter contents 11. CRANKCASE / CRANK Clean the crankshaft. Apply a layer of grease on the lip of oil seal, Puts on the left crank shaft. Install the oil seal in the left crankcase with care not to damage the lip of the oil seal. By oil seal driver (27×42×7), oil seal will knock into located.
Page 132: Cooling System
Home page Contents 12. COOLING SYSTEM Mechanism Diagram ··························12-1 System Test ········································ 12-5 General Information ···························12-2 Radiator ·············································· 12-6 Trouble Diagnosis ······························12-2 Water Pump ········································ 12-8 Thermostat ········································· 12-12 Trouble Diagnosis for Cooling System ·····························································12-3 Mechanism Diagram Radiator filler cap Reserve tank By-pass pipe To cylinder head...
Page 133: General Information
Boiling point Pressurized: 125.6 Torque Value For water pump impeller 1.0~1.4kgf-m Tools Requirement Special tools Water pump bearing driver (6901): TGB-440640 Water pump oil seal driver (Inner): TGB-440641 Water pump mechanical seal driver: TGB-440642 Inner bearing puller: TGB-440645 Trouble Diagnosis...
Page 134 To this chapter contents 12. COOLING SYSTEM Trouble Diagnosis for Cooling System The temperature indicated is too high A. Stop and waiting for the A1.Refill the radiator with engine is completely coolant then check for any Water leaking problem cooled down, open cap to leakage? check the capacity of coolant in radiator.
Page 135 To this chapter contents 12. COOLING SYSTEM Preceding page E. Keep eng. 3000~4000 rpm E-1. Measure thermal switch to and inspect cooling fan was confirm voltage be Replace thermal switch operating after the changed (12→0V)? temperature gauge over 3 checks? E-2.
Page 136: System Test
● Stop the engine. Add coolant to proper level if necessary. ● Screw and tighten up the radiator filler cap. Caution In order to avoid the water tank rusting, please do not use the unclear trade mark refrigerant. Coolant recommended: TGB Bramax radiator agent. Concentration: 50% 12-5...
Page 137: Radiator
To this chapter contents 12. COOLING SYSTEM Check reserve tank ● Remove the front center cover, and then remove reserve tank filler cap. ● Check the liquid level in the front fender right side. Add coolant to proper level if too low. ●...
Page 138 To this chapter contents 12. COOLING SYSTEM Coolant inlet pipe Loosen the radiator 4 bolts. Remove coolant upper side pipes. 4 bolts Remove coolant outlet pipe. coolant outlet pipe Disconnect the couplers for the thermo switch and fan motor, and then remove radiator and cooling fan. thermo switch Disassembly Loosen the 3 bolts from the fan duct, and then...
Page 139: Water Pump
To this chapter contents 12. COOLING SYSTEM Water Pump Check water pump seal / cooling system divulges inspection ● Disassembles the refrigerant drain bolt, overflows little buckles the N actually fluid, confirmed overflows the refrigerant whether has the greasy dirt. ●...
Page 140 To this chapter contents 12. COOLING SYSTEM Check any wear and damage of the mechanical Mechanical seal seal and inside seal. Caution The mechanical seal and inside seal must be replaced as a unit. Replacement of Mechanical Seal Water pump bearing Remove the inside bearing by inner bearing puller.
Page 141 To this chapter contents 12. COOLING SYSTEM Install the new inner seal onto the right crankcase. Water pump oil seal Special tools: driver (inner) Water pump oil seal driver (inner) Install a new outside bearing to the right Water pump bearing crankcase cover.
Page 142 To this chapter contents 12. COOLING SYSTEM Install the seal washer into the impeller. Caution Washer must be replaced together with the mechanical seal. Install the impeller onto the water pump shaft and Water pump rotor tighten. Torque Value: 1.0~1.4kgf-m Caution The impeller is left thread.
Page 143: Thermostat
To this chapter contents 12. COOLING SYSTEM Thermostat Temperature sensor By-pass pipe Please refer to chapter 17 for inspection of temperature sensor. Removal Drain out the coolant. Remove the thermostat set. (2 bolts) 2 Bolts Inspection Visually inspect thermostat for any damage. Place the thermostat into heated water to check its operation.
Page 144: Body Cover
13. BODY COVER Mechanism Diagram 13-1...
Page 145: Body Cover
