Royal Alloy TG300S ABS Maintenance Manual
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Royal Alloy TG300S ABS Maintenance Manual

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  • Page 2 Dear Users, Thank you for choosing the Royal Alloy brand scooter – TG300S. In order to make your driving safer and more comfortable, please read and fully understand the contents of this manual. This manual explains the structure, characteristics and maintenance of the motorcycle, as well as the main information such as the structure and maintenance of the engine EFI system, so that you can carry out regular maintenance operations of your vehicle.

  • Page 3: Table Of Contents

    Warning: Specific procedures implemented to prevent injury to persons. INDEX (1) Overview of characteristics ----------------------------------------------------------------------------------------- 4 (2) Tools ------------------------------------------------------------------------------------------------------------------------ 17 (3) Maintenance ------------------------------------------------------------------------------------------------------------- 22 (4) Electrical system ------------------------------------------------------------------------------------------------------- 48 (5) Engine removal --------------------------------------------------------------------------------------------------------- 55 (6) Engine disassembly --------------------------------------------------------------------------------------------------- 72 (7) EFI system ---------------------------------------------------------------------------------------------------------------- 89 (8) Braking system-------------------------------------------------------------------------------------------------------- 110 (9) Cooling system-------------------------------------------------------------------------------------------------------- 125 (10) Final inspection ----------------------------------------------------------------------------------------------------- 130...

  • Page 4: Overview Of Characteristics

    (1) Overview of characteristics Repair rules Vehicle identification Technical parameters Description of the variable speed system Lubrication system description Fuel system description Cooling system instructions Chassis and suspension system description Front and rear wheel description Description of the braking system Electrical system description Tightening torque...
  • Page 5 Repair rules 1. Must use parts and lubricants recommended by us or our company; Parts and lubricants that do not meet our design specifications may damage the motorcycle. Recommended oil brand model: Motul Scooter Expert Semi-synthetic 4-stroke SAE 10W/40-SJ. 2. When reassembled, new elastic washers, gaskets, O-rings, stand-up pins and retaining rings must be replaced. 3.
  • Page 6 Vehicle Identification: Frame number: engraved under the right pedal. Engine number: engraved on the rear gearbox.
  • Page 7 NOTE: These numbers are necessary for vehicle registration identification and changing the identification number may be severely punished by law, in particular modifying the chassis number will immediately void the warranty Technical details Vehicle parameters Engine parameters Model TG300S Engine model 1P75MN Vehicle size (mm).
  • Page 8 Front tyre 110/70-12 Maximum net 24.5/6000 specifications/inflation 32 PSI torque (Nm/r/min). pressure Rear tyre 120/70-12 Startup mode Electric start specifications/inflation 34 PSI pressure Front brake Disc brakes Ignition method EFI (Magneti Marelli). ± Intake valve: 0.10 Rear braking Disc brakes Valve clearance ±...
  • Page 9 Description of the variable speed system Items Description Variable speed transmission C V T + V-belt + final gear reduction gearbox 2.3～0.815：1 C V T gear ratio Final gear ratio 7.823 Overall gear ratio of the rear wheels 6.38～18 of the engine...
  • Page 10 Lubrication system description Items Quantit y Change 1200ml oil only total capacity Change 1250ml engine lubricating oil is oil and filter 1300ml element Grade: SAE10W-40-SJ Remove 1300ml engine fill it with oil Total capacity Change 200ml transmission lubricating transmission oil 250ml Grade: 75W-80 Remove 250ml engine...
  • Page 11 Fuel Items Description Fuel grade Unleaded gasoline above 95# Fuel tank capacity 10.5L Cooling system description Items Description When 1.15L replaced Coolant capacity When 1.20L disassembling Coolant or ethylene glycol antifreeze of the Recommended antifreeze same quality is mixed with distilled water at a 1:1 rate, the freezing point reaches -40 °...
  • Page 12 Chassis and suspension system description Items Description Chassis High-strength steel tubular chassis with single bar at the front and double brackets at the rear For ward tilt 26.30° Front suspension Adjustable preload, hydraulic , retractable fork Front suspension travel 70mm Rear suspension Adjustable preload,...
  • Page 13 Rear tyre inflation pressure 34/234（ Psi/KPa） Description of the braking system Items Description Braking system Front wheel brakes ¢220mm disc hydraulic brake Rear wheel brakes ¢220mm disc hydraulic brake Brake fluid FMVSS DOT4+ Electrical system description Items Description Batter y capacity 12V-9Ah Fuse 20-15-15-15A...
  • Page 14 Tail light (daytime light) License plate lights Brake lights Front and rear turn signals appearance Indicator dial light Turn warning lights High beam warning light Engine pressure warning light Low oil warning light EFI fault warning light...
  • Page 15 Tightening torque Fastening parts Quantity Thread specifications Torque: Nm Engine hanger mounting nut Engine mounting nut Front axle nut Rear axle nut Bolts are mounted on the rear shock absorber Bolts are installed under the rear shock absorber Fixed bolts above the front shock absorber Fixed bolts under the front shock absorber...
  • Page 16 Other specifications of bolt reference: GB1231-2006 bolt torque standard Engine section: Fastening parts Quantity Thread specifications Torque: Nm Head bolt A 24～26 10～12 Head bolt B 10～12 Camshaft cover fixing bolts Timing sprocket bolts 25～30 Exhaust pipe joint fixing bolts 12～14 Oil filter cover 9～12...

