Four Stroke 50 cc SERVICE MANUAL
Contents
1. Four Stroke 50 cc SERVICE MANUAL TGB CONTENTS CONTENTS GENERAL INFORMATION TROUBLE DIAGNOSIS MAINTENANCE INFORMATION LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL CYLINDER HEAD VALVE CYLINDER PISTON V TYPE BELT DRIVING SYSTEM KICK STARTER ARM FINAL DRIVING MECHANISM A C GENERATOR STARTING CLUTCH CRANKCASE CRANKSHAFT SPECIAL TOOL TGB SPECIFICATIONS 1 GENERAL INFORMATION TROUBLE DIAGNOSIS TORQUE VALUES ENGINE SPECIFICATIONS Overall Length 1800mm Overall Height 1125mm Deceleration equipment DIMENSION Wheel Base 1285mm Front 39mm Rear 57mm WEIGHT Curb Weight Total 96mm Type 4 STROKE ENGINE c Oo 4 2 D C O x O W c O O Installation and Vertical below center incline 80 arrangement Fuel Used Unleaded 92 95 4 stroke forced air cooled 639 0 mm Cycle Cooling Bore Stroke Number Arra ngement 41 5 mm Single Cylinder horizontal 49 6 cc Cyl inder Displacement ENGINE Compression Ratio Max HP 11 840 1 2 35KWI 7500 rpm Max Torque 2 96N m 6500 rpm Ignition Starting System Electrical amp foot type U Exhaust Pipe Position and Direction Lubrication Svstem Primarv Secondarv Clutch One way C V T Right side and Backward Separated lubrication 15 4 Solid Particulate CO 2540 5 4 Below 800 PPM L B 1 1 GENERAL INFORMATION TROUBLE DIAGNOSIS T2. 1 6mm Check the contact condition of valve seat Valve seat grinding The worn valve seat has to be grinded with valve seat chamfer cutter Use 45 valve seat chamfer cutter to cut anv rough or uneven surface from valve seat IN Caution Old valve seat width After valve guide had been replaced it has to be grinded with 45 valve seal chamfer cutter to correct its seat face Use 32 cutter to cut a quarter upper part out 6 10 TGB Use 60 cutter to cut a quarter lower part out Remove the cutter and check new valve seat Use 45 cutter to grind the valve seat to specified width A Caution Make sure that all roughness and uneven faces had been grinded Grind valve seat again if necessary Coat the valve seat surface with red paint Install the valve through valve guide until the valve contacting with valve seat slightly press down the valve but do not rotate it so that a seal track will be created on contact surface M Caution The contact surfaces of valve and valve seat are very important to the valve sealing capacity If the contact surface too high grind the valve seat with 32 cutter Then grind the valve seat with 45 cutter to specified width If the contact surface too low grind the valve seat with 60 cutter Then grind the valve seat with 45 cutter to specified width 6 CYLINDER HEAD VALVE Old valve seat width Contact surface too high An ehe N 4 Old v
3. Add some engine oil according the specified quantitv Exhaust muffler 10 5 TGB 11 CRANKCASE CRANKSHAFT OPERATIONAL PRECAUTIONS 11 1 CRANKSHAFT INSPECTION 11 4 TROUBLE DIAGNOSIS ASSEMBLY OF CRANKCASE 11 5 DISASSEMBLY OF CRANKCASE 11 2 OPERATIONAL PRECAUTIONS General Information e This Section contains descriptions concerning disassembly of the crankcase so that the crankshaft can be serviced e Complete following operations before disassembling crankcase Engine Chapter 5 Cylinder head Chapter 6 Cylinder and piston Chapter 7 V belt Drive pulley Chapter 8 AC generator Starting Clutch Chapter 10 If the crankshaft bearing or timing sprocket need be replaced then the crankshaft set have to replaced Specification Unit mm Left right clearance of the big end of the connecting rod 0 100 0 350 0 550 Radial clearance of the big end of the connecting rod 0 000 0 008 0 050 Run ou Below 0 030 Torque value Bolts for crankcase 0 8 1 2 kgf m Bolts for cylinder cylinder head 0 7 1 0 kgf m Engine oil draining plug 3 9 4 5 kgf m Bolts for cam chain tensioner 0 8 1 2 kgf m Special Service Tools Crankcase remover set Crankshaft installation puller Inner type bearing puller Outer type bearing puller Bearing pressing tools Oil seal pressing tools TROUBLE DIAGNOSIS Engine noise e Loose crankshaft bearing e Loose crankshaft pin bearing e Wear piston pin or piston pin hole 11 1 11 CRANKCASE CRAN
4. Loosen drain screw and drain out residual fuel in float chamber Remove screws 2 screws of vacuum chamber cover and the cover Remove compress spring and vacuum piston 4 CARBURETOR AIR CLEANER rottle valve cable PIE WW vacuum throttle valve cabl A At W hose i AS a 7 siifclamp strip of isolator ie Be ee compress spring l L I 4 CARBURETOR AIR CLEANER Remove fuel needle seat spring and injector needle Check if the vacuum piston for wear out crack or other damage Check if the diaphragm for damage or crack Cautions Do not damage vacuum diaphragm Installation Install injector needle spring and fuel needle seat to vacuum piston IN Cautions e Note direction as installing the piston set because wrong direction of the piston cab not be installed e Align the indent of vacuum diaphragm with the carburetor bodv Install vacuum piston to carburetor bodv Install compress spring Install vacuum chamber cover and tighten 2 SCrews fuel needle seat fuel needle p l spring L T needle injector gt position screwsx2 TGB 4 CARBURETOR AIR CLEANER AIR CUT OFF VALVE Removal Remove the vacuum hose clamp and then the vacuum hose Screws x2 A i Aj Remove the screws screw x 2 of the air cut off valve and its cover screws Remove the spring and vacuum diaphragm Check if the vacuum diaphragm for deteriorati
5. TGB 4 CARBURETOR AIR CLEANER FLOAT CHAMBER Disassembly Remove 4 mounting screws and then the float chamber cover Remove the float pin and float valve Checking Check float needle valve and valve seat for drop difference damage wear out dirty or clogged float pin ei a float needle AN Cautions _ ar In case of worn out or dirt the float valve and valve seat will not tightly close causing fuel level to increase and as a float pin result fuel flooding A worn out or dirty float valve must be replaced with a new a new one il 4 main jet Remove main jet fuel needle jet holder fuel a fuel needle needle jet slow jet fuel amount adjustment la holder a fuel needle jet M Cautions fuel amount adjustment screw e Take care not to damage jets and adjust screw e Before removing adjustment screw turn it all the way down and note the number of turns e Do not turn adjustment screw forcefully to avoid damaging valve seat face fuel needle jet fuel needle holder main jet Clean jets with cleaning fluid Then use compressed air to blow dirt off zu Blow carburetor body passages with nn 2 compressed air i slow jet el u d 4 CARBURETOR AIR CLEANER TGB Installation Install main jet fuel needle jet seat fuel needle jet slow speed jet and fuel amount adjustment screw Cautions Set the adjustment screw in according to RE Hf ra number of turns
6. Torque value 0 8 1 2 kgf m Transmission oil capacitv 120 c c 110 c c for change Recommended King Mate HVPOID GEAR OIL 140 VALVE CLEARANCE ADJUSTMENT Caution Checks and adjustment must be performed hen engine is cold below 35 C Remove luggage box and front center cover Remove the left bodv cover 6 left side cover Remove cvlinder head cap Remove the ignition timing check hole on the cooling fan cover With T type wrench turn crankshaft in clockwise motion so that mark T on the generator flywheel aligns with the mark on the crankshaft and camshaft is at TDC position also as same as level of cylinder head top end A single hole on camshaft sprocket is forward to up Piston is at TDC position in the compression stroke Caution The crankshaft can not be rotated in counter clockwise to prevent from damage so that valve clearance can not be measured TGB Gear oil refilling bolt TGB 2 MAINTENANCE INFORMATION Check amp adjust valve clearance with feeler Feeler gauge gauge Valve clearance IN EX 0 06 0 02 mm Loosen fixing nut and turn the adjustment nut for adjustment Caution It has to make sure that valve rocker arm is be adjusted to standard level when adjusting it and re check the valve clearance after tightened the fixing nut CARBURETOR IDLE SPEED ADJUSTMENT Caution e Inspection amp adjustment for idle speed have to be performed after all other
7. damage of cam chain e Camshaft sprocket wear out e Rocker arm or rocker arm shaft wear out White smoke e Valve guide or valve stem wear out e Valve stem seal wear out 6 CYLINDER HEAD VALVE CAMSHAFT REMOVAL Remove the shroud of the engine Remove the crankcase blow bv svstem hose from the cvlinder head Remove the cvlinder head bolts and then the cvlinder head 4 bolts Loosen the bolt of camshaft chain adjuster and remove O ring With a flat screwdriver to tighten the screw of camshaft chain adjuster in a clockwise motion for release adjuster Turn the flywheel in counter clockwise motion with T type wrench until the T mark on flywheel aligned with the mark on the crankcase so that the hole on the camshaft sprocket is forward up and piston is at TDC position Remove camshaft holder nuts and washers Caution Loosen the nuts diagonally by 2 3 sequences 6 4 TGB Blow by hose _ TGB 6 CYLINDER HEAD VALVE Remove the camshaft holder and rocker arm set Remove the camshaft chain from the camshaft sprocket Remove the camshaft Camshaft Inspection Inspect cam lobe height for damaged Service Limit IN Replacement when less than 25 29 mm EX Replacement when less than 25 12 mm Inspect the camshaft bearing for looseness or wear out If any replace whole set of camshaft and bearing Camshaft bearing Disassembly Of Camshaft Holder With a5 mm bolt to screw in the cam rocker arm shaft so that t