13. BODY COVER Maintenance Body covers dissemble sequence Fuel tank cover Right and left foot board Right and left foot board Right and left front internal fender Right and left front shock mount, front bumper Front air inlet plate Right and left head lamp support, body cover Rear body cover Front protector rear protector...
Page 146 13. BODY COVER Remove seat Remove 2 bolts from battery fixed Remove cable and battery fixed Remove 1 screw and take off shift lever Remove fuel cap Remove 4 screws，and then remove fuel tank cover Installation Install in reverse order of removal procedures. 13-3...
Page 147 13. BODY COVER Remove screws from right or left foot board (each side 4 screws) Remove screws from right or left foot board (each side 8 screws) Remove M6 bolts from right or left foot board remove right or left foot board (each side 3 bolts) Remove bolts from right or left front internal fender (each side 5 bolts)，and then remove right or left front internal fender...
Page 148 13. BODY COVER Remove screws from front bumper (each side 3 screws) Remove head lamp couplers，and then remove front bumper Remove bolts from right and left head lamp support (each side 2 bolts) Remove bolts from front air inlet plate (each side 2 bolts) ，and then remove front air inlet plate Remove bolts from front body cover (each side 1 bolts)
Page 149 13. BODY COVER Remove lock cap Remove power source couplers，and then remove front body cover Remove bolts (each side 1 bolts) Remove 2 couplers Installation Install in reverse order of removal procedures. 13-6...
Page 150 13. BODY COVER Remove 1 couplers and 1 nut from starting motor relay，and then remove starting motor relay Remove 1 bolts from rear body covert Remove 1 nut from bear reflector assembly (each side 1 bolts) Remove number-plate lamp couplers 、rear lamp assembly couplers (L/R) and turn signal lamp couplers (L/R) Installation...
Page 151 13. BODY COVER Remove screws from rear body covert (each side 2 screws) ，and then remove rear body covert Remove 2 bolts from front protector Remove 2 bolts from front protector，and then remove front protector Remove bolts from bear protector (each side 1 bolts) Installation Install in reverse order of removal procedures.
Page 152 13. BODY COVER Remove bolts from bear protector (each side 1 bolts)，and then remove bear protector Remove bolts from upper bracket assembly (each side 2 bolts) Remove speedometer assembly couplers，and then remove upper bracket assembly Installation Install in reverse order of removal procedures. 13-9...
Page 153 Home page Contents 14. FRONT BRAKE & FRONT WHEEL Adding Brake Fluid ···························· 14-8 Mechanism Diagram···························14-1 Maintenance Description ···················14-2 Brake fluid replacement / Air-bleed ·· 14-9 Trouble Diagnosis ······························14-3 Front Brake Caliper···························· 14-10 Brake Disk ·········································· 14-11 Front Wheel·········································14-4 Front Brake Master Cylinder ············· 14-11 Front Wheel Hub·································14-4 Disk Brake System Inspection ··········14-7 Mechanism Diagram...
Page 154: Maintenance Description
To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Maintenance Description Operational precautions Caution Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. ●...
Page 155: Trouble Diagnosis
To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Trouble Diagnosis Soft brake lever Hard steering 1. Air inside the hydraulic system 1. Faulty tire 2. Hydraulic system leaking 2. Insufficient tire pressure 3. Worn master piston 4. Worn brake pad 5.
Page 156: Front Wheel
To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Front Wheel Removal Raise the front wheels off the ground by placing a jack or other support under the frame. 4 screws Remove the front wheel nuts, and then remove front wheels.
Page 157 To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Remove 4 socket bolts, and then remove the 4 bolts brake disk from wheel hub. Installation Install the front brake disk to the wheel hub. Install wheel hub and brake disk on to knuckle. Install wheel hub washer and tighten the wheel hub nut.
Page 158: Disk Brake System Inspection
To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Disk Brake System Inspection Inspection By visual examination whether divulges or the damage, with spanner inspection brake tube seam whether becomes less crowded, and the inspection handle bar turn right or turn left, or pressure the cushion, whether besides the pipeline protection department, whether there is interferes, contacts other parts of.