  • Page 17: Tools

    Other specifications of bolt reference: GB1231-2006 bolt torque standard (2) Tools 1. Special tools: (The following tools are only operated by professional technicians, and the owner is not allowed to operate without authorization). Item The name of the Tool Image dedicated tool number Valve...
  • Page 18 Crankshaft positioning bolts (top dead center positioning) Clutch drive wheel limiter Bearing punches of Z06.1--- various Z06.8 specifications...
  • Page 19 Oil seal punches of Z07.1-- various Z07.9 specifications Magneto rotor extractor Spark plug sleeve 8、 Troubleshooter 9、 Shock absorbers adjust the handles...
  • Page 20 2. General tools: Item Description T" sleeves: 8#, 10#, 12#, Toolbox 1...
  • Page 21 Toolbox 2 Circlip pliers Screwdriver Pliers...
  • Page 22 Nylon hammer multimeter...

  • Page 23: Maintenance

    (3) Maintenance Basic maintenance 1. Spark plug 2. Inspection and replacement of gear oil 3. Inspection and replacement of engine oil 4. Throttle handle adjustment 5. Clean air filter 6. Coolant inspection and replenishment 7. Braking system 8. Front headlight line inspection and adjustment: Preparation for maintenance 1.
  • Page 24 The maintenance schedule I: Inspection and cleaning, adjustment, fastening, adding, lubrication or replacement if necessary. C: Cleaning. R: Replace. The running-in period of motorcycles is 600miles/1000km, so the riding speed should not exceed 50mph/80km/h for first 1000km.
  • Page 25 Basic maintenance 1. Spark plug A. Removal and cleanup WARNING: Allow the engine and silencer to cool down before doing the following, to avoid the risk of burning. Support the middle brace of the locomotive, loosen and remove the three screws of the right guard plate (1), remove the right side panel (2), and find the spark plug cap (3).
  • Page 26 2. Remove the spark plug cap (3). 3. Remove the stain on the bottom of the spark plug with compressed air. Then use the spark plug wrench in the toolbox to unscrew it and remove it from the engine, taking care not to let dust or other substances enter the cylinder.
  • Page 27 5. Check the electrode spacing with a feeler gauge. The spacing should be 0.7 - 0.8 mm. Adjust the spacing by bending the ground electrode if necessary. B: Assembly fastening 1. Make sure the gasket is in good condition and fixed, and tighten it manually with the help of the spark plug sleeve (Z05).
  • Page 28 Reminder: 1. If the spark plug insulation material is cracked and the electrode corrosion is serious, the spark plug needs to be replaced. 2. Tighten the spark plug correctly, otherwise the engine may overheat and be damaged; Use only recommended spark plug models, otherwise engine duration and performance may be jeopardized. 2.
  • Page 29 2. Check whether the oil quantity is sufficient (see the technical data), if it is insufficient, it must be topped up. Visually observe the color of the oil, if it is black or has iron filings, change the oil immediately. 3.
  • Page 31 2. Tighten the bolt (3). Tightening torque: 16--20Nm 3. Add oil to the gearbox from the dipstick port (2) and tighten dipstick (2). 4. Check whether the oil quantity meets the specified requirements, and if it is insufficient, it must be supplemented to the specified amount.
  • Page 32 4. Wipe the oil on the dipstick (1) with a clean rag, insert the dipstick (1) into the dipstick port (be sure not to screw back in), take out the dipstick again (1) and observe whether the oil level is between "H" and "L".
  • Page 33 5. If the oil level is not close to the mark "H", please add a small amount of oil and wait for 5 minutes and check the oil level according to step (4) until it is close to the mark "H", screw in and tighten the oil dipstick (1).
  • Page 34 B: Replacement of engine oil 1. Support the main stand, loosen and remove the dipstick (1). Loosen and remove the oil drain bolt on the right box (2), drain the oil (prepare a suitable container in advance to collect the waste oil).
  • Page 35 (3) Replacement of oil filter Use an oil filter wrench to loosen and remove the oil filter (do not re-use) and install a new oil filter (3);...
  • Page 36 4. Screw in and tighten the bolt (2). 5. Add about 1250ml of oil from the inlet of the dipstick (1). 6. Screw in and tighten the dipstick (1). 7. After starting the engine and running for a few minutes, stop the engine and cool down. 8.
