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TGB Blade 525 Service Manual

TGB Blade 525
209 pages
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BLADE 500/525
SERVICE MANUAL
TAIWAN GOLDEN BEE CO.,LTD.
PDF created with pdfFactory Pro trial version www.pdffactory.com

Table of Contents

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TGB Blade 525 Specifications

General IconGeneral
BrandTGB
ModelBlade 525
CategoryOffroad Vehicle
LanguageEnglish

Summary

FORWARD

1. GENERAL INFORMATION

Symbols and Marks

Defines various symbols and marks used in the manual for service procedures.

General Safety

Outlines crucial safety precautions related to operating and servicing the ATV.

Service Precautions

Provides essential guidelines and warnings for performing maintenance and repairs correctly.

Specifications

Lists detailed technical specifications for the ATV model.

Torque Values

Details standard and engine-specific torque values for various fasteners.

Troubles Diagnosis

Offers a systematic approach to diagnosing common engine starting and running issues.

2. MAINTENANCE INFORMATION

Precautions in Operation

Lists operational precautions for performing maintenance tasks safely and effectively.

Periodical Maintenance Schedule

Outlines a recommended maintenance schedule based on time and mileage intervals.

Valve Clearance

Provides instructions for checking and adjusting valve clearance.

Brake System (Disk Brake)

Details maintenance for the disk brake system, including fluid and bleeding.

Special Tools List

Lists specialized tools required for maintenance tasks.

3. LUBRICATION SYSTEM

Precautions in Operation

Outlines important safety and operational precautions for lubricating the system.

Troubleshooting

Provides solutions for common low oil pressure and dirty oil issues.

Engine Oil

Covers procedures for checking and changing engine oil.

4. FUEL SYSTEM

Precautions in Operation

Lists safety and operational precautions for working with the fuel system.

Trouble Diagnosis

Provides troubleshooting steps for common fuel system issues.

Carburetor Remove / Install

Details the procedure for removing and installing the carburetor.

5. ENGINE REMOVAL

Precautions in Operation

Lists precautions for engine removal and handling.

Engine Removal

Provides step-by-step instructions for removing the engine from the ATV frame.

Engine Installation

Details the procedure for reinstalling the engine onto the ATV frame.

6. CYLINDER HEAD/VALVE

Precautions in Operation

Lists precautions for servicing the cylinder head and valve system.

Troubleshooting

Provides solutions for common issues like low/high compression and noise.

Cylinder Head Removal

Details the steps to remove the cylinder head from the engine.

Valve Clearance Adjustment

Explains how to adjust the valve clearance.

7. CYLINDER/PISTON

Precautions in Operation

Lists precautions for handling cylinder and piston components.

Trouble Diagnosis

Covers diagnosis for low compression, noise, smoking, and overheating.

Cylinder and Piston Removal

Details the procedure for removing the cylinder and piston.

8. V-BELT DRIVING SYSTEM

Maintenance Description

Provides an overview of maintenance for the V-belt driving system.

Trouble Diagnosis

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

Drive Belt

Covers the removal, inspection, and installation of the drive belt.

9. FINAL DRIVING MECHANISM

Transmission system

Covers the removal of the driven output shafts and separation of components.

Inspection

Covers inspection of bearings, joint surfaces, and reassembly of shafts.

10. ALTERNATOR/STARTING CLUTCH

Precautions in Operation

Lists precautions for working with the alternator and starter motor.

Flywheel Removal

Details the procedure for removing the flywheel.

Starting Clutch

Covers inspection and installation of the starting clutch.

11. CRANKSHAFT / CRANKCASE

Oil SEAL

Covers the removal and installation of oil seals using special tools.

BEARING REASEMBLY

Explains the process of reassembling bearings with thread locker.

Recoil starter

Covers disassembly and reassembly of the recoil starter mechanism.

CRANKSHAFT

Details mounting the crankshaft and installing the gearshift cam stopper.

12. COOLING SYSTEM

Precautions in Operation

Lists precautions for handling cooling system components.

Trouble Diagnosis

Offers troubleshooting for engine temperature issues and coolant leaks.

Change of coolant

Details the procedure for changing the coolant and bleeding air bubbles.

Water Pump

Covers inspection of the water pump seal and removal/installation.

13. BODY COVER

Maintenance

Outlines the sequence for disassembling and assembling body covers.

Remove seat

Details the procedure for removing the seat and related components.

Remove screws from right or left foot board

Covers removal of footboards and related parts.

14. FRONT BRAKE & FRONT WHEEL

Maintenance Description

Provides operational precautions and specifications for the front brake system.

Trouble Diagnosis

Lists common problems related to soft/hard brake levers, uneven/tight brakes, and noise.

Front Wheel

Details the removal and installation of the front wheel.

Brake fluid replacement / Air-bleed

Covers the procedure for replacing brake fluid and bleeding the system.

Front Brake Master Cylinder

Details removal, inspection, and assembly of the front brake master cylinder.

15. STEERING / FRONT SUSPENSION

Operational Precautions

Lists torque values and precautions for the steering and suspension system.

Trouble Diagnosis

Covers troubleshooting for hard steering, wheel wobbling, and suspension noise.

Steering Handle

Details removal and installation of the steering handle assembly.

Steering Shaft

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

Toe-In

Explains how to adjust the front wheel toe-in.

16. REAR BRAKE & REAR WHEEL & REAR CUSHION

Maintenance Description

Provides operational precautions and specifications for the rear brake system.

Trouble Diagnosis

Lists common problems for the rear brake, wheel, and suspension.

Rear Wheel

Details removal and installation of the rear wheel.

Rear Wheel Axle

Details removal and inspection of the rear wheel axle and bearings.

Brake fluid replacement / Air-bleed

Covers replacing rear brake fluid and bleeding the system.

Rear Cushion

Covers removal and installation of the rear suspension cushion.

17. ELECTRICAL SYSTEM

Maintenance Data

Provides operational precautions and technical data for electrical systems.

Trouble Diagnosis

Lists common electrical system problems and diagnostic steps.

Battery

Covers battery specifications and charging precautions.

Charging System

Details technical specifications for the charging system.

Ignition System

Covers spark plug, ignition coil, and ignition timing specifications.

Starting System

Addresses troubleshooting for the starter motor.

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