Page 159: Adding Brake Fluid
To this chapter tents 14. FRONT BRAKE & FRONT WHEEL Adding Brake Fluid Master cylinder Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, and then remove the brake fluid reservoir. When maintenance brake system, will be supposed to paint the surface or the rubber parts catches up by the rags.
Page 160: Brake Fluid Replacement / Air-Bleed
o this chapter contents 14. FRONT BRAKE & FRONT WHEEL Brake fluid replacement / Air-bleed Connect drain hose to air-bleed valve. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out.
Page 161: Front Brake Caliper
To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Front Brake Caliper Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Caution Do not spill brake fluid on painted surfaces. Remove two caliper bolts and the caliper.
Page 162: Brake Disk
To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Brake Disk Brake disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit.
Page 163 To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Remove the rubber boot. Remove the cir clip. Cir clip Remove the piston and the spring. Rubber boot Clean the master cylinder with recommended Piston brake fluid. Piston cup Spring Master cylinder Master Cylinder Inspection Check the master cylinder for damage or scratch.
Page 164 To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Master Cylinder Install Install the rubber pad into the groove correctly. Place the master cylinder onto handlebar, and install the bolts. Install the brake lever, and connect leads to brake Brake light switch Brake lever bolt light switch.
Page 165 To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Notes: 14-13...
Page 166 Home page Contents 15. STEERING / FRONT SUSPENSION Mechanism Diagram ··························15-1 Steering Tie-Rod ································ 15-6 Operational Precautions ····················15-2 Knuckle ··············································· 15-7 Trouble Diagnosis ······························15-2 Front Cushion ···································· 15-8 Steering Handle ··································15-3 Suspension Arm ································ 15-9 Steering Shaft ·····································15-5 Toe-In ·················································· 15-10 Mechanism Diagram 300~350 kgf-cm 300~350 kgf-cm...
Page 167 To this chapter contents 15. STEERING / FRONT SUSPENSION Operational Precautions Torque Values Handlebar upper holder bolt 300~350 kgf-cm Steering shaft holder bolt 300~350 kgf-cm Steering shaft nut 250~350 kgf-cm Steering tie-rod nut 250~350 kgf-cm Knuckle nut kgf-cm Tie rod lock nut 450~550 kgf-cm Suspension arm nut 450~550 kgf-cm...
Page 168 To this chapter contents 15. STEERING / FRONT SUSPENSION Steering Handle Removal Remove the handle cover, meter set, handle protect cover and front fender. (Refer to chapter Handle protect cover Loosen the socket bolts for the front brake master brocket bolts cylinder, and remove front brake master cylinder.
Page 169 To this chapter contents 15. STEERING / FRONT SUSPENSION Loosen 2 screws, and then remove handle left switch and choke hosing. 2 screws 4 socket bolts Remove switch wire band. Remove handle mounting bolt, and then remove the handle upper holder, handle. Remove 2 nuts to remove handle under holder and meter bracket.
Page 170: Steering Shaft
To this chapter contents 15. STEERING / FRONT SUSPENSION Steering Shaft Remove Remove cotter pins, and loosen right and left steering tie-rod nuts. Remove tie-rod. Steering shaft nut Remove the cotter pin steering shaft, and below remove steering shaft nut and washer. Cotter pin Bend out the steering shaft holder nut fixed plate.
Page 171 To this chapter contents 15. STEERING / FRONT SUSPENSION Steering Tie-Rod Remove Remove cotter pin and tie-rod nut from steering shaft side. Remove cotter pin and tie-rod nut from wheel side. Inspection Inspect the tie-rod for damage or bending. Inspect the ball joint rubbers for damage , wear or deterioration.
Page 172 To this chapter contents 15. STEERING / FRONT SUSPENSION Knuckle Remove Remove front wheel, front brake caliper, front wheel hub and brake disk. Tie-rod Remove cotter pin and tie-rod nut, remove tie rod. Cotter pin Universal holder Remove cotter pin and ball joint nut. Remove upper and under ball joints by ball joint driver.
Page 173 To this chapter contents 15. STEERING / FRONT SUSPENSION Front Cushion Remove Remove front cushion under bolt nut, and remove the bolt. Remove front cushion upper bolt nut, and remove the bolt and cushion. Installation Install in reverse order of removal procedures. Torque value: Front cushion nut 4.6kgf-m...