8. instructions They are prohibited to be adjusted or repaired by unauthorized people Otherwise TGB is no responsible for the charge 2 Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the Heavily polluted environment 3 Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the motorcycle has accumulated a higher mileage 4 Preventive maintenance a Ignition system Perform maintenance and check when continuous abnormal ignition misfire after burn overheating occur b Carbon deposit removal Remove carbon deposits in cylinder head piston heads exhaust system when power is obvious lower than ever c Replace worn out pistons cylinder head TGB 2 LUBRICATION SYSTEM Engine Oil Capacity Caution e The vehicle must be parked on a level ground when checking oil capacitv e Run the engine for 2 3 minutes then stop wait about 2 3 more minutes allowing engine oil to settle before checking the oil level Remove dipstick to check the oil level If oil level is below the lower limit mark add oil to the specified upper limit mark Oil change Shut off the engine and remove dipstick Remove the oil drain plug on the bottom left of crankcase to drain oil After draining out oil clean oil plug and its gasket and reinstall Replace the gasket if it is damaged Torque value 3 5 4 5 kgf m AN Caution Warm up
9. motorcycle e Driving belt and driving pulley surface must be free of grease Specification Unit mm Driving belt with S ID of siding pullev bushing 20035 20085 OD of siding pulley hub 20 0120025 Thickness of clutch lining 4 000 eC Free length of driving pulley 97 20 spring OD of driving pulley 33 965 33 985 33 ID of sliding pulley 34 000 34 025 34 060 ID Inner Diameter OD Outer diameter Torque value Special Service Tools Sliding pulley nut 5 0 6 0kgf m Clutch spring compressor Clutch outer nut 5 0 6 0kgf m Bearing puller inner type driving pulley nut 5 0 6 0kgf m Clutch mounting nut wrench Universal fixture TROUBLE DIAGNOSIS Engine can be started but motorcycle can not be moved 1 Worn driving Belt 2 Worn tilt plate 3 Worn or damaged clutch lining 4 Broken driven pulley Insufficient horsepower or poor high speed performance 1 Worn driving belt 2 Insufficient spring capacity of driven pulley 3 Worn roller 4 Driven pulley operation un smoothly Shudder or misfire when driving 1 Broken clutch lining 2 Worn clutch lining 8 V BELT DRIVING SYSTEM KICK STARTER ARM LEFT CRANKCASE COVER Left crankcase cover removal Remove air cleaner 2 bolts Remove kick starter arm 1 bolt Loosen vent strap on the front left side of cover and then remove the vent Remove engine left side cover 8 bolts Friction spring Starter shaft KICK STARTER ARM Disassembly Remove the
10. parts in engine that needed adjustment have been adjusted Idle speed check and adjustment have to be done after engine is being warm up around 10 minutes Park the motorcycle with main stand and warn up engine Open the carburetor cover from the luggage box Turn the throttle valve stopper screw to specified idle speed Specified idle speed 2200 100 rpm Emission adjustment in Idle speed Warm up the engine for around 10 minutes and then conduct this adjustment 1 Connect the tachometer onto engine 2 Adjust the idle speed adjustment screw and let engine runs in 2200 100 rpm 3 Insert the exhaust sampling muffler of exhaust analyzer into the front section of exhaust pipe Adjust the air adjustment screw so that emission value in idle speed is within standard 4 Slightiv accelerate the throttle valve and release it immediately Repeat this for 2 3 times 5 Read engine RPM and value on the exhaust analyzer Repeat step 2 to step 4 procedures until measured value within standard Emission standard CO below2 5 0 5 HC below 800 ppm 2 MAINTENANCE INFORMATION IGNITION SYSTEM Ignition timing Caution C D I ignition system is set by manufacturer so it can not be adjusted Ignition timing check procedure is for checking whether C D l function is in normal or not Remove right side cover Remove ignition timing hole cap located on the cooling fan cap or remove the cooling fan cap Che
11. return spring starter shaft Remove driving gear friction spring and washer Inspection Check if starter shaft driving gear for wear or damage Replace it with new one if necessary Check the return spring for spring force or damaged Replace it with one if poor parts found Reassembly Apply with some specified grease on the gear shaft Install the friction spring of driving gear onto convex part of the case cover Install return spring and starter shaft as diagram shown Install kick starter arm temporary Rotate the lever and then align driving gear with width tooth on the starter shaft Install thrust washer and socket onto starter shaft Installation of the left crankcase cover Install the left crankcase cover 8 bolts Install front vent tube of left cover and tighten the strap Install kick starter arm 1 bolt Tighten the air cleaner 2 bolts Kick starter arm shaft ta f he i B bl 5 L a sI a u 4 7 i i L ki a P L al g a 7 wl See ti j a a az ar i k ful driving gear SE TGB Return spring TGB 8 V BELT DRIVING SYSTEM KICK STARTER ARM DRIVING BELT aa Bulle eae Ge Removal ps gT A Remove left crankcase cover J gt jil Hold the sliding pullev with a universal fixture and then remove the nut and sliding pullev Hold driving pullev with universal fixture and remove nut and clutch outer AN Caution Using special service tools for tighte
12. sealing end should be forwarded to outside Apply with specified grease Recommended to use the KING MATE G 3 Install the snap ring and hold the bearing Install a new inner bearing LN Caution e Its sealing end should be forwarded to outside as bearing installation e Install needle bearing with hydraulic presser Install ball bearing by means of hydraulic presser Align oil seal lip with bearing and then install the new oil seal if necessary SYSTEM KICK STARTER ARM Outer bearing Inner needle bearing Outer bearing Sealing end Sealing end 8 11 8 V BELT DRIVING SYSTEM KICK STARTER ARM INSTALLATION OF CLUTCH DRIVEN Oil seal PULLEY ASSEMBLY Install new oil seal and O ring onto sliding pullev Applv with specified grease to lubricate the inside of sliding pulley Sliding pullev Install sliding pullev onto driven pullev Install guide pin and guide pin roller Install oil socket Install driving belt spring and clutch into clutch spring compressor and press down the assembiv by turning manual lever until mounting nut that can be installed Hold the compressor bv bench vise and tighten the mounting nut to specified torque with special nut wrench Remove the clutch spring compressor Torque value 5 0 6 0 kg m Install clutch driven pullev and driving belt onto driving shaft atoa Clutch spring compressor 8 12 TGB Oil seal Guide pin roller m I kur TGB 9 FINA
13. system Clogged air cleaner Malfunction of automatic by starter Malfunction of throttle valve operation Stall after started Malfunction of automatic by starter Incorrect ignition timing Malfunction of carburetor Dirty engine oil Air existing in intake system Incorrect idle speed Rough idle Malfunction of ignition svstem Incorrect idle speed Malfunction of carburetor Dirtv fuel Intermittentiv misfire as acceleration e Malfunction of ignition svstem Late ignition timing e Malfunction of ignition svstem e Malfunction of carburetor TGB Power insufficiencv and fuel consuming Fuel svstem clogged Malfunction of ignition system xture too lean Clogged fuel injector Vacuum piston stick and closed Malfunction of float valve Fuel level too low in float chamber Clogged fuel tank cap vent Clogged fuel filter Obstructed fuel pipe Clogged air vent hose Air existing in intake system xture too rich Clogged air injector Malfunction of float valve Fuel level too high in float chamber Malfunction of automatic by starter Dirty air cleaner TGB Carburetor Removal Open the seat Remove the luggage box Loosen the adjustment nut and fixing nut of throttle valve cable and release the cable from carburetor Remove fuel pipe vacuum hose Disconnect auto by starter connectors Release the clamp strip of air cleaner Release the clamp strip of carburetor isolator Take the carburetor out VACUUM CHAMBER Removal
14. the 3 positions top center and bottom of cylinder measure the X and Y direction values respective in the cylinder Service limit 38 090mm Calculate both the real roundness the Alert difference between X and Y motion values mic Center and the cylindrical roundness the ees Bottom difference in the top center or bottom F positions of X or Y motion values Then determinate by the max value Service limit Real roundness correct or replace as over 0 05 mm Cylindrical roundness correct or replace as over 0 05 mm Exhaust side Intake side Check Cylinder flat Service limit correct or replace as over 0 05 mm 7 4 TGB 7 CYLINDER PISTON PISTON REMOVAL Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other parts falling into crankcase when disassembling Hold another snap ring with pliers Push out the piston pin from the side that not removed the snap ring Remove piston rings Caution Pay attention to remove piston rings because they are fragile Disassemble the piston rings Check if the piston rings are damaged or its grooves are worn Cleaning the carbon in piston ring grooves Install the piston rings and then measure clearance between piston ring and its grooves Service Limit Top ring replace if over 0 09mm A 2nd ring replace if over piton 19 0 09mm A Feeler gauge Take out the piston rings and place them respective into cvlinde