  • Page 37 4. Throttle handle adjustment The free travel of the throttle handle (4) should be 2-3mm, confirm and adjust as follows: 1. Slide out the protective cover (1). 2. Loosen the nut (3). 3. Rotate the bolt (2) to reach the specified value. 4.
  • Page 38 5. Clean air filter The air filter element is polyurethane foam, if the filter element is clogged with dust, it will cause increased intake resistance, decreased output power, and increased fuel consumption, and must be inspected, cleaned or replaced according to maintenance intervals. 1.
  • Page 39 2. Loosen and remove 8 screws (2) 3. Remove the air filter cover (3) and filter element (4). 4. Check whether the filter element (4) is damaged and replace it if necessary 5. Filter element (4) cleaning: • A suitably sized container is filled with a non-flammable water-soluble cleaning solvent and the filter element is immersed in the solvent for cleaning.
  • Page 40 • Do not twist or twist the filter element to avoid tearing the filter element. • Rinse in free-flowing warm water and dry the filter element with compressed air or a warm air dryer. • Soak the filter element in clean engine oil and squeeze the excess oil out of the filter element to allow the oil to slightly wet the filter element.
  • Page 41 6. Coolant inspection and replenishment WARNING: Allow the engine and silencer to cool down to avoid the risk of burning. Remove the left side panel by removing the 3 bolts (1). A: Water tank level inspection: 1. Loosen counterclockwise slowly but do not remove the tank cap (2). 2.
  • Page 42 5. Screw clockwise into the tank cap (2). B: Expansion tank liquid level inspection: Confirm that the coolant level of the expansion box (3) is between the MIN and MAX shown, otherwise add coolant. Add process: 1. Remove the plug (4) on the expansion box (3).
  • Page 43 2. Add coolant until the liquid level is close to the mark "MAX", do not exceed the mark "MAX", otherwise the coolant will overflow during engine operation. 3. Load the plug (4). Reminder: If the coolant transition loss or the expansion box is empty, check the cooling system for leaks. 7.
  • Page 44 1. Place scooter onto the main stand. 2. Check that the liquid level of the pump on the left and right brakes is above the marked "LOWER" scale line, if the liquid level is lower than the marked "LOWER" scale line, then check the friction shoe block and brake disc to confirm that there is no need to replace and add brake fluid.
  • Page 45 NOTE: To avoid the risk of brake fluid spillage, do not grip the brake lever after removing the 2 screws and mainly removing the upper pump cover. (b) Add brake fluid to the proximity mark "MAX" mark...
  • Page 46 Reminder: 1. Only in the case that the friction shoe block is new, the liquid level to mark "MAX", the brake fluid level will gradually decrease with the wear of the friction shoe block. 2. When the friction shoe block and brake disc have been worn but do not need to be replaced, the liquid level must not exceed the marked "MAX"...
  • Page 47 If the ABS indicator does not light up or the front and rear wheels move at the same time, the ABS light does not go out. 1. Check the gap between the front wheel Hall sensor (1) and the front wheel counting chainring ( 2), and ensure the gap is 1.0--1.6mm.
  • Page 48 2. Check the gap between the rear wheel Hall sensor (3) and the front wheel counting chainring (4), and ensure the gap is 0.5--1.6mm. If it is exceeded, check and adjust the position of the Hall sensor (3).
  • Page 49 8. Front headlight line inspection and adjustment: A: Quick check of light light 1. Place the motorcycle as shown flat on floor [not on stand], making sure to distance 10m from the vertical wall and the ground level. 2. Turn on the dipped beam, sit on the locomotive, and detect that the light of the lamp shining on the wall should be a little below the horizontal straight line of the headlight (about 9/10 of the total height).
  • Page 50 B: Adjustment of headlights Use a No. 5 inner hexagonal wrench to loosen the headlight adjustment bolt (1); Pushing the bolt in the R direction (1) lowers the headlight line, and when pushing the bolt in the direction F (1), the headlight line is raised.