Page 174 To this chapter contents 15. STEERING / FRONT SUSPENSION Suspension Arm Remove Remove front wheel, wheel hub, and brake caliper, brake disk, tie-rod, knuckle and front cushion. Suspension arm nuts and bolts Loosen upper arm nuts, remove swing suspension arm bolts. Remove upper s arm.
Page 175 To this chapter contents 15. STEERING / FRONT SUSPENSION Toe-In When repair or disassemble steering system parts, must to adjustment the toe-in. Keep the vehicle on level ground and the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center height.
Page 176 Home page Contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Disk Brake System Inspection ·········· 16-10 Mechanism Diagram···························16-1 Maintenance Description ···················16-2 Adding Brake Fluid ···························· 16-11 Trouble Diagnosis ······························16-3 Brake fluid replacement / Air-bleed ·· 16-12 Rear Wheel ··········································16-4 Rear Brake Caliper ·····························...
Page 177: Maintenance Description
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Maintenance Description Operational precautions Caution Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. ●...
Page 178: Trouble Diagnosis
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Trouble Diagnosis Soft brake lever Vibration or Wobble 1. Air inside the hydraulic system 1. Axle is not tightened well 2. Hydraulic system leaking 2. Bent rim 3.
Page 179: Rear Wheel
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Wheel Removal Raise the rear wheels off the ground by placing a jack or other support under the frame. Remove rear axle cover (4 screws). 4 screws Remove the rear wheel nuts, and then remove rear wheels.
Page 180: Rear Wheel Axle
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Wheel Axle Remove right and left rear wheel, wheel connecter. Remove 2 bolts, and then remove rear brake caliper. Remove 2 bolts and 1 nut, and remove drive chain 2 bolts cover.
Page 181 To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Remove 4 nuts, and remove driven sprocket. Bend out the rear axle nut fixed plate. Bend out the rear wheel axle holder nut fixed plate. Fixed plate Remove rear wheel axle nuts.
Page 182 To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Remove rear wheel axle and driven sprocket holder. Driven sprocket holder Inspection Check bearings on rear wheel axle bearing seat. Rotate each bearing’s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on bearing seat.
Page 183 To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Installation Install rear wheel axle and driven sprocket holder. Driven sprocket holder Install rear brake disk bracket and disk. Brake disk bracket Install rear wheel axle nuts, rear axle nut fixed plate and tighten the nuts.
Page 184: Rear Swing Arm
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Install driven sprocket, drive chain, drive chain Master link Moving direction cover and brake caliper. Caution ● Note the chain lock clip direction. Install rear wheel shaft connecter, rear wheel. Lock clip Driven sprocket inspection Check the condition of the driven sprocket teeth.
Page 185: Disk Brake System Inspection
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Disk Brake System Inspection Inspection By visual examination whether divulges or the damage, with spanner inspection brake tube seam whether becomes less crowded, and the inspection handle bar turn right or turn left, or pressure the cushion, whether besides the pipeline protection department, whether there is interferes, contacts other parts of.
Page 186: Adding Brake Fluid
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Adding Brake Fluid Fluid cup Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, and then remove the brake fluid reservoir.
Page 187: Brake Fluid Replacement / Air-Bleed
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Brake fluid replacement / Air-bleed Air-bleed valve Connect drain hose to air-bleed valve. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out.
Page 188: Rear Brake Caliper
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Brake Caliper Brake hose bolt Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Caution Do not spill brake fluid on painted surfaces.
Page 189: Brake Disk
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Brake Disk Brake disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit.