15. the engine This will make the oil flow out easily Add oil to the specified capacity Oil Viscosity SAE 10W 30 recommended using King Mate serial oil Engine oil capacity Disassembly 850cc Change 750cc When checking for oil leak run the engine at idle speed for a few minutes then check oil capacity with dipstick Cleaning the oil strainer Drain oil from engine remove the strainer cover spring and strainer If there is an accumulation on the screen wash it off with suitable solvent recommended using compressed air Check O ring for damage replace if necessary Reinstall strainer spring O ring and strainer cover Torque value 1 3 1 7 kgf m MAINTENANCE INFORMATION Dipstick 2 MAINTENANCE INFORMATION Gear Oil Inspection Check gear oil if leaking Park the motorcycle with main stand on flat level place Turn off engine and remove the gear oil draining plug Place a measurement cup under the draining hole Remove the oil drain plug and drain gear oil into a measurement cup Check gear oil if enough Replacement At first remove the gear oil refilling bolt and then remove the draining plug Install the draining plug after drained oil out Torque value 0 8 1 2 kgf m Caution Inspect if washer is in good condition Replace it with new one if it was deformed or damaged Fill out gear oil to specified quantitv from the engine oil filling hole Install the oil filling bolt
16. 0 rom Idling speed 2200 100 rpm Cylinder compression pressure 12 2 kg cm Valve clearance IN EX 0 06 0 02 mm 2 MAINTENANCE INFORMATION TGB PERIODICAL MAINTENANCE SCHEDULE Me 1 year aintenance Item Initial 300KM Code Every1000KM Every3000KM Everv6000KM 7 12000k rn ee Rn 2 VA NR BEE DEE Oer BE eo o d S e EZ 4 Engine oil change R Replacement for every 1000km _ 5 Gearoil check for leaking Joo o ooo o o 76 jispakpugcheckorchangs 1 O J Rn 7 Gear oil change R Replacement for every 5000km _ 76 foont o o S T f 79 xEmissioncheckiniaing a o o p ao xEnginebotttightening 1 J O o or To To o o o o r T RR 12 j OVTdivingdevioetrole BETZ BEN DE GE 14 jWavedermee HEN TE oO J oa L 0000 YxCrankcase blow by overflow pipe l Replacement forevery2000km 2 Code Inspection cleaning and adjustment R Replacement C Cleaning replaced if necessary L Lubrication Have your motorcycle checked adjusted and recorded maintenance data periodically by your TGB Authorized Dealer to maintain the motorcycle at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first Remarks 1 These marks yx in the schedule are emission control items According to EPA regulations these items must be perform normally periodical maintenance following the use r manual
17. 7 seconds Compression pressure 1242 Kg cm Check following items if the pressure is too low e Incorrect valve clearance e Valve leaking e Cvlinder head leaking piston piston ring and cvlinder worn out If the pressure is too high it means carbon deposits in combustion chamber or piston head DRIVING SVSTEM Gear teeth DRIVING BELT Remove left side cover Remove mounting bolt located under air cleaner Remove 9 bolts of the engine left crankcase Remove the left crankcase cover Check if the belt is crack or worn out Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it Width limit above 17 5 mm Clutch pad Clutch pad Start the motorcycle and gradually increase throttle valve openness to check clutch pad operation If the motorcycle moves with shaking then check its clutch pad for wearing Replace it if necessary TGB 3 LUBRICATION SYSTEM MECHANISM DIAGRAM CLEANING ENGINE OIL STRAINER 3 3 OPERATIONAL PRECAUTIONS OIL PUMP TROUBLE DIAGNOSIS GEAR OIL ENGINE OIL MECHANISM DIAGRAM Valve rocker arm Forcediv lubrication Camshaft Scoop lubrication Inner passage Connecting rod Forcediv lubrication Crankshaft Oil strainer 3 1 3 LUBRICATION SYSTEM TGB OPERATIONAL PRECAUTIONS General Information e This chapter contains maintenance operations for the engine oil pump engine oil and gear oil Specifications O
18. BLE DIAGNOSIS E CLUTCH DRIVING AND DRIVING PULLEY V FAULT CONDITIONS PROBABLE CAUSES m 1 Engine can be started but motorcycle can not be moved GE B 6 Engine running and misfire as motorcycle initial forward moving 1 or jumping suddenly rear wheel 2 rotating as engine in running 3 Poor initial driving Poor i climbing performance Driving belt worn out or deformation Driving disk damaged Driving pulley spring broken Clutch ling broken Driving slide shaft gear groove broken Transmission gear damaged Clutch ling spring broken Clutch outer stick with clutch balance weights Connection parts in clutch and shaft worn out or burned Driving belt worn out or deformation Balance weight roller worn out Driving sliding gear shaft worn out Driving disk spring deformation Driving sliding gear shaft worn out Greased in driving belt and sliding gear TGB 2 MAINTENANCE INFORMATION PRECAUTIONS IN OPERATION CARBURETOR IDLING SPEED ADJUSTMENT 2 5 PERIODICAL MAINTENANCE SCHEDULE IGNITION SYSTEM SPARK PLUG 2 6 LUBRICATION SYSTEM CYLINDER COMPRESSION PRESSURE 2 VALVE CLEARANCE ADJUSTMENT 2 4 DRIVING SYSTEM PRECAUTIONS IN OPERATION change 750 c c i 120 c c Transmission Gear oil 110 c c Clearance of throttle valve Spark plug TORCH A7RC Gap 0 6 0 7 mm Specification Engine Oil F Mark in idling speed Before TDC 13 2200 rpm Full timing advanced Before TDC 26 800
19. GB TORQUE VALUES ENGINE THREAD DIA TORQUE ika BET m rere Cylinder head cover bolts head cover bolts 2 1 2 Cylinder head nuts 1 0 1 4 oil thread a Neen ead 0 7 1 1 Tighten to crankcase two ends bolts Valve adjustment fixing nuts 0 7 1 1 Apply oil to thread connecting nuts Engine left side cover bolts 9 6 0 8 1 2 e d LU attached a w g 0 45 0 6 Hex socket bolt bolts TGB 1 GENERAL INFORMATION TROUBLE DIAGNOSIS 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 5mm bolt nut 0 45 0 60kgf m 0 05 0 08kgf m 6mm bolt nut 0 80 1 20kgf m 0 10 0 15kgf m 8mm bolt nut 1 80 2 50kgf m 0 35 0 50kgf m 10mm bolt nut 3 00 4 00kgf m 6mm screw SH nut 0 70 1 10kgf m 12mm bolt nut 5 00 6 00kgf m 6mm bolt nut 1 00 1 40kgf m 8m bot nut 2 40 3 00kgf m Oo S S Obo 3 50 4 50kgf m 1 GENERAL INFORMATION TROUBLE DIAGNOSIS TGB TROUBLES DIAGNOSIS A Engine hard to start or can not be started Check and adjustment and Check and adjustment Fault condition condition Probablecauses Probablecauses Loosen carburetor drain No fuel in fuel tank bolt to check if there is Check if the pipes fuel tank to gasoline inside the carburetor and intake vacuum carburetor are clogged 3 Float valve clogged 4 Lines in fuel tank e
20. ITEM L R CRANK DISASSEMBLE TOOL ITEM CLUTCH NUT WEENCH PURPOSE CRANKSHAFT DISASSEMBLE PURPOSE LOOSE THE CLUTCH NUT ITEM UNIVERSAL HOLDER ITEM CLUTCH SPRING COMPRESSOR PURPOSE HOLDER THE MDF CLUTCH PURPOSE DISASSEMBLE THE CLUTCH OUTER ITEM TAPPET ADJUSTING WRENCH ITEM ACG FLYWHEEL PULLER PURPOSE ADJUST VALVE CLEARANCE PURPOSE REMOVE ACG FLYWHEEL ITEM OIL SEAL DRIVER ITEM OIL SEAL DRIVER PURPOSE OIL SEAL INSTALLATION PURPOSE OIL SEAL INSTALLATION 11 1
21. KSHAFT DISASSEMBLY OF CRANKCASE Remove the 1 bolt from the right crankcase Remove the cam chain tensioner hex socket bolt from the left side of crankcase Place the left side of crankcase upward and then install the crankcase remover set onto the crankcase Drive the screw of the crankcase remover set into the crankcase and then separate the left and the right crankcases Remove the cam chain Caution e Never pry out the connection surfaces of crankcases as separating Otherwise the connection surfaces could be damaged and cause oil leaking e It have to separate the cam chain and the drive gear before pressing out the both left and riaht crankcases Special Service Tools Crankcase remover set 11 2 TGB 11 CRANKCASE CRANKSHAFT Remove the crankshaft from the right crankcase AN Caution e The left and right bearings of crankshaft is to press fit onto the crankshaft Remove gasket and dowel pins 2 Scrape gasket residues off the crankcase contact surface Caution e Do not damage contact surface of the crankcase e Soap the gasket residues into solvent and the residues will be removed easily Remove oil seal from the left crankcase 11 3 11 CRANKCASE CRANKSHAFT TGB CRANKSHAFT INSPECTION Measure left and right clearance of connecting rod big end Service limit Replace when it is more than 0 55 mm Measure the radical clearance of the big end at th
22. L DRIVING MECHANISM OPERATIONAL PRECAUTIONS INSPECTION OF FINAL DRIVING MECHANISM 9 2 TROUBLE DIAGNOSIS BEARING REPLACEMENT DISASSEMBLY OF FINAL DRIVING MECHANISM RE ASSEMBLY OF FINAL DRIVING MECHANISM OPERATIONAL PRECAUTIONS Specification Torque value Application gear oil 4 stroke lubricant Gear box cover 2 0 2 4 kgf m Recommended oil KING MATE serial gear Gear oil drain plug 1 0 1 4 kgf m oils Gear oil filling bolt 0 8 1 2 kgf m Oil quantity 120 c c 110 c c when replacing Tools Special service tools Inner type bearing puller Outer type bearing puller Gear box oil seal installer Gear box bearing installer TROUBLE DIAGNOSIS Engine can be started but motorcycle Gear oil leaks can not be moved e Excessive gear oil c Damaged driving gear e Worn or damage oil seal e Burnt out driving gear e Broken driving belt Noise e Worn or burnt gear e Worn gear 9 1 9 FINAL DRIVING MECHANISM TGB DISASSEMBLY OF FINAL DRIVING MECHANISM Remove the rear wheel refer to chapter 15 Remove the clutch Drain gear oil out from gear box Remove gear box cover bolts 7bolts and then remove the gear box cover and the final driving shaft Remove gasket and setting pin Remove countershaft and gear Remove final driving gear and shaft INSPECTION OF FINAL DRIVING MECHANISM Check if the countershaft and the gear are wear or damage final driving shaft Check if the final driving shaft and gear are burn wea
