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TGB BLADE 250 Service Manual

TGB BLADE 250
218 pages
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BLADE 250/300
SERVICE MANUAL
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Table of Contents

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TGB BLADE 250 Specifications

General IconGeneral
BrandTGB
ModelBLADE 250
CategoryOffroad Vehicle
LanguageEnglish

Summary

FORWARD

HOW TO USE THIS MANUAL

SERIAL NUMBER

1. GENERAL INFORMATION

Symbols and Marks

Explains symbols used in the manual for service procedures.

General Safety

Covers essential safety precautions when operating and servicing the ATV.

Service Precautions

Provides guidelines for proper maintenance and handling of ATV parts.

Specifications

Details technical specifications for the ATV models.

Torque Values

Lists standard and engine torque values for proper assembly.

Troubles Diagnosis

Offers guidance for diagnosing and resolving common engine issues.

Lubrication Points

Illustrates key points requiring lubrication for the ATV.

2. MAINTENANCE INFORMATION

Precautions in Operation

Outlines essential precautions before performing maintenance operations.

Periodical Maintenance Schedule

Provides a schedule for regular maintenance tasks and intervals.

Spark Plug

Explains the procedure for checking and replacing the spark plug.

Valve Clearance

Details the process for inspecting and adjusting valve clearance.

Carburetor Idle Speed Adjustment

Guides on adjusting the carburetor for optimal idle speed.

Ignition System

Explains how to check and adjust the ignition timing.

Brake System (Disk Brake)

Explains maintenance procedures for the disk brake system.

Nuts, Bolts Tightness

Emphasizes checking the tightness of all nuts and bolts on the frame.

Special Tools List

Lists specialized tools required for maintenance procedures.

3. LUBRICATION SYSTEM

Precautions in Operation

Provides general information and precautions for lubrication system maintenance.

Troubleshooting

Offers guidance for diagnosing and resolving lubrication system issues.

Engine Oil

Covers procedures for checking and changing engine oil.

Oil Pump

Explains removal, disassembly, inspection, and re-assembly of the oil pump.

Gear Oil

Covers procedures for changing gear oil.

4. FUEL SYSTEM

Precautions in Operation

Provides general information and safety precautions for fuel system work.

Specifications

Lists specifications related to the carburetor.

Trouble Diagnosis

Offers guidance for diagnosing common fuel system issues.

Carburetor Remove / Install

Details the steps for removing and installing the carburetor.

Throttle Valve

Explains the disassembly and assembly of the throttle valve.

Float Chamber

Details disassembly, inspection, and assembly of the float chamber.

Air Cleaner

Details removal, installation, and cleaning of the air cleaner element.

5. ENGINE REMOVAL

Precautions in Operation

Lists precautions and specifications before engine removal.

Removal of Engine

Step-by-step guide for safely removing the engine from the ATV.

Engine Installation

Details the process for installing the engine back into the ATV.

6. CYLINDER HEAD/VALVE

Precautions in Operation

Provides precautions and specifications for cylinder head and valve service.

Troubleshooting

Offers guidance for diagnosing issues related to the cylinder head and valves.

Cylinder Head Removal

Step-by-step instructions for removing the cylinder head.

Cylinder Head Inspection

Covers inspection of the cylinder head, camshaft, rocker arm, and valve components.

Valve Stem Replacement

Details the procedure for replacing valve stem seals.

Valve Seat Inspection and Service

Explains how to inspect and service valve seats, including grinding.

Cylinder Head Reassembly

Guides on reassembling the cylinder head components.

Cylinder Head Installation

Details the process for installing the cylinder head.

Valve Clearance Adjustment

Explains how to adjust the valve clearance.

7. CYLINDER/PISTON

Precautions in Operation

Lists precautions and specifications for cylinder and piston service.

Trouble Diagnosis

Offers guidance for diagnosing common cylinder and piston issues.

Cylinder and Piston Removal

Step-by-step instructions for removing the cylinder and piston.

Piston Ring Installation

Details the correct procedure for installing piston rings.

Piston Installation

Guides on installing the piston into the cylinder.

Cylinder Installation

Covers installing the cylinder onto the crankcase.

8. V-BELT DRIVING SYSTEM

Maintenance Description

Provides an overview, precautions, specifications, and torque values for the V-belt system.

Trouble Diagnosis

Lists common problems and their probable causes within the V-belt system.

Left Crankcase Cover

Details the removal, installation, and inspection of the left crankcase cover.

Drive Belt

Covers drive belt removal, inspection, and installation.

Drive Face

Explains the removal, inspection, and reassembly of the drive face components.

Clutch Outer/Driven Pulley

Details disassembly, inspection, and replacement of clutch outer and driven pulley parts.

Clutch weight Replacement

Guides on replacing the clutch weights and related components.

Replacement of Driven Pulley Bearing

Covers the procedure for replacing the driven pulley bearing.

9. FINAL DRIVING MECHANISM

Precautions in operation

Lists precautions, specifications, and troubleshooting for the transmission.

Trouble Diagnosis

Offers guidance for diagnosing transmission issues like gear damage or leaks.

Disassembly of Transmission

Step-by-step instructions for disassembling the transmission.

Inspection of Mission Mechanism

Covers inspection of shift spindle, drum, forks, shafts, and bearings.

Bearing Replacement

Details the process of replacing various bearings within the crankcase and gear box.

Re-assembly of Final Driving Mechanism

Guides on reassembling the final drive mechanism components.

10. ALTERNATOR/STARTING CLUTCH

Precautions in Operation

Lists precautions and specifications for alternator and starter motor service.

Right Crankcase Cover Removal

Details the removal of the right crankcase cover and associated parts.