Page 190 To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Right footrest side – rear brake master cylinder Place a container under the brake master cylinder, remove fluid hose clamp, and drain out the brake fluid. Loosen the brake hose bolt and finally remove the brake hose.
Page 191 To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Measure the outer diameter of the piston. Replace the piston if its measured value exceeds allowable limit. Allowable limit: Hand brake 13.954 mm Foot brake 15.850 mm Master Cylinder Assembly Caution ●...
Page 192 To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Right footrest side – rear brake master cylinder Install the master cylinder bolts and the master cylinder. Install brake push rod to the brake pedal, and install pin and clip. Caution To adjustment brake pedal, you must be removed push rod pin fist.
Page 193: Rear Cushion
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Cushion Removal Support the frame. Loosen rear cushion under bolt nut, and remove rear cushion under bolt. Rear cushion under bolt Remove rear cushion upper bolt, and then remove rear cushion.
Page 194: Electrical System
Home page Contents 17. ELECTRICAL SYSTEM Mechanism Diagram ··························17-1 Meters ················································· 17-12 Maintenance Data ·······························17-2 Light / Bulb········································· 17-13 Technical Specification······················17-2 Switch / Horn······································ 17-16 Trouble Diagnosis ······························17-3 Fuel Unit ············································· 17-19 Battery ·················································17-4 Cooling Fan Thermo Switch ············· 17-20 Charging System ································17-5 Thermo unit········································...
Page 195: Maintenance Data
To this chapter contents 17. ELECTRICAL SYSTEM Maintenance Data Operational precaution ● When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) ● The model of the spark plug and the tightening torque. ●...
Page 196: Trouble Diagnosis
To this chapter contents 17. ELECTRICAL SYSTEM Trouble Diagnosis Charging system does not operate No voltage ● Battery discharged properly ● ● Burnt fuse The cable disconnected ● ● Poor contact, open or short circuit The fuse is blown ● ●...
Page 197 To this chapter contents 17. ELECTRICAL SYSTEM Battery Removal Remove the seat, and then you can see the battery. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery clamp, and then remove battery... Clamp Voltage Check Use the digital voltmeter to check the voltage of the battery.
Page 198: Charging System
To this chapter contents 17. ELECTRICAL SYSTEM Charging System Charging circuit Main switch Green Black Yellow Yellow Fuse 20A Yellow Battery Regulator rectifier AC. Generator Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery. Connect an ammeter between the negative cable terminal and the battery negative terminal.
Page 199 To this chapter contents 17. ELECTRICAL SYSTEM Inspection on Charging Voltage Connect a tachometer. Turn on the headlight to high beam and start the engine. Voltmeter Accelerate the engine to the specified revolution per minute and measure the charging voltage. Ammeter Specified Charging Current: 1.2 A / 6000 rpm...
Page 200 To this chapter contents 17. ELECTRICAL SYSTEM Inspection on regulator rectifier Remove the seat, rear carrier and rear fender. Disconnect two 3 pin couplers of the regulator rectifier. Inspection the rectifier coupler to the wire harness passes the condition. Item Check Points Standard Value Main switch Battery voltage...
Page 201 To this chapter contents 17. ELECTRICAL SYSTEM Ignition System Ignition circuit diagram Black Shift gear control unit CDI. Unit Green White Yellow Blue Fuse 15A Ignition coil Main fuse Spark plug Battery Main switch Pulse generator C.D.I unit Disconnect connectors of the C.D.I unit. Check the following connectors as indicated in the table at the harness side.
Page 202 To this chapter contents 17. ELECTRICAL SYSTEM Inspection on Ignition Coil Disengage the connector of the ignition coil and the spark plug cap. Measure the resistance between the terminals of the primary winding. Ω ± 10% Standard resistance: 0.17 Remove the cap from the spark plug and measure the resistance between the spark plug and the primary winding.
Page 203: Starting System