23. Torque Values Engine suspension bolt 4 5 5 5kgf m Engine suspension nut 4 5 5 5kgf m Bolt of rear shock absorber upper connection 3 5 4 5kgf m Bolt of rear shock absorber lower connection 2 4 3 0kgf m 5 ENGINE REMOVAL ENGINE REMOVAL Remove the power connector of auto by start Remove the generator wire and pulse generator connector Remove the spark plug Remove the fuel pipe vacuum hose and throttle valve cable from the carburetor Loose the strap screw of the air cleaner guide and then the air cleaner guide Remove the exhaust muffler Bolts x 2 Nuts x 2 Generator connector Auto by start connector lt a S TGB pulse generator connector TGB 5 ENGINE REMOVAL Remove the rear wheel Nut x 1 Remove the air cleaner connection bolts 2 bolts RR Brake cable E S Remove the rear brake cable nut gt bu Brake cable ant dr Remove the rear brake cable I Ti i Remove the rear shock absorber lower bolt 5 ENGINE REMOVAL Loose the strap screw of engine left guide Ca un i Ti nn Strap screw of guide Remove the engine suspension nut and bolt and then remove the engine Caution e With a bracket to support the engine to prevent from it damage by falling down as removing the engine Check if the engine suspension rear shock absorber bushing and cushion rubber for damage Replace them with new ones if SO INSTALLATION OF ENGINE Ch
24. ake it out Remove cam rocker arm Inspection Of Camshaft Holder Check if the camshaft holder cam rocker arm and rock arm shaft for wearing out or damage Caution e Further check is necessary if any wear is found on the moveable surface of cam rocker arm e Check if the camshaft bearing mounting surface for wear or damage Measure the cam rocker arm I D of the camshaft holder Service Limit Replace when it is above 10 10 mm rocker arm shaft 6 CYLINDER HEAD VALVE Measure the valve rocker arm I D Service Limit Replace when it is above 10 100 mm Measure the active O D of the valve rocker arm shaft and valve rocker arm Service Limit Replace when it is above 9 910 mm Calculate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is above 0 10 mm ri CYLINDER HEAD REMOVAL NR Remove double seat luggage box and front en center cover Js Remove the engine refer to Chapter 5 Remove the cooling fan cover Remove the engine shroud Remove the camshaft chain and camshaft cooling fan cover N yh TGB TGB Remove the 2 cylinder head mounting bolts from cylinder head left side cover Remove cylinder head gasket and 2 dowel pins Remove chain plate Clean up residues from the matching surfaces of cylinder and cylinder head MA Caution e Do not damage the matching surfaces of cylinder and cylinder head e Avoid residues of gasket or forei
25. alve seat width a surface Old valve seat 09 Ow width 6 11 6 CYLINDER HEAD VALVE TGB After the valve seat grinded coat valve seat surface with emerv and then slightly press the grinded surface Clean up all emerv coated onto cvlinder and valve after grinded Valve cotters N o Valve stem CVLINDER HEAD REASSEMBLV Lubricate valve stem with engine oil and U alve spring then insert the valve into valve guide retainer Install new valve stem oil seal Install valve springs and retainers A Caution The closed coils of valve spring should face down to combustion chamber Use valve spring compressor to press valve spring Install valve split locks and release the valve compressor A Caution oil seal In order to avoid to loosing spring tension do not compress the spring too much Its length is based on the installation of latch Special tool valve spring compressor Tap valve stem to make valve retainer and valve stem sealing properly AN Caution Place and hold cylinder head on to working table so that can prevent from valve damaged 6 12 TGB CYLINDER HEAD INSTALLATION Install the lock pins and new cylinder head gasket onto the cylinder head Install the camshaft chain plate Install the cylinder head CAMSHAFT INSTALLATION Assemble the camshaft holder Install the exhaust valve rocker arm set onto the camshaft holder showing EX mark Install intake va
26. ck ignition timing with ignition light Start engine and set engine idle speed in 1700 rpm and if the mark aligns with the F then it means that ignition timing is correct Increase engine speed to 8000 rpm to check ignition timing advance If the detent aligns with advance mark ir then it means ignition timing advance is in functional If not check CDI set pulse flywheel and pulse generator Replace these components if malfunction of these parts are found SPARK PLUG Appointed spark plug TORCH A7RC Remove luggage box Remove body side cover Remove spark plug cap Clean dirt around the spark plug hole Remove spark plug Measure spark plug gap Spark plug gap 0 6 0 7 mm Carefully bend ground electrode of the plug to adjust the gap if necessary Screw the park plug into the plug hole with hands then tighten the plug with a wrench to prevent from damaging the spark plug s thread Torque value 1 0 1 2 kgf m Connect spark plug cap enter electrode TGB TGB 2 MAINTENANCE INFORMATION CYLINDER COPMRESSION PRESSURE Warn up engine and then turnoff the engine Open the seat Remove the luggage box Remove spark plug cap and spark plug Install compression gauge Full open the throttle valve and rotate the engine bv means of stepping the kick starting lever Caution Rotate the engine until the reading in the gauge no More increasing Usuallv the highest pressure reading will be obtained in 4
27. e forward to intake valve Install new piston pin snap ring Caution e Do not let the opening of piston pin snap ring align with the opening piston ring e Place a piece of cleaning cloth between piston skirt section and crankcase in order to prevent snap ring from falling into crankcase as operation CYLINDER INSTALLATION Clean up all residues and foreign materials on the matching surface of crankcase Pay attention to not let these residues and foreign materials fall into crankcase Caution To soap the residues into solvent so that the residues can be removed more easily Install 2 lock pins and new gasket Coat engine oil to inside of cvlinder piston and piston rings Care to be taken when installing piston into cvlinder Press piston rings in one bv one as installation Caution Do not push piston into cvlinder forcefullv because this will cause the piston and the piston rings to be damaged Install the cam chain plate the cvlinder gasket and lock pins Install cvlinder head refer to Chapter 6 Install the cam chain auto adjuster 2 bolts TGB IN mark TGB 8 V BELT DRIVING SVSTEM KICK STARTER ARM MAINTENANCE DESCRIPTION DRIVING BELT TROUBLE DIAGNOSIS SLIDING PULLEV LEFT CRANKCASE COVER CLUTCH DRIVEN PULLEV KICK STARTER ARM MAINTENANCE DESCRIPTION PRECAUTIONS IN OPERATION GENERAL INFORMATION e Driving pulley clutch and driven pulley can be serviced on the
28. e vertical directions Service limit 0 05 mm Place the crankshaft onto a V block and measure run out of the crankshaft with dial gauge Service limit 0 10 mm Bearing Inspection Rotate the bearing with fingers and make sure the bearing can be rotated smoothly and quietiv Check if the inner ring is connected onto the crankshaft tightly Replace crankshaft as a set when noise or looseness is detected 11 4 TGB 11 CRANKCASE CRANKSHAFT ASSEMBLY OF CRANKCASE Install cam chain into the chain hole of the left crankcase and then split out the cam chain Caution e Do not damage the cam chain as installing the crankshaft Install crankshaft into the left crankcase and then install two dowel pins and new crankcase gasket i ppn WT IN 1 l ERA Bdowel pins Install the right crankcase and tighten the crankcase bolts 1 bolts Torque value 1 5 2 0 kgf m Install the cam chain tensioner Install a new O ring onto the mounting bolt of the chain tensioner Applv some oil on the O ring and tighten the bolt Torque value 0 8 1 2 kgf m Caution e The O ring must be installed into the bolt s groove 11 5 11 CRANKCASE CRANKSHAFT TGB Apply with some grease onto the oil seal lip and then install it onto the left crankcase Press fit the oil seal to specified position with the oil seal installer Special service tools the oil seal installer 11 6 TGB 12 SPECIAL TOOL