A.C.G. Set Removal

Covers the removal of the AC generator coil set and pulse generator.

Right Cover Bearing

Guides on inspecting and replacing the right cover bearing.

Flywheel Removal

Details the procedure for removing the flywheel.

Starting Clutch

Covers inspection of the starting clutch gear, reduction gear, and rollers.

One way clutch Installation

Guides on installing the one-way clutch components.

Flywheel Installation

Details the process for installing the flywheel.

A.C.G. Set Installation

Covers the installation of the AC generator coil set and pulse generator.

Right Crankcase Cover Installation

Details the installation of the right crankcase cover.

11. CRANKCASE / CRANK

General information

Provides operational precautions and general information for crankcase disassembly.

Disassembly of crankcase

Step-by-step instructions for disassembling the crankcase.

Crankshaft Inspection

Covers inspection of the crankshaft and its bearings.

Assembly of crankcase

Details the process for assembling the crankcase.

12. COOLING SYSTEM

General Information

Provides general information and safety warnings for the cooling system.

Technical Specification

Lists technical specifications for cooling system components like thermostat and boiling point.

Trouble Diagnosis

Offers guidance for diagnosing cooling system issues like overheating or leaks.

System Test

Details procedures for testing the filler cap and changing the coolant.

Radiator

Covers radiator check and removal procedures.

Water Pump

Explains inspection, removal, and replacement of the water pump and its seals.

Thermostat

Guides on thermostat removal, inspection, and installation.

13. BODY COVER

Mechanism Diagram

Illustrates the assembly of various body cover components.

Maintenance

Outlines the sequence for disassembling body covers.

Remove seat

Details the steps for removing the vehicle seat.

Remove fuel tank cover

Covers removing the fuel tank cover.

Remove front bumper

Details removing front bumper bolts.

Remove starting motor relay

Details removing the starting motor relay.

Remove rear body cover

Details removing rear body cover screws.

Remove upper bracket assembly

Covers removing upper bracket assembly bolts.

14. FRONT BRAKE & FRONT WHEEL

Maintenance Description

Provides precautions, specifications, and torque values for the front brake system.

Trouble Diagnosis

Lists common front brake and steering issues and their causes.

Front Wheel

Covers removal and installation procedures for the front wheel.

Front Wheel Hub

Details the removal and installation of the front wheel hub components.

Disk Brake System Inspection

Guides on inspecting the disk brake system for wear and fluid levels.

Adding Brake Fluid

Covers procedures for adding brake fluid and cleaning the brake disk.

Brake fluid replacement / Air-bleed

Explains how to replace brake fluid and bleed the hydraulic system.

Front Brake Caliper

Details removal, inspection, and installation of the front brake caliper.

Front Brake Master Cylinder

Details master cylinder removal, inspection, assembly, and installation.

15. STEERING / FRONT SUSPENSION

Operational Precautions

Lists torque values and precautions for steering and suspension maintenance.

Trouble Diagnosis

Offers guidance for diagnosing steering and suspension issues.

Steering Handle

Details the removal and installation of the steering handle.

Steering Shaft

Covers removal, inspection, and installation of the steering shaft.

Steering Tie-Rod

Details removal, inspection, and installation of the steering tie-rod.

Knuckle

Explains the removal, inspection, and installation of the knuckle.

Front Cushion

Covers removal and installation of the front suspension cushion.

Suspension Arm

Details removal, inspection, and installation of the suspension arm.

Toe-In

Explains how to measure and adjust the vehicle's toe-in.

16. REAR BRAKE & REAR WHEEL & REAR CUSHION

Maintenance Description

Provides precautions, specifications, and torque values for rear brake, wheel, and cushion.

Trouble Diagnosis

Lists common rear brake, wheel, and suspension issues and their causes.

Rear Wheel

Covers removal and installation procedures for the rear wheel.

Rear Wheel Axle Connecter

Details removal and installation of the rear wheel axle connector.

Rear Wheel Axle

Explains removal of drive chain cover, rear under protect, and drive chain.

Disk Brake System Inspection

Guides on inspecting the rear disk brake system for wear and fluid levels.

Adding Brake Fluid

Covers procedures for adding brake fluid to the rear master cylinder.

Brake fluid replacement / Air-bleed

Explains how to replace rear brake fluid and bleed the system.

Rear Brake Caliper

Details removal, inspection, and installation of the rear brake caliper.

Rear Brake Master Cylinder

Details master cylinder removal, inspection, assembly, and installation for both left and right sides.

Rear Cushion

Covers removal and installation of the rear suspension cushion.

17. ELECTRICAL SYSTEM

Mechanism Diagram

Illustrates the layout of major electrical system components.

Maintenance Data

Provides operational precautions and technical specifications for charging and ignition systems.

Technical Specification

Lists specifications for battery, charging system, and ignition system.

Trouble Diagnosis

Offers guidance for diagnosing common electrical system issues like no voltage or no spark.

Battery

Covers battery removal, voltage check, and charging procedures.

Charging System

Details charging circuit diagram and current leakage inspection.

Ignition System

Provides ignition circuit diagram and checks for CDI unit, pulse generator, and ignition coil.

Starting System

Provides starting circuit diagram and inspection of the starter relay.

Meters

Details removal and checking of the meter assembly.

Light / Bulb

Guides on replacing headlight bulbs.

Switch / Horn

Details inspection and replacement of main switch and handle switches.

Fuel Unit

Details fuel unit removal and resistance checks for the fuel gauge.

Cooling Fan Thermo Switch

Guides on testing the cooling fan thermo switch.

Thermo unit

Covers testing the thermo unit's resistance at different temperatures.

18. ELECTRICAL DIAGRAM

Notes:

Provides general notes related to the electrical diagram.

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