Table Of Contents - TGB BLADE 600 Service Manual

Table of Contents

How To Use The Manual3
General Information3
Table Of Contents4
Serial Number5
Frame Number5
Engine Number5
General Information Contents6
Symbols And Marks6
General Safety7
Service Precautions8
Specifications14
Lubrication System14
Torque Values18
Standard Torque Values For Reference18
Engine Torque Values18
Frame Torque Values19
Engine Hard To Start Or Can Not Be Started20
Engine Run Sluggish21
Clutch, Driving And Driving Pulley23
Poor Handling23
Oil And Lubrication Points25
Brake Fluid25
Grease25
Gear Oil26
Maintenance Information Contents27
Precautions In Operation27
Periodical Maintenance Schedule28
Fuel Lines29
Acceleration Operation29
Air Cleaner29
Spark Plug29
Valve Clearance30
Carburetor Idle Speed Adjustment31
Emission Adjustment In Idle Speed31
Ignition System32
Cylinder Compression Pressure32
Drive Belt33
Maintenance Information33
Brake System (Disk Brake)34
Filling Out Brake Fluid34
Air Bleed Operation34
Brake Light Switch/Starting Inhibitor Switch35
Brake Lining Wear35
Brake Lining Replacement35
Headlight Beam Distance36
Clutch Shoe Wear36
Cushion36
Steering Handle37
Wheel/Tire37
Nuts, Bolts Tightness37
Appointed Tire Pressure37
Special Tools List38
Lubrication System Contents43
Mechanism Diagram43
Engine Oil45
Engine Oil Strainer Clean45
Replace The Oil Filter45
Oil Pump Removal46
Oil Pump Disassembly46
Oil Pump Inspection47
Oil Pump Re-Assembly47
Oil Pump Installation48
Fuel Injection System Contents49
Fuel Injection System Components49
Precautions In Servicing50
General50
Fuel System50
Connector/Coupler51
Fuse51
Ecu/Various Sensors51
Electrical Circuit Inspection Procedure52
Open Circuit Check52
Continuity Check53
Voltage Check53
Short Circuit Check54
Parts Location56
Wiring Diagram57
Ecu Terminal58
System Troubleshooting Customer Compliant Analysis59
Efi System Components Inspection61
T-Map Sensor61
Ect Sensor Inspection62
Ect Sensor Removal/Installation63
Tp Sensor Inspection64
Vehicle Speed Sensor65
Injector66
Injector Inspection67
Injector Removal67
Injector Installation67
Crank Position Sensor68
Ignition Coil69
Throttle Body Removal, Disassembly And Assembly70
Pressure Regulator Removal/Installation71
Roll Over Sensor Inspection, Removal And Installation72
Ecu Removal And Installation73
Power Input Line73
Fuel Line Inspection74
Fuel Pressure Inspection74
Fuel Flow Inspection76
Fuel Pump Inspection76
Fuel Pump Removal77
Fuel Filter Replacement77
Fuel Filter Installation77
Fuel Pump Relay Connection77
Fuel Tank/Reservoir Removal78
Sensor Circuit Troubleshooting79
Cps Sensor Circuit Malfunction79
Sensor Inspection79
T-Map Sensor Circuit Malfunction81
T-Map Inspection81
Tp Sensor Circuit Malfunction83
Ect Sensor Circuit Malfunction87
Ignition System Malfunction90
Troubleshooting90
Fuel Injector Circuit Malfunction92
Fp Relay Circuit Malfunction94
Fp Relay Inspection94
Roll Over Sensor Circuit Malfunction95
Roll Over Sensor Inspection95
Idle Speed Controller Circuit Malfunction98
Idle Speed Controller Inspection98
Fault Diagnosis100
Efi Circuit Inspection100
Can Not Start The Engine Or Difficult To Start Inspection101
Idle Flameout Diagnosis102
Integrated Fault Diagnosis Program103
Fault Diagnosis Note104
Fault Code And The Sensors Of The Table105
Use Diagnosis Tool107
Method Of Use107
Vehicle Info108
Diagnostic Trouble Code109
Current109
History109
Freeze Data110
Erase Dtc111
Live Data112
Actuator112
Special Function113
Troubleshooting Table115
Comprehensive Maintenance List116
Engine Removal Contents117
Engine Removal118
Engine Installation125
Engine Disassembly128
Cylinder Head/Valve Contents130
Cylinder Head Removal133
Cylinder Head Inspection136
Camshaft136
Rocker Arm137
Rocker Arm Shaft137
Valve Spring Free Length137
Valve Stem137
Valve Guide138
Valve Stem Replacement139
Valve Seat Inspection And Service140
Valve Seat Width140
Valve Seat Grinding140
Cylinder Head Reassembly142
Cylinder Head Installation143
Valve Clearance Adjustment145
Cylinder/Piston Contents146
Trouble Diagnosis147
Cylinder And Piston Removal148
Cylinder And Piston Inspection148
Remove Piston Rings149
Piston Ring Installation151
Piston Installation152
Cylinder Installation152
V-Belt Driving System Contents154
Maintenance Description155
Clutch Cover Removal156
Clutch Cover Installation156
Clutch Cover Inspection156
Drive Belt Removal And Inspection157
Drive Belt Installation158
Drive Face Removal159
Drive Face Inspection160
Drive Face Reassembly/Installation160
Driven Pulley Installation161
Clutch Outer/Driven Pulley Disassembly162
Clutch Outer Inspection162
Driven Pulley Spring Inspection163
Driven Pulley Inspection163
Installation Of Clutch Outer/Driven Pulley Assembly164
Front Drive (Front Differential)166
Drive System167
Front Drive167
Wheel Hub Removal167
Wheel Hub Inspection167
Drive Shaft Removal, Inspection And Installation168
Drive Shaft Boot Removal168
Front Differential168
Drive Shaft Boot Installation169