29. eal is damage Replace it if necessary Check if needle bearing is damage or too big clearance Replace it if necessary Rotate the inside of inner bearing with fingers to check if the bearing rotation is in smooth and silent Outer ball bearing 8 V BELT DRIVING SYSTEM KICK STARTER ARM TGB Clutch Block Replacement Remove snap and washer and the remove clutch block and spring from driving plate Check if spring is damage or insufficient elasticity Snap ring Check if shock absorption rubber is damage or deformation Replace it if necessary Apply with grease onto setting pins Apply with grease onto setting pins But the clutch block should not be greased If so replace it Install new clutch block onto setting pin and then push to specified location Caution e Grease or lubricant will damage the clutch block and effect the block s connection capacity Install the spring snap into groove with pliers 8 10 TGB 8 V BELT DRIVING Install snap ring and mounting plate onto setting pin REPLACEMENT OF DRIVEN PULLEV BEARING Remove inner bearing Caution e If the inner bearing equipped with oil seal on one side in the driven pulley then remove the oil seal firstly e If the pulley equipped with ball bearing it has to remove snap ring and then the bearing Remove snap ring and then push bearing forward to other side of inner bearing Place new bearing onto proper position and its
30. eck if the bushings of engine suspension frame and shock absorber for damaged If so replace with new ones Install the engine according to the reversing order of removal 5 4 TGB 5 ENGINE REMOVAL MA Caution e Notice both feet and hands safety for squeezing as engine installation e Do not bent or squeeze each wires or hose e Route all cables and wires in accordance with the routine layout Engine suspension nut Torque Value 4 5 5 5kgf m Rear shock absorber bolt Torque Value Top 3 5 4 5kgf m lower 2 4 3 0kgf m Rear wheel axle nut Torque Value 11 0 13 0kgf m RR Brake cable f fi Da A Rear shock absorber lo us I TGB 6 CYLINDER HEAD VALVE CYLINDER HEAD INSPECTION VALVE SEAT INSPECTION AND SERVICE 6 10 CYLINDER HEAD REASSEMBLY CYLINDER HEAD INSTALLATION CAMSHAFT INSTALLATION 1 0 1 4 kgf m 1 8 2 2 kgf m 1 0 1 4 kgf m 6 1 6 CYLINDER HEAD VALVE TGB PRECAUTIONS IN OPERATION General Information e This chapter is contained maintenance and service for cvlinder head valve and camshaft as well as valve rocker arm e Cvlinder head service cannot be carried out when engine is in frame Specification unit mm Height of cam lobe B cker ID of valve rocker arm 10 00 10 000 10 015 au OD of valve rocker arm shaft 10 00 9 985 10 00 OD of valve stem Clearance between 0 010 0 037 0 080 valve stem and guide er mA Free length of valve spring 32 410 en Valve seat widt
31. et or foreign materials on the connection surfaces of both the cover and crankcase Caution Do not damage the connection surfaces 8 bolts 10 A C GENERATOR STARTING CLUTCH TGB RIGHT CRANKCASE COVER INSTALLATION Install setting pin and new gasket on the crankcase Replace the right crankshaft oil seal of the crankcase and apply some oil onto the oil seal lip Install right crankcase cover onto the right crankcase 8 bolts Torque value 1 5 2 0kgf m MOUNTED COIL SET INSTALLATION Install the coil set onto right crankcase cover 2 bolts Install pulse generator 2 bolts Torque 1 5 2 0kgf m Tie the wire harness hose onto the indent of crankcase LN Caution Make sure that the wire harness is placed under the pulse generator Install A C generator connector and pulse generator connector Pulse generator si Ja uto bv start connector Fi connector FLYWHEEL INSTALLATION un FI Make sure that there is no magnetic powder A ie _ gms Universal mure If so clean up it A Erz Align insert on crankshaft with the flywheel 7 T nd oe groove and then install the flywheel ens 1 SS Hold the flywheel with flywheel holder and tighten its nut Torque value 5 0 6 0kgf m Special service tool Universal fixture 10 4 TGB 10 A C GENERATOR STARTING CLUTCH Install the cooling fan 4 bolts Install the cooling fan shroud 4 bolts Cooling fan shroud Install the exhaust muffler 2 bolts 2 nuts
32. etween piston and ii ID of piston pin hole 13 002 13 008 13 040 OD of piston pin 13 000 12 994 13 000 Clearance between piston and piston pin 0 002 0 014 0 020 ID of connecting rod small end 13 005 13 020 TROUBLE DIAGNOSIS Low Or Unstable Compression Pressure Smoking in Exhaust Pipe Cylinder or piston ring worn out Piston or piston ring worn out Compress pressure to high Piston ring installation improperly Too much carbon deposited in combustion Cylinder or piston damage chamber and piston Knock or Noise Engine Overheat Cylinder or piston ring worn out Carbon deposits on cylinder head top side Carbon deposits on cylinder head top side Piston pin hole and piston pin wear out 7 2 TGB 7 CYLINDER PISTON CYLINDER REMOVAL Remove cylinder head refer to chapter 6 Remove 2 bolts and then take out the cam chain auto adjuster Cam chain auto adjuster Cam chain guide Remove cam chain plate Remove cylinder Remove cylinder gasket and lock pins Clean the residues attached onto the matching surfaces of cylinder and crankcase 7 CYLINDER PISTON TGB Cover the holes of crankcase and cam chain with a piece of cleaning cloth Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution To soap the residues into solvent so that the residues can be removed more easily INSPECTION Check if the inner diameter of cylinder is worn out or damaged In
33. g onto crankcase Then install the driving shaft Specified tool Press the bearing in with C type hydraulic presser or bearing installer final driving shaft ft Vip bearing lt Install a new final driving shaft bearing onto crankcase Specified tool Press the bearing in with C type hydraulic presser or the bearing installer Apply with some grease onto the lip section of oil seal and then install the seal TGB 9 FINAL DRIVING MECHANISM RE ASSEMBLY OF FINAL DRIVING MECHANISM Install final driving shaft and final driving gear countershaft and countershaft gear Install the setting pins 2 pins and new gasket Apply with grease onto the oil seal lip of final driving shaft Install the gear box cover and 7 bolts tighten the bolts Torque 2 0 2 4 kgf m Install the clutch sliding driving pulley Install the driving pulley belt and left crankshaft cover Install the rear wheel Filling bolt Add gear oil j 4 Recommended usage SEM HYPOID m AS GEAR OIL SAE 85W 140 Fi hr i 110 cc standard capacity 100 cc when replacement TGB 10 A C GENERATOR STARTING CLUTCH PRECAUTIONS IN OPERATION A C GENERATOR REMOVAL MOUNTED COIL SET INSTALLATION RIGHT CRANKCASE COVER REMOVAL 10 3 FLY WHEEL INSTALLATION PRECAUTIONS IN OPERATION General information e Refer to chapter 5 Engine removal and installation e Refer to chapter 1 The troubleshooting and inspection of A C generat
34. gn materials falling into crankcase as cleaning CYLINDER HEAD DISASSEMBLY Use a valve compressor to press the valve spring After removed valve cotters release the compressor and then take out spring retainer valve spring and valves MA Caution In order to avoid to loosing spring tension do not compress the spring too much Its length is based on the installation of latch Special Service Tool Valve spring compressor Remove valve stem guide seal Clean carbon deposits in combustion chamber Clean residues and foreign materials on cylinder head matching surface MA Caution Do not damage the matching surface of cylinder head 6 CYLINDER HEAD VALVE dowel pins Fin m vos Nr Cylind ir head gasket a 7 Chain plate valve cotters 6 CYLINDER HEAD VALVE TGB CVLINDER HEAD INSPECTION Check if spark plug and valve holes are crack Measure cvlinder head flat with a straightedge and flat feeler gauge Service limit 0 5mm Valve spring free length Measure the free length of intake and exhaust valve springs Standard 32 410 mm The narrow pitch of the spring shall face to the combustion chamber Valve stem Check if valve stems are bend crack or burn Check the operation condition of valve stem in valve guide and measure amp record the valve stem outer diameter Service Limit IN 4 900mm EX 4 900mm Valve guide IN Caution Before measuring the valve guide clean carbo
35. h 1 000 1 600 Connection Flatness of cylinder head Ls oo 0 050 Torque Value Cylinder head cover bolt 0 8 1 2kgf m Cylinder head bolt LH 0 8 1 2kgf m Cylinder head Nut 1 0 1 4kgf m apply with oil on bolt thread amp seat Sealing bolt of timing chain auto adjuster 0 8 1 2kgf m Bolt of timing chain auto adjuster 0 8 1 2kgf m Timing gear cover bolts 0 7 1 1kgf m apply with oil on bolt thread amp seat Spark plug 1 0 1 4kgf m TOOLS Special service tools Valve reamer 5 0mm Valve guide driver 5 0mm Valve spring compressor 6 2 TGB 6 CYLINDER HEAD VALVE TROUBLE SHOOTING Engine performance will be effected by troubles on engine top end The troubles usually can be determinate or bv performing cvlinder compression test and judging the abnormal noise generated Rough Idle Low compression pressure Low compression pressure 1 Valve e Improper valve adjustment e Burnt or bended valve e Improper valve timing e Valve spring damaged e Valve carbon e Poor sealing on valve seat e Improper spark plug installation 2 Cylinder head e Cylinder head gasket leaking or damage e Tilt or crack cylinder surface 3 Piston e Piston ring worn out High compression pressure e Too much carbon deposit on combustion chamber or piston head Noise e Improper valve clearance adjustment e Burnt valve or damaged valve spring e Camshaft wear out or damage e Cam chain wear out or looseness e Auto adjuster wear out or