  • Page 51: Electrical System

    4. Electrical systems First, the arrangement of electrical components:...
  • Page 53 1. Headlights; 2. Horn; 3. Front left and right turn signals; 4. Wheel speed sensor; 5. ABS unit; 6. Water temperature sensor; 7. Fan; 8. Side stand cutout switch; 9. Oil pressure sensor; 10. Rear left and right turn signals; 11. Rear tail light; 12. Throttle body and control unit assembly; 13. Spark plug; 14. Battery; 15. Left handle switch;...
  • Page 54 Second, the indication of the dashboard 1. Time indication; 2. Bluetooth; 3. Engine speed indication; 4. Atmospheric temperature; 5. Speed indication; 6. Water temperature indication; 7. Single travel time; 8. Total mileage; 9. Right turn indicator; 10. Oil pressure warning light; If it is long and bright while driving, it needs to be repaired or consult a dealer;...
  • Page 55 13. ABS fault warning light, if it is long on during driving, it needs to be inspected/repaired consult the dealer. 14. Water temperature warning light: if it is long on during driving, it needs to be repaired or consult the dealer; 15.
  • Page 56 5. Wiring harness diagram...
  • Page 57 The wiring harness schematic...

  • Page 58: Engine Removal

    4. Engine removal NOTE: Wash the engine thoroughly with an appropriate cleaner before removing engine associated parts. First, remove the left and right guards 1. Remove 6 bolts (1) and remove the right panel (2) and the left panel (3). Second, remove the centre cover / hoop.
  • Page 59 1. Loosen and remove 2 bolts (2), remove the seat cushion (1), loosen and remove 2 bolts (3). 2. Loosen and remove 1 bolt (4), remove the battery cap plate (5), loosen and remove 2 bolts (6). 3. Loosen and remove the 4 bolts (7) and remove the luggage rack (8).
  • Page 60 4: Loosen and remove the two nuts (Fig. 9) and remove the rear taillights (Fig. 10). 5、Loosen and remove the 2 bolts (Figure 11) and remove the middle cover.
  • Page 61 Third, remove the fuel tank 1. Disconnect the oil pump plug (1) and the oil level sensor plug (2); 2、Remove 3 relays (3), loosen and remove 1 bolt (4), remove the relay bracket;...
  • Page 62 3. Loosen and remove 4 bolts (5) (6) and remove the battery holder; 4. Loosen and remove the 2 bolts (7), remove the bolt securing the ABS (8), and insert the key (9) into the tank lock (10) Rotate counterclockwise together with the lock cover to remove the tank lock, loosen the clamp and pull out the air pipe (11).
  • Page 63 6、Remove the tank by pinching and unplugging the high-pressure tubing quick coupling (Figure 12) by hand.
  • Page 65 Remove the fuel evaporation system 1. Loosen the clamp (1), pull out the air pipe (2), loosen and remove 1 bolt (3), and remove the carbon canister; Reminder: Each tubing in the system does not need to be disassembled, if it is disassembled and assembled, pay attention to: connect the tilt valve arrow direction to the carbon canister "TANK"...
  • Page 66 5. Remove the air filter 1. Unclamp (1) and separate the air pipe (2), Twist the clamp (5) to separate the air filter outlet pipe (6) 2. Loosen and remove 3 bolts (5), remove the air filter;...
  • Page 67 6. Remove the exhaust system 1. Loosen but do not remove the clamp bolt (1), loosen and remove the bolt (2)
  • Page 68 2. Loosen but do not remove the 2 bolts (3), remove the silencer (4) Reminder: Check the graphite sleeve after each disassembly of the silencer (6), and replace the inner hole if it is damaged or broken.
  • Page 69 3. Disconnect the oxygen sensor plug (8) 5. Remove 2 nuts (7) and remove the exhaust pipe;...
  • Page 70 NOTE: When reassembling, screw in the 2 nuts (7) and bolts (2) initially but do not lock, and then lock the 2 nuts (7) after the clamp bolt (1) is locked and bolts (3). 7. Drain the coolant 1. Loosen the clamp bolts (1, 3), slide out the water pipe (Figs. 2, 4), and collect the coolant into the container prepared in advance.
  • Page 71 Reminder: Removing the expansion box cap helps coolant drain. Raising the front wheels at least 55cm above the ground allows optimum drainage of coolant in the system circuit. 8. Remove the connecting plug 1. Pull out the spark plug cap (1) 2.
  • Page 72 3. Disconnect the injector plug (3) 4. Disconnect the cable plug of the starter motor (4) 5、disconnect the magneto plug (5) and disconnect the regulator plug (6) 6. Disconnect the ECU plug (7)
  • Page 73 7. Loosen the clamp (8) and remove the throttle body (9) 8. Loosen and remove the bolt (10), remove the grounding wire; Remove the grounding wire and tighten the removed bolt to prevent loss;...
  • Page 74 9. Remove the rear wheel 1. Loosen and remove the bolts (1 and 2), remove the right rear shock absorber (3); 2. Loosen and remove the four bolts (4) (5) and nuts (6), and remove the rear flat fork (7); 3.
  • Page 75 Reminder: The bolt thread part of (13) is coated with Loctite 243 thread glue when reassembling; Tightening torque: 60Nm. 4. Loosen and remove 2 bolts (11), remove bushings (12) and brake discs (13); 10. Remove the engine 1. Loosen and remove 1 bolt (1) to remove the left rear shock absorber from the frame; loosen and remove the engine fixed shaft nut (2), do not remove the fixed shaft;...
  • Page 76 2. Reconfirm that the connection of the engine has been removed, remove the shaft, and remove the engine. 11. Reassembly Reminder: The reassembly is carried out according to the above reverse process, according to the required...

