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See our Privacy Policy and User Agreement for details.You can change your ad preferences anytime. This Service Manual has easy-to-readtext sections with top quality diagrams and instructions. Trust TGBBlade 250 ATV Service Repair Manual will give you everything youneed to do the job.All pages are printable.Thanks for visiting! Now customize the name of a clipboard to store your clips. This TGB Blade 250 ATV Service Manual pays much attention to practicality from the view point of users, and the content is reasonably arranged. 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In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment. Never run your engine in a closed area.Using non-designed parts for unsmooth control and premature worn out.When separating a connector, it locker has to be unlocked firstly.And then conduct connection operation later.Please see standard values for not listed in the table.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. Remove front fender, fuel tank cover and fuel tank. 2 bolts Remove cylinder head cover. Remove cylinder head side cover. Connect tachometer and ignition light. Remove 9 bolts of the engine left side cover and the cover. 9 bolts Check if the belt is crack or worn out. 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. Turn the headlight adjustment screw to adjust headlight beam high.Lift the front wheel out of ground. Turn handle from right to left alternative and check if turning is smoothly. So not screw the dipstick into engine as checking. http://nonogos.com/images/7dayshop-bluetooth-wireless-stereo-headphones-manual.pdf If oil level is nearly low level, fill out recommended oil to upper level. Make sure that pump shaft can be rotated freely. Remove 2 screws on the oil pump, and then remove oil pump. Remove drain bolt and drain gear oil out. Install the drain bolt after drained.Remove the choke cable. Choke cable Vacuum pipe Fuel pipe Disconnect the fuel hose. 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. 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. Fuel level plate Inspection Check float valve and valve seat for damage, blocking. Needle jet holder Main jet Caution Take care not to damage jets and adjust screw.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. Loosen the clamp strip of air cleaner, and then remove the air cleaner vapor hose. Remove the air cleaner (2 bolts). Remove front fender and the footrest (refer chapter 13). Positive Remove starter motor wire. Starter motor wire Remove the spark plug cap. Clamp Disconnect the carburetor upper parts and cable. Release the 2 nuts of carburetor insulator, and then remove the carburetor. 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). 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. Specification Item Standard. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1. Remove 1 bolt of thermostat and then remove the Thermostat bolts thermostat. Remove hole bolt and spring for the cam chain tensioner. Remove cam sprocket bolts and then remove the sprocket by prying chain out. Remove the cylinder head. 2 bolts Gasket Remove cylinder head gasket and 2 dowel pins. 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. 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. 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. Otherwise, the cylinder head may be deformed as heating it. Apply with emery slightly onto valve contact face.Remove the cutter and check new valve seat.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. 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. Align sprocket bolt hole with camshaft bolt hole. Tighten the sprocket mounting bolts. Caution 2 bolts Make sure timing marks are matched. 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. 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. 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. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown.Caution Soap the residues into solvent so that the residues can be removed more easily. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation.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. 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. Hold drive face with universal holder, and remove nut and drive face.Install drive belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft. 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. Thus, if weight rollers are worn out or damaged, the centrifuge force will be affected. Check if rollers are worn or damaged. 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. Caution Do not press the compressor too much. 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. Caution Some of models are equipped with one mounting plate instead of 3 snap rings. Check if spring is damage or insufficient elasticity. Snap ring Replacement of Driven Pulley Bearing Outer bearing Remove inner bearing.Apply with specified grease to lubricate the inside of movable driven face. Specified grease O-ring Install the movable driven face onto driven face. Remove 3 bolts and remove drive chain protector. Turn the socket bolt clockwise, and then remove speedometer gear box. 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. Bearing setting plate Remove the drive shaft. Special tool: Shaft protector Remove gasket and dowel pin.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. 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. 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. 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. 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. Reverse shaft Drive shaft Install counter shaft, reverse shaft and final shaft onto gear box. Final shaft Counter shaft Shift drum. Dowel pins Install dowel pins and new gasket. 9 bolts Install gear box cover and bolts, and tighten.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. 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. 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. 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. Caution Tape a tightening tape onto the thread of hexagon bolt.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. Water pump cover bolts Connect water hoses to the right crankcase cover and water pump cover. 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. 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. 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. 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. Dowel pins Install the left crankcase onto the right crankcase. 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.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.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. COOLING SYSTEM Coolant inlet pipe Loosen the radiator 4 bolts. Remove coolant upper side pipes. 4 bolts Remove coolant outlet pipe.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. 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. 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.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. 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. When maintenance brake system, will be supposed to paint the surface or the rubber parts catches up by the rags. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out. Caution Do not spill brake fluid on painted surfaces. Remove two caliper bolts and the caliper. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. 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. 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. Remove handle mounting bolt, and then remove the handle upper holder, handle. Remove 2 nuts to remove handle under holder and meter bracket. 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. 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. 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. 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. Suspension arm nuts and bolts Loosen upper arm nuts, remove swing suspension arm bolts. Remove upper s arm. 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. Remove rear axle cover (4 screws). 4 screws Remove the rear wheel nuts, and then remove rear wheels. Remove 2 bolts, and then remove rear brake caliper. Remove 2 bolts and 1 nut, and remove drive chain 2 bolts cover. 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. 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. 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. Install rear wheel shaft connecter, rear wheel. Lock clip Driven sprocket inspection Check the condition of the driven sprocket teeth. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out. Caution Do not spill brake fluid on painted surfaces. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Loosen the brake hose bolt and finally remove the brake hose. Replace the piston if its measured value exceeds allowable limit.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. 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. 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. 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. 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.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. 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. ELECTRICAL SYSTEM Inspection on Ignition Coil Disengage the connector of the ignition coil and the spark plug cap.ELECTRICAL SYSTEM Removal of Starter motor Negative Remove the seat. Remove starter motor cable. 2 Bolts Loosen the lock bolts and remove the starter motor. 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. Remove bulb setting hook. Take out the bulb connector and the bulb.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. ELECTRICAL SYSTEM Replacing Bulb of Taillight Turn the taillight and rear winker light bulb connectors by CCW.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. Replace the switch if damaged.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.ELECTRICAL SYSTEM Cooling Fan Thermo Switch The thermo switch mounted on the radiator controls the operation of the cooling fan motor.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.ELECTRICAL SYSTEM Notes: 17-22. ELECTRICAL DIAGRAM Notes: 18-2. 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