36. il viscosity Engine oil quantity Disassembly 850 c c a Replacement 750 c c O IMI ANNA Oil viscositv SAE 10W 30 or equivalent mali Recommended King Mate sem u serial oils Gear Oil Disassembly 120 c c TH u Replacement 110 c c Oil viscosity of gear oil SAE 85W 140 Recommended King Mate gear oil series HYPOID GEAR OIL unit mm U imerroorciesanoe m Clearance between outer Clearance between rotor Torque value Engine oil drain plug 3 5 4 5kgf m Engine oil screen cover 1 3 1 7kgf m Gear oil drain bolt 0 8 1 2kgf m Gear oil filling bolt 1 0 1 4kgf m Oil pump connection screw 0 1 0 3kgf m TROUBLE DIAGNOSIS Low engine oil level Dirty oil Oil leaking No oil change in periodical Valve guide or seat worn out Cylinder head gasket damage Piston ring worn out Piston ring worn out Low Oil Pressure Low engine oil level Clogged in oil strainer circuits or pipes Oil pump damage 3 2 TGB ENGINE OIL Turn off engine and park the motorcvcle in flat ground with main stand Check oil level with oil dipstick after 3 5 minutes Do not rotate the dipstick into engine as checking If oil level is nearly low level fill out recommended oil to upper level Dipstick Oil Replacement l Caution Drain oil as engine warmed up so that make sure oil can be drained smoothly and completely Place an oil pan under the motorcycle and remove oil strainer cap Make sure if the aluminum washer of the drai
37. ith that of inner rotor Install the driving shaft Install the oil pump cover and fixing pin properly and then tighten screw 1 screw 3 LUBRICATION SYSTEM 2 O rings er l Q Oil Pump Installation Install the 2 O rings Install the oil pump pin Install the oil pump Install the oil pump body bolts 3 bolts Install the oil pump driving gear nut Install the alternator refer to chapter10 Install the engine right crankcase cover pump driving gear nut TGB GEAR OIL Oil Level Inspection Park the motorcycle on flat ground with main stand Turn off engine and remove both engine oil filling bolt and oil draining bolt Remove gear oil filling hole bolt and place a measurement cup under the draining plug Remove the oil draining plug and the pour gear oil into the measurement cup Measure the gear oil quantitv if within standard value Add specified gear oil if the oil level too low Standard quantity 100cc Replacement 90 cc Gear Oil Replacement Remove the gear oil filling hole bolt and its draining plug and then drain oil completely Install the draining plug and tighten it Make sure if the plug washer is damaged If so replace it with new one Torque Value 0 8 1 2 kgf m Add new gear oil 100 c c from the gear oil filling hole and then install the gear oil filling hole bolt after added oil And then tighten the bolt Torque Value 1 0 1 4 kgf m ix Recommended to apply
38. l O m i Lt A SAN MA Adjust the valve guide driver and let valve guide height is in 13mm Press in new valve guide from rocker arm side Tool Valve guide driver 5 mm Wait for the cylinder head cooling down to room temperature and then correct the new valve guide with reamer MA Caution e Using cutting oil when correcting valve guide with a reamer e Turn the reamer in same direction when it be inserted or rotated Correct valve seat and clean up all metal residues from cylinder head Special tool Valve guide reamer 5 mm 6 CYLINDER HEAD VALVE TGB VALVE SEAT INSPECTION AND SERVICE Clean up all carbon deposits onto intake and exhaust valves Applv with emerv slightiv onto valve contact face Grind valve seat with a rubber hose or other manual grinding tool IN Caution e Do not let emery enter into between valve stem and valve guide e Clean up the emery after corrected and apply with red paint onto contact faces of valve and valve seat Remove the valve and check its contact Tr En face core 0 0 0 0 0 0 8 0 0 8 IE IN caution ee Replace the valve with new one if valve seat is roughness wear out or incomplete contacted with valve seat If the valve and the valve seat still can not be matched sealing after grinded replace it with new one L L Roughness Valve seat inspection If the valve seat is too width narrow or rough correct it Valve seat width Service limit
39. ll the title plate guide boot onto the title plate Install the title plate Tilt plate TGB 8 V BELT DRIVING SVSTEM KICK STARTER ARM Applv with grease 4 5 g to inside of driving shaft hole and install driving pullev hub AN Caution The pulley surface has to be free of grease Clean it with cleaning solvent Install siding pulley assembly onto crankshaft Sliding pulley _ Crankshaft DRIVING PULLEY INSTALLATION ug Press down Press driving belt into pulley groove and then press down the up amp down sides of the driving belt to separate it away from the driving pulley hub Caution To press down the up amp down sides of the driving belt can avoid to pressing and damaging the belt when installing the driving pullev and also can make sure that the driving pulley can be tighten Install driving pullev washer and nut Caution Make sure that two sides of pullev surfaces have to be free of grease Clean it with cleaning solvent Hold driving pullev with universal fixture Tighten nut to specified torque Torque value 5 0 6 0 kgf m Install left crankcase cover Pullev surface Pullev hub 8 V BELT DRIVING SYSTEM KICK STARTER ARM TGB CLUTCH DRIVEN PULLEV FET Special nut wrench DISASSEMBLY Remove driving belt and clutch driven pulley Install clutch spring compressor onto the pulley assembly and operate the compressor to let nut be installed more easily AN Caution Do not pres
40. logged Malfunction of automatic bv starter 1 4 TGB 1 GENERAL INFORMATION TROUBLE DIAGNOSIS B Engine run sluggish Speed does not pick up lack of power Probable causes Check and adjustment Fault condition Try gradual acceleration and check engine speed Engine speed can be Engine speed can not be increased increased Check ignition timing Using ignition lamp Ignition timing correct Incorrect ignition timing 1 Check cylinder compression pressure using compression pressure gauge Compression pressure correct No compression Check if carburetor jet is clogged No clogged Clogged Remove spark plug No foul or discoloration Fouled and discoloration Check if engine over heat Continually drive in acceleration or high speed OO D O AOUON gt RWN OO BON Air cleaner clogged Poor fuel supplv Lines in fuel tank evaporation svstem clogged Exhaust pipe clogged Fuel level too low in carburetor Fuel nozzle clogged in carburetor Malfunction of CDI Malfunction of AC alternator Cvlinder amp piston ring worn out Cylinder gasket leaked Sand hole in compression parts Valve deterioration Seized piston ring Remove foreign Remove dirt Incorrect spark plug heat range Piston and cylinder worn out Lean mixture Poor fuel quality Too much carbon deposited in combustion chamber Ignition timing too advanced Poo
41. lve rocker arm and rocker arm shaft Caution The tangent of rocker shaft of intake valve should match with the bolt hole of camshaft mounting seat With T type wrench to turn crankshaft in a clockwise motion so that the T mark on the fivwheel aligns with the mark on crankcase piston is at TDC position Place the TDC marks of the cam sprocket at same level of the top end of cylinder head The other single hole of the cam sprocket is in upward Then install the cam chain onto the cam sprocket 6 CYLINDER HEAD VALVE Lock pins _ Gylinder head gasket TM IE 4 ZA i l WZ BA Cx 5mm blot Rocker arm shaft 6 13 6 CYLINDER HEAD VALVE TGB Install the lock pins Install the camshaft holder gasket and nut onto the cvlinder head Tighten the cvlinder head nuts 4 nuts At first tighten the 4 nuts on the cvlinder top and then tighten the 2 bolts on the left side of cvlinder head Torque value 1 8 2 2 kgf m Install the spark plug and tighten it Torque value 1 0 1 2 kgf m Caution e Apply with oil onto the thread of cylinder head bolts and tighten the bolts in diagonally for 2 3 sequences e Do not over tightening the bolts to avoid the cylinder head deformation noise created or leaking so that effects motorcycle s performance VALVE CLEARANCE ADJUSTMENT Loosen valve clearance adjustment nuts and bolts located on valve rocker arm Measure and adjust valve clearance wi
42. ments make sure both rpm and CO value are in standard values after engine running in stable If rpm and CO value i Da MAD air volume fluctuated repeat the procedures described above ae adjustment screw for adjusting to standard value 4 8 TGB AIR CLEANER Removal Open the seat and remove the luggage box Loosen the clamp strip of air cleaner Remove evaporative return hose Remove body side cover Remove the air cleaner body bolts 2 bolts Remove the air cleaner Installation Install the air cleaner in the reverse order of removal Air Cleaner Element Cleaning Remove left body side little cover 2 screws Remove the air cleaner cover 7 screws Remove the air cleaner element 2 screws With compressed air to clean dirty around the element Replace it if it is too dirty to clean Cautions The air cleaner element is made of paper so do not soap it into water or wash it ith water CARBURETOR AIR CLEANER screws X 2 TGB 5 ENGINE REMOVAL OPERATIONAL PRECAUTIONS ENGINE REMOVAL OPERATIONAL PRECAUTIONS General Information e Engine must be supported by a bracket or adjustable tool in height e The following parts can be serviced with the engine installed on the frame 1 Carburetor 2 Driving disk driving belt clutch and transporting disk 3 Final reduction gear mechanism Specification Engine Oil Capacitv Pinar Gil Papel Replacement ear OI Lapac ill