  • Page 77: Engine Disassembly

    tightening torque (5) Engine disassembly and maintenance NOTE: Clean the engine thoroughly with an appropriate cleaner before disassembling it so that impurities do not enter the inside of the engine. Basic principles: 1. Replace rubber parts In principle, if the engine is disassembled for more than 2 years, it is recommended to directly replace the rubber parts such as oil seals and O-rings, and check the crankshaft oil seal (F2) and the drive shaft oil seal (1) within 2 years Whether the lip is damaged or aged, otherwise replace.
  • Page 78 4. Oil packaging and matching principle If the oil seal is conditionally c o a t e d w i t h a little anaerobic glue on the A side when replacing, the B side at the bottom of the oil seal is the stressed surface, and the uniform force should be ensured when tapping, and a little butter should be applied to the lips when replaced;...
  • Page 79 First, check and adjust the compression pressure: insufficient compression pressure will lead to insufficient power or difficulty in starting. 1． Check: Valve clearance, exceeding the specified value = > adjustment, see section "Valve clearance adjustment". Start the engine, warm up for a few minutes and shut down. 2.
  • Page 82 3． Remove: Spark plug. Note: Before removing the spark plug, blow off the surrounding dirt with compressed air to prevent it from falling into the engine. 4． Installation: Pressure gauge (1). 5． Measure: Compression pressure, start the engine when the throttle is fully open until the compression reading is stable.
  • Page 83 As shown in the following table: Compression pressure (injection of oil into the cylinder) reading diagnosis Higher than when there is The piston is worn or damaged no oil Same as when there is no Piston rings, valves or seals of cylinder heads or pistons can be damaged = >...
  • Page 85 Third, drain oil and refuel 1. Drain oil from the gearbox Loosen and remove the gearbox drain bolt (3) and drain the oil (prepare a suitable container in advance to collect the gear oil).
  • Page 86 Reassembly Notes: (1) Rear gearbox: 75W /80 lubricating oil 200 C C . (2) The tightening torque of the oil drain bolt (3) is 25N • m 2. Oil drainage from crankcase Loosen and remove the crankcase drain bolt (2) and drain the oil (prepare suitable containers in advance to collect the oil).
  • Page 87 Reassembly Note : (1) Crankcase: 10 W /40 lubricating oil 1000C C , it is recommended to use the grade APL SJ above grades. The tightening torque of the drain bolt (2) is 24 to 30N • m Fourth, the adjustment of valve clearance: 1.
  • Page 89 2、 Check with a thick gauge that the gap between the valve and the adjustment gasket meets the specified value. If the intake and exhaust valve clearances are different from the following specified values, loosen the locknuts according to the figure and adjust the valve clearance. Intake valve (cold engine state): 0.10mm Exhaust valve (cold state): 0.1to 5mm 5.