Front Differential Removal169
Front Differential Disassembly170
Front Differential Assembly173
Lock Mode Cable Adjustment174
2Wd/4Wd Mode Cable Adjustment174
Front Differential Installation175
Differential Motor Installation175
Rear Drive (Rear Differential)176
Rear Differential Removal177
Rear Differential Installation178
Rear Differential Disassembly180
Rear Differential Assemble182
Lock Mode Assy. Disassemble183
Lock Mode Assy. Assemble184
Rear Differential Adjustment185
Pivot Gear Disassemble186
Pivot Gear Assemble187
Differential Motor Removal And Installation187
Alternator/Starting Clutch Contents188
Left Crankcase Cover Removal190
A.c.g. Set Removal190
Left Cover Bearing Inspection190
Flywheel Removal191
Alternaotor/Starting Clutch192
One Way Clutch Removal193
One Way Clutch Installation193
Flywheel Installation194
A.c.g. Set Installation195
Left Crankcase Cover Installation195
Crankshaft/Crankcase198
L Case198
R Case198
Oil Seal199
Oil Separator199
Bearing Reasembly200
Drive Belt Cover201
Drive Belt Cover Reassembly201
L Crank Case Cover202
L Crank Case Assembly202
L Crank Case Reassembly203
Crankshaft204
Balancer204
Oil Pump206
Oil Pump Drive Gear207
Cam Chain207
Clutch Shoe207
Neutral Switch208
Clutch Case208
Air Defector And Fixed Drive Face209
Movable Drive/Driven Face And Drive Belt209
Clutch Cover210
Oil Filter210
Water Pump Gear211
Generator212
Gearshift213
Starter Driven Gear/Idle Gear213
Left Crankcase Cover213
Speedometer Gearbox214
Water Pump214
Starter Cup215
Gearshift For Parking216
Cooling System218
Trouble Diagnosis For Cooling System219
System Test221
Test On The Filler Cap221
Change Of Coolant221
Radiator Check And Removal222
Check Reserve Tank222
Radiator Disassembly, Assembly And Installation223
Check Water Pump Seal / Cooling System Divulges Inspection224
Removal Of Water Pump224
Thermostat Removal And Inspection225
Thermostat Technical Data225
Thermostat Installation225
Oil Radiator Check And Installation226
Blade Model Mechanism Diagram228
Body Cover228
Blade Model Maintenance229
Target Model237
Body Covers Dissemble Sequence238
Brake243
Front Brake243
Rear Brake/Rear Wheel/Rear Cushion244
Brake Specifications245
Brake System Service Notes246
Brake Light Switch Location247
Brake Light Switch Continuity Test247
Brake Light Switch Replacement247
Master Cylinder Removal248
Master Cylinder Inspection248
Master Cylinder Installation248
Caliper Removal249
Caliper Installation249
Brake Pads Replacement250
Brake Disc Inspection250
Brake Disc Replacement250
Steering System251
Eps Model251
Non Eps Model252
Steering System General253
Procedures254
Handlebar Cover Removal254
Handlebar Cover Inspection254
Handlebar Cover Installation254
Handlebar Removal255
Handlebar Inspection255
Handlebar Installation255
Steering Shaft Removal256
Steering Tie-Rod Assembly257
Wheel And Tire General258
Wheels Removal And Installation258
Tire Pressure258
Tire Inspection And Replacement258
Front Suspension259
Front Suspension General260
Shock Absorber Removal260
Shock Absorber Installation261
Lower Arm Removal261
Lower Arm Installation261
Upper Arm Removal262
Upper Arm Installation262
Rear Suspension263
Rear Suspension General264
Tension Bar Removal265
Tension Bar Installation265
Eps (Electric Power Steering)268
(Eps) Electric Power Steering General269
System Descriptio269
Eps Assist Mode269
De-Rating Explanation269
Eps System Description270
Eps Unit270
Eps Unit Protection270
Steering Torque Sensor270
How To View Eps Mode Selection271
How To Change Eps Mode271
Eps Unit System Description272
Torque Offset Reset Adjustment272
Eps Unit Power Fuse Test274
Eps Unit Input Voltage Test275
Eps Unit Ground Circuit Test276
Eps Unit Communication Link (Can)276
Ps System Load Test277
Eps Unit Current Test278
Eps Unit Removal279
Steering Lower Bearing Seat281
Control Unit Removal281
Fuse Removal282
Fuse Installation282
Electrical System Contents283
Maintenance Data284
Technical Specification284
Battery Removal286
Battery Charging286
Charging System287
Charging Circuit287
Current Leakage Inspection287
Inspection On Charging Voltage288
Inspection On Regulator Rectifier289
Ignition Circuit Diagram290
C.d.i Unit290
Inspection On Ignition Coil291
Ignition Coil Replacement291
Inspection Of Pulse Generator291
Starting System292
Starting Circuit Diagram292
Inspection On Starter Relay292
Removal Of Starter Motor293
Installation Of Starter Motor293
Meters Removal294
Light / Bulb295
Replacing Bulb For Headlight295
Replacing The Front Winker Light Bulb296
Replacing Bulb Of Position Light296
Replacing Bulb Of Taillight297
Rear Winker Light297
Replacing Bulb Of License Light297
Switch / Horn298
Handle Switches298
Start Switch298
Headlight Switch299
Winker Switch299
Horn Switch299
Hazard Switch299
Lock Switch300
Front Brake Switch301
Rear Brake Switch301
Horn301
Fuel Unit302
Function Of Over-Ride302
Cooling Fan Switch303
Thermo Unit304
Water Temperature Indicator Light304