43. n deposits with reamer Special Service Tool 5 0mm valve guide reamer Measure and record each valve guide inner diameters Service limit 5 030mm 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 guide Service Limit IN gt 0 08mm EX 0 10mm 6 8 TGB 6 CYLINDER HEAD VALVE M Caution If clearance between valve stem and valve guide exceeded service limit check whether the new clearance that only replaces new valve guide is within service limit or not If so replace valve guide Correct it with reamer after replacement If clearance still exceeds service limit after replaced valve guide replace valve stem too MA Caution It must correct valve seat when replacing valve guide Valve guide replacement Heat up cylinder head to 100 150 C with heated plate or toaster MA Caution e Do not let torch heat cylinder head directly Otherwise the cylinder head may be deformed as heating it e Wear on a pair of glove to protect your hands when operating Hold the cylinder head and then press out old valve guide from combustion chamber side Tool Valve guide driver 5 mm 13 mmi 0 15in T A Caution l e Check if new valve guide is deformation after pressed it in e When pressing in the new valve guide cvlinder head still must be kept in 100 150 C Valve guide driver 5 0mm i t P Jee k KA I
44. ning bolt is damaged If so replace it with new one Install the drain bolt and tighten it Torque value 3 5 4 5 kgf m CLEANING ENGINE OIL STRAINER Remove the oil strainer cap Remove oil strainer and spring Clean oil strainer recommended using compressed air to clean dirty foreign Check if the strainer and O ring of the oil strainer are broken Replace with new one if found Install the oil strainer and spring Install the oil strainer cap and tighten it Torque value 1 3 1 7 kgf m Fill out oil to the oil filler Oil viscosity SAE 10W 30 Recommended King Mate serial oils Engine oil quantity Replacement 850 c c 3 LUBRICATION SYSTEM 3 LUBRICATION SYSTEM OIL PUMP Qil Pump Removal Remove the alternator refer to chapter10 Remove the engine right crankcase cover Make sure that the pump axle can be rotated freelv Remove the oil pump driving gear nut pump driving 4 gear nut Remove oil pump body bolts 3 bolts Remove the oil pump pin Remove the oil pump Remove the 2 O rings 3 4 TGB 3 LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor Limit below 0 12 mm Check clearance between inner and outer rotors Limit below 0 12 mm Check clearance between rotor side face and pump bodv Limit below 2 0 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving shaft w
45. ning or loosening the nut Fixed rear wheel or rear brake only will damage reduction gear system Push the driving belt into belt groove as diagram shown so that the belt can be loosened and then remove Driving belt and clutch at same time Inspection Check the driving belt for crack or wear Replace it if necessary Measure the width of driving belt as diagram shown Replace the driving belt if it exceed maintenance limited specification Service Limit 17 50mm Caution e Using the genuine parts for replacement e The surfaces of driving belt or pulley must POOL be free of grease e Clean up all grease or dirt before installation 8 V BELT DRIVING SYSTEM KICK STARTER ARM Installation Pull out the driving pulley and then insert the driving pulley AN Caution Pull out driving pulley and then insert the driving belt into the driving pulley so that the driving belt set can be installed onto sliding pulley more easily Install the starter gear WU Install the clutch set with driving belt onto the y driving shaft Install the sliding pulley on the other end of belt Install clutch outer f S T ke Ma mm Ko 4 3 ai E sliding pulley Install the clutch with universal fixture and then tighten nut to specified torque value Torque value 5 0 6 0 kgf m AN Caution When install the driving belt if there is a arrow mark then the arrow mark must point to rotation motion If not
46. noted before it was removed ya nst fuel amount 7 adjustment screw Install the float valve float and float pin p Hr Checking Fuel Level Cautions Check again to ensure float valve float for proper installation e To ensure correct measurement position the float meter in such a way so that float chamber face is vertical to the main jet Fuel level 17 5 mm INSTALLATION OF CARBURETOR Install carburetor in the reverse order of removal Following adjustments must be made after installation e Throttle valve cable clearance adjustment G Idle speed adjustment IDLE SPEED ADJUSTMENT jA throttle valve stopper screw Caution e Fuel amount adjust screw was set at factorv so no adjustment is needed Note the number of turns it takes to screw it all the wav in for ease of installation e Never screw in forcediv to avoid damaging the screw seat e The main stand must be used to support the motorcvcle to perform the adjustments Use a tachometer when adjusting engine RPM Screw in adjustment screw gentiv then back up to standard turns Standard turns 1 3 4 3 4 turns Warm up engine adjust throttle valve stopper screw to standard RPM Idle speed rpm 1700 100 rpm Connect the sampling hose of exhaust analyzer to exhaust front end Press test key on the analyzer Adjust the air volume adjustment screw and read CO reading on the analyzer CO standard value 1 0 1 5 Accelerate in gradual incre
47. on or crack Installation Install the valve as reverse order of removal Cautions Do not damage the vacuum diaphragm or in opposite installation direction 4 5 4 CARBURETOR AIR CLEANER TGB AUTO BY STARTER Inspection Turn off engine and waiting for over 10 minutes for cooling Check resistance across the two terminals of the auto by starter Resistance value Max 100 Measured after engine stopped for more than 10 minutes Replace the auto by starter with a new one if resistance value exceeds standard Remove the carburetor allow it to cool off for 30 minutes Connect a hose to fuel richment circuit Pump compressed air to the circuit Replace the auto bv starter if the circuit clogged Connect battery posts 12V to starter s connectors After 5 minutes test the rich circuit with compressed air If air flow through the circuit then replace the starter automatic Removal by starter Remove fixing plate screw and then remove the plate and auto by starter from carburetor round point Valve inspection Check if auto by starter and valve needle for damage or wear out Installation Install auto by starter to the carburetor body Install fixing plate to the upper groove of auto by starter and install its flat surface to carburetor Install screw and tighten it MA Cautions Align the round point of the starter with the screw hole of air intake side 4 6 fixing plate valve needle
48. or Specification Unit mm Item Service Limit ID of starting driven gear 32 060 OD of starting clutch cover 27 940 Torque value Flywheel nut 3 9 4 5kgf m Exhaust muffler bolt 6 mm 0 7 1 1kgf m Oil screen cover 1 3 1 7kgf m Special service tools Flywheel puller Universal fixture 10 1 10 A C GENERATOR STARTING CLUTCH TGB A C GENERATOR REMOVAL Pulse generator Cooling fan shroud Drain out the engine oil Remove the exhaust muffler 2 bolts 2 nuts Remove the fan shroud Cooling fan shroud Remove the fan 4 bolts Hold the flywheel with the universal fixture Remove the nut on the fivwheel N en Universal fixture Special Service Tools k TAT Universal Fixture nd A 10 2 TGB 10 A C GENERATOR STARTING CLUTCH Remove the flywheel with the flywheel puller Special service tools Flywheel puller Shaft protector Caution Install a shaft protector on the right end of crankshaft to avoid damaging the crankshaft before installing the flywheel puller STOOL Flywheel puller Remove the connectors of the A C generator connector generator and pulse generator Pulse generator connector Remove the bolts for the pulse generator the A C generator coil Then remove the A C generator assembly Caution Do not damage the alternator coil RIGHT CRANKCASE COVER REMOVAL Remove the right crankcase cover 8 bolts Remove setting pin and gasket Remove the gask
49. r below 20mm of cylinder top Measure each piston ring gaps i Caution Push the piston rings into cylinder with piston top end in parallel motion Service Limit Top ring replace if over 0 50mm 2nd ring replace if over 0 650mm 7 CYLINDER PISTON TGB Measure the outer diameter of piston pin Service Limit 12 994mm Measure the inner diameter of connecting rod small end Service Limit 13 020mm Measure the inner diameter of piston pin hole Service Limit 13 040mm Calculate clearance between piston pin and its hole Service Limit 0 02mm Measure piston outer diameter Caution The measurement position is 10 mm distance from piston bottom side and 90 to piston pin Service limit 38 970mm Compare measured value with service limit to calculate the clearance between piston and cylinder 7 6 TGB 7 CYLINDER PISTON PISTON RING INSTALLATION Clean up piston top ring groove and piston shirt Install the piston ring onto piston carefully Place the openings of piston ring as diagram shown MA Caution e Do not damage piston and piston rings as installation e All marks on the piston rings must be forwarded to up side e Make sure that all piston rings can be rotated freely after installed Oil ring Side ring Over 20 mm Top groove 2nd groove Oil groove 7 CYLINDER PISTON PISTON INSTALLATION Install piston and piston pin and place the IN mark on the piston top sid