  • Page 90 6. Disassembly and assembly inspection of CVT 1. Lock the clutch cover of the driven pulley with a special tool. Remove the nut, clutch cover, and driven pulley assembly. Check the cleanliness of the belt cavity and blow the air gun to clean all dust (A&B&C) from all parts of the cavity.
  • Page 91 2. Check whether the clutch cover is worn or damaged. Measure the inner diameter of the clutch cover. Standard value: ¢134+0.2 /0mm Maximum: ¢134.5mm Note: Check eccentricity: 0.20mm max. 3. Inspection and installation of clutch ‘shoe’ Check the minimum thickness of the friction material of the shoe piece, the minimum thickness: 1mm.
  • Page 92 Minimum allowable diameter: ¢40 950mm Standard diameter: ¢41(-0.015/-0.035)mm 5. Remove 2 leather bowls and 2 sealing rings, and measure the inner diameter of the sliding sleeve of the moving driven disk Maximum permissible diameter: ¢41.08mm Standard diameter: ¢41(+0.035/0)mm 6. Check the transmission belt for damage Check belt width: Minimum width: 19.5mm Standard value: 21.3±0.2mm 7.
  • Page 93 measure the inner diameter A. Maximum permissible diameter: φ26.12mm Standard diameter: φ26 (+0.021/0) mm Note: Never lubricate or clean the bushing. (2) The outer diameter B of the active roller slide sleeve indicated in the measurement drawing. Minimum permissible diameter: ¢25 95mm Standard diameter: ¢26(-0.02/ -0.041)mm (3) Check whether the roller is damaged or worn.
  • Page 94 7. Maintenance of the engine 1. Starting the engine should gently operate the throttle to start. After 30~60s of operation, it will be moderately opened. Do not accelerate immediately after the cold engine starts, wait for 1~3min of operation before accelerating. 2.

  • Page 95: Efi System

    the occurrence of burning engine oil or insufficient power. (6) EFI system This model uses Magneti Marelli EFI system, the schematic diagram is as follows:...
  • Page 98 The fuel supply circuit consists of oil pump assembly (including filter, pressure regulator), high-pressure oil pipe and fuel injector; The ignition circuit consists of ECU, high-voltage coil, high-voltage wire, spark plug cap and spark plug. 1. Instructions for the maintenance of EFI system 1.
  • Page 99 • Disconnect the plug-in connection between the oil pump assembly harness and the vehicle wiring harness; • Start the engine until the engine automatically goes out, then turn on and off the ignition key 2-3 times in a row, each time with an interval of 3 seconds, and then turn off the key switch; •...
  • Page 100 1. Fault information recording The electronic control unit continuously monitors the sensor, actuator, related circuit, fault indicator and battery voltage, etc., and even the electronic control unit itself, and detects the reliability of the sensor output signal, actuator drive signal and internal signals (such as lambda closed-loop control, cylinder temperature/coolant temperature, idle speed control and battery voltage control, etc.).
  • Page 101 P0135 Lambda sensor heater Oxygen sensor heater P0201 Injector nozzle P0230 Fule pump relay Oil pump relay P0335 Engine rpm sensor Engine speed sensor P0351 Coil high tension