To this chapter contents 17. ELECTRICAL SYSTEM Starting System Starting circuit diagram Shift gear control unit Fuse 15A BR/Y Main switch Main fuse Brake switch Battery Change switch Starter relay Black Starter motor Green White Starter switch Yellow Brown Brake light Inspection on starter relay Open the main switch.
Page 204 To this chapter contents 17. ELECTRICAL SYSTEM Removal of Starter motor Negative Remove the seat. Disconnect the cable negative terminal (-), then the cable positive terminal (+). Remove starter motor cable. 2 Bolts Loosen the lock bolts and remove the starter motor.
Page 205 To this chapter contents 17. ELECTRICAL SYSTEM Meters Removal Loosen 4 bolts of the meter stay. Each side 2 bolts Remove the front center cover, and then remove meter couplers and main switch coupler. Remove speedometer cable. Main switch coupler Remove speedometer cable, and then remove meter set, main switch and handle cover speedometer cable...
Page 206 To this chapter contents 17. ELECTRICAL SYSTEM Light / Bulb Replacing Bulb for Headlight Remove waterproof cover for the headlight. Remove bulb setting hook. Take out the bulb connector and the bulb. Replace with new bulb if necessary. (Main beam H3 12V 55W) (Dipped 12V 55W) Caution ●...
Page 207 To this chapter contents 17. ELECTRICAL SYSTEM Replacing the Front winker light Bulb Front winker bulb Pull out the front winker light bulb seat. Replace with new front winker light bulb. (12V 21W) Position light bulb Replacing Bulb of Position Light Pull out the position light bulb seat.
Page 208 To this chapter contents 17. ELECTRICAL SYSTEM Replacing Bulb of Taillight Turn the taillight and rear winker light bulb connectors by CCW. Taillight Replace with new taillight bulb. (12V 5W/21W) Rear Winker Light Rear winker light Replace with new rear winker light bulb. (12V 21W) License light Replacing Bulb of License Light...
Page 209: Switch/Horn
To this chapter contents 17. ELECTRICAL SYSTEM Switch / Horn Main Switch Inspection Remove the front center cover. Disconnect the main switch coupler. Check the continuity between two points as indicted below: BAT1 BAT2 Position Main switch coupler Wire Color Black Replacement of main switch Disconnect the coupler of the main switch.
Page 210 To this chapter contents 17. ELECTRICAL SYSTEM Headlight Switch Headlight switch Position BAT3 ● Wire color White / Black White Blue Brown Winker switch Position PUSH OFF Wire color Pink Black Brown / Winker switch White Horn switch Position BAT3 FREE Wire Color White/ Black...
Page 211 To this chapter contents 17. ELECTRICAL SYSTEM Front Brake Switch Brake light switch While grasp the brake lever firmly, the terminals of brown/blue and green/yellow of the brake should have continuity. Replace the switch if damaged. Rear Brake Switch Brake light switch While grasp the brake lever firmly, the terminals of white/black and green/yellow of the brake should have continuity.
Page 212: Fuel Unit
To this chapter contents 17. ELECTRICAL SYSTEM Fuel Unit 4 bolts Remove the seat. Remove the fuel tank cap. Remove the fuel tank cover and front fender (refer chapter 13). Disconnect the coupler of the fuel unit. Remove the fuel unit (4 bolts). Caution ●...
Page 213: Cooling Fan Thermo Switch
To this chapter contents 17. ELECTRICAL SYSTEM Cooling Fan Thermo Switch The thermo switch mounted on the radiator controls the operation of the cooling fan motor. In case that the fan motor fails to work, disconnect the green and black/blue leads and connect jump wires to the terminals, then, turn on the main switch, the fan motor should operate.
Page 214: Water Temperature Indicator Light
To this chapter contents 17. ELECTRICAL SYSTEM Thermo unit Thermo unit Remove the thermo unit. Hang the thermo unit in an oil heater, heat the oil and measure the resistance at each temperature. Temperature 50°C 80°C 100°C 120°C Standard (Ω ) 134~149 47.5~57.0 26~29 14.8~17.2 Caution ●...
Page 215 To this chapter contents 17. ELECTRICAL SYSTEM Notes: 17-22...
Page 216: Electrical Diagram
Home page Contents 18. ELECTRICAL DIAGRAM 18-1...
Page 217 Home pae Contents 18. ELECTRICAL DIAGRAM Notes: 18-2...

TGB BLADE 250 Service Manual

1. General Information

2. Maintenance Information

3. Lubrication System

4. Fuel System

6. Cylinder Head/Valve

8. V-Belt Driving System

9. Final Driving Mechanism

10. Alternator/Starting Clutch

11. Crankcase / Crank

12. Cooling System

14. Front Brake & Front Wheel

16. Rear Brake & Rear Wheel & Rear Cushion

17. Electrical System

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Chapters

Troubleshooting

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