50. r circuit on the cooling system Too much carbon deposited in combustion chamber Lean mixture Poor fuel quality Ignition timing too advanced 1 GENERAL INFORMATION TROUBLE DIAGNOSIS TGB C Engine runs sluggish especially in low speed and idling Check and adjustment Fault condition Probable causes Check ignition timing using ignition lamp Adjust the air screw of carburetor 2 Lean mixture tighten the screw Air sucked through carburetor gasket Remove spark plug install spark plug into spark plug 1 Incorrect ignition timing malfunction of CDI or AC alternator Poor heat insulation gasket Carburetor lock loose Poor intake gasket Poor carburetor O ring Vacuum hose crack OP ODND cap and perform spark test Spark plug fouled Malfunction of CDI against engine ground Malfunction of AC generator Good spark Malfunction of ignition coil Open or short circuit in spark plug JAN leads Malfunction of main switch D Engine runs sluggish High speed Check and adjustment and Check and adjustment Fault condition condition Probablecauses Probablecauses Check ignition timing 2 Malfunction of AC alternator Check for fuel supplying system in automatic fuel cup oRON O 1 Insufficient fuel in fuel tank 3 Restricted fuel tank vent Check if carburetor clogged No clogged Clogged 1 Cleaning TGB 1 GENERAL INFORMATION TROU
51. r or damage final driving gear TGB Check bearings on the gear box cover 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 gear box amp cover tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Check oil seal for wear or damage and replace it if necessary Check driving shaft and gear for wear or damage BEARING REPLACEMENT i Caution Never install used bearings Once bearing removed it has to be replaced with new one Remove driving shaft bearing from left crankcase using following tools Inner type bearing puller Install new driving shaft bearing into left crankcase Tool Press the bearing into cover with C type hydraulic presser or bearing installer 9 FINAL DRIVING MECHANISM 9 3 9 FINAL DRIVING MECHANISM Press out the driving shaft from the crankcase Remove oil seal from the crankcase Remove the driving shaft bearing from the gear box cover with the inner type bearing puller Caution Using the bearing protector as pressing out the driving shaft from the gear box cover Specified tool Inner type bearing puller If the driving shaft is pulled out with its bearing then remove the bearing with bearing puller and bearing protector Tool Multi functional bearing puller Bearing protector Install a new driving shaft bearin
52. s the compressor too much Hold the clutch spring compressor onto bench vise and then remove mounting nut with special nut wrench Release the clutch spring compressor and remove clutch and spring from driven pulley Remove socket from driven pulley Socket Remove oil seal from driven pulley Remove guide pin guide pin roller and sliding pulley and then remove O ring amp oil seal seat from sliding pulley Oil seal Guide pin Guide pin roller INSPECTION Clutch outer Measure the inner diameter of clutch outer friction face Replace the clutch outer if exceed service limit Service limit 107 2 mm Inner diameter n Clutch outer TGB 8 V BELT DRIVING SVSTEM KICK STARTER ARM Clutch lining Measure each clutch lining thickness Replace it if exceeds service limit Service limit 2 0mm Clutch lining Driven pulley spring Measure the length of driven pulley spring Replace it if exceeds service limit Service limit 93 2mm Free length Driven pulley Check following items wi If both surfaces are damage or wear Paver DUBEY e If guide pin groove is damage or wear Replace damaged or worn components Measure the outer diameter of driven surface and the inner diameter of driven pulley Replace it if exceeds service limit Service limit Outer diameter 33 94mm Inner diameter 34 06mm Guide pin Sliding disc groove Driven Pulley Bearing Inspection Check if the inner bearing oil s
53. th feeler gauge After valve clearance had been adjusted to standard value hold adjustment bolt and then tighten the adjustment nut Standard Value 0 06 0 02mm With flat screwdriver turn the cam sprocket adjuster in counter clockwise motion so that the adjuster is pushed out to contact the cam chain plate tightly Apply with oil onto a new O ring and then install it onto the adjuster hole Tighten the bolt cap of the adjuster adjustment hole Caution The O ring must be installed into glove Replace the O ring of the cylinder head with new one Install the cylinder head Tighten the cylinder head lock bolts Connect the blow by hose onto the cylinder head Install the engine onto the engine frame Refer to Chapter 5 6 14 TGB 7 CYLINDER PISTON MECHANISM DIAGRAM PISTON REMOVAL PRECAUTIONS IN OPERATION PISTON RING INSTALLATION TROUBLE DIAGNOSIS PISTON INSTALLATION CVLINDER REMOVAL CVLINDER INSTALLATION MECHANISM DIAGRAM 0 8 1 2kgf m 7 1 7 CYLINDER PISTON TGB PRECAUTIONS IN OPERATION General Information e Both cylinder and piston service cannot be carried out when engine mounted on frame Specification unit mm Bend wrap age en 0 050 Cylinder Cylindrical 0 005 0 030 Clearance between 0 025 0 060 0 090 pistonirings 0 015 0 050 0 090 0 200 0 400 0 500 Ring end gap 0 250 0 400 0 650 Piston ring OD of piston 38 970 38 990 m n Lower end up 5mm Piston OD measurement position ee TTI Clearance b
54. the letters on the belt must be forwarded to assembiv direction TGB Sliding driven pulley clutch outer Clutch outer TGB 8 V BELT DRIVING SYSTEM KICK STARTER ARM SLIDING PULLEY REMOVAL Remove left crankcase cover Hold driving pulley with universal fixture and then remove driving pulley nut Remove driving pulley Remove the driving belt from the pulley Remove sliding pulley set and driving pulley hub from crankshaft Remove the belt and the starter gear Crankshaft Remove tilt plate Tilt plate Remove weight rollers from sliding pulley Roller 8 V BELT DRIVING SYSTEM KICK STARTER ARM TGB Inspection The operation of sliding pulley is means of Weight roller the weight roller to pressing on it with centrifuge force And then the speed is changed by the title plate rotation Thus if weight rollers are wear out or damage the centrifuge force will be effected Check if rollers are wear out or damage Replace it if necessary Measure each rollers outer diameter Replace it if exceed the service limit Service limit 15 92 mm Check the pulley hub if damaged or wear out Replace it if necessary Measure the pulley hub s outer diameter Replace it if exceed the service limit Service limit 20 025 mm Measure the pulley hub s inner diameter Replace it if exceed the service limit Service limit 20 028 mm Assembly Installation Install the weight rollers Insta
55. vaporation tem clogged Fuel supplied tom No fuel is supplied to gt l carburetor sufficient carburetor 9 Malfunction of fuel pump 6 Loosen or damaged fuel pump vacuum hose 7 Fuel filter clogged Remove spark plug install it into spark plug cap and perform a spark test against engine ground Malfunction of spark plug Spark plug foul Malfunction of CDI set Malfunction of AC generator Check if sparks Weak sparks no spark N nor at all Ignition coil is in open or short circuit 6 Ignition coil leads open or short j circuit perform cylinder l l l compression pressure test 7 Malfunction of main switch 1 Piston ring seized cylinder compression Low compression 2 Malfunction of cylinder valves pressure normal pressure or no pressure 3 Worn cylinder and piston ring 4 Cylinder gasket leak 5 Sand hole in compression parts Re start by following the starting procedures 1 Malfunction of throttle valve There are some signs of operation ignition nut engine can 2 Air sucked into intake manifold not be started 3 Incorrect ignition timing Remove the spark plug again and check it Dry spark plug Wet spark plug Remove carburetor after 30 minutes oRONM 1 Fuel level in carburetor too high 2 Malfunction of throttle valve operation 3 Throttle valve opening too wide and connect a hose onto fuel rich circuit Then blow the hose with air Blowing in normal Blowing c
56. with SEMI HVPOID GEAR OIL SAE 85W 140 Start engine and run it for 2 3 minutes Turn off engine and check if oil leaking 3 LUBRICATION SVSTEM TGB 4 CARBURETOR AIR CLEANER PRECAUTIONS IN OPERATION AUTO BY STARTER TROUBLE DIAGNOSIS FLOAT CHAMBER CARBURETOR REMOVAL INSTALLATION OF CARBURETOR 4 8 VACUUM CHAMBER IDLE SPEED ADJUSTMENT AIR CUT OFF VALVE AIR CLEANER PRECAUTIONS IN OPERATION General Information Warning Gasoline is a low ignition point and explosive materials so alwavs work in a well ventilated place and strictiv prohibit flame when working with gasoline MA Cautions e Do not bend or twist throttle valve cable Damaged cable will make unstable drivabilitv e When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly e There is a drain screw in the float chamber for draining residual gasoline e Do not disassemble automatic by starter and air cut off valve arbitrarily Specification Venturi diameter I D number Fuel level Idle speed 2200 100 rpm FUE dua 1 3 443 4 turns adjustment screw Torque value Fuel valve tightening nut 1 5 2 0 Kgf m Tool Special service tools Vacuum air pressure pump General service tools Fuel level gauge 4 1 4 CARBURETOR AIR CLEANER TROUBLE DIAGNOSIS Poor engine start No fuel in fuel tank Clogged fuel tube Too much fuel in cylinder No spark from spark plug malfunction of ignition
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