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TGB BLADE 425 Service Manual

TGB BLADE 425
229 pages
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BLADE 425/400
SERVICE MANUAL

Table of Contents

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TGB BLADE 425 Specifications

General IconGeneral
BrandTGB
ModelBLADE 425
CategoryOffroad Vehicle
LanguageEnglish

Summary

1. General Information

General Safety

Essential safety guidelines for operating and servicing the ATV.

Service Precautions

Important procedures and warnings for vehicle maintenance and repair.

Torque Values

Specific torque settings for various fasteners and bolts.

Troubles Diagnosis

Common problems and their probable causes and solutions.

2. Maintenance Information

Periodical Maintenance Schedule

Recommended intervals and tasks for regular vehicle upkeep.

Valve Clearance

Procedure for inspecting and adjusting valve clearance.

Drive Belt

Inspection and replacement guidelines for the drive belt.

Brake System (Disk Brake)

Maintenance procedures for the hydraulic disc brake system.

3. Lubrication System

Engine Oil

Procedures for checking and changing engine oil.

Oil Pump

Removal, disassembly, and inspection of the oil pump.

4. Fuel System

Precautions in Operation

Safety guidelines for handling gasoline and fuel system components.

Carburetor Remove / Install

Step-by-step guide for carburetor removal and installation.

Adjustment of Idle Speed

Procedure for setting and adjusting engine idle speed.

5. Engine Removal

Engine Removal

Detailed steps for safely removing the engine from the chassis.

Engine Installation

Procedures for reinstalling the engine onto the chassis.

Front differential set oil

Maintenance procedures for the front differential oil.

6. Cylinder Head/Valve

Cylinder Head Removal

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

Valve Clearance Adjustment

Procedure for setting and adjusting valve clearance.

7. Cylinder/Piston

Cylinder and Piston Removal

Steps for removing the cylinder and piston assembly.

Piston Ring Installation

Correct procedure for installing piston rings onto the piston.

8. V-Belt Driving System

Drive Belt

Inspection and replacement guidelines for the drive belt.

Clutch Outer/Driven Pulley

Disassembly and inspection of clutch outer and driven pulley.

9. Final Driving Mechanism

Inspection

Checking bearings and joint surfaces for defects.

FINAL ASSEMBLY

Reassembly steps for the final drive assembly.

10. Alternator/Starting Clutch

Flywheel Removal

Step-by-step guide to remove the flywheel.

Starting Clutch

Inspection and testing of the starting clutch mechanism.

11. Crankshaft / Crankcase

Crankshaft

Steps for mounting and installing the crankshaft.

Oil Pump

Installation procedures for the oil pump assembly.

12. Cooling System

Water Pump

Service procedures and replacement of the water pump.

Thermostat

Inspection and installation of the thermostat.

13. Body Cover

Body Covers Disassemble Sequence

Order of operations for removing and reinstalling body covers.

14. Front Brake & Front Wheel

Front Wheel

Steps for removing and installing the front wheel.

Brake Fluid Replacement / Air-Bleed

Process for replacing brake fluid and bleeding the system.

Front Brake Master Cylinder

Removal and assembly of the front brake master cylinder.

15. Steering / Front Suspension

Trouble Diagnosis

Identifying issues with steering and front suspension.

Toe-In

Adjusting the front wheel alignment (toe-in).

16. Rear Brake & Rear Wheel & Rear Cushion

Rear Wheel

Steps for removing and installing the rear wheel.

Rear Brake Caliper

Service procedures for the rear brake caliper.

Rear Cushion

Removal and installation of the rear suspension cushion.

17. Electrical System

Battery

Procedures for battery removal, voltage check, and charging.

Ignition System

Testing ignition coil and pulse generator resistance.

Light / Bulb

Steps for replacing headlight bulbs.

Switch / Horn

Inspection and replacement of handlebar switches and horn.

18. Electrical Diagram

Wiring Diagram

Comprehensive schematic of the ATV's electrical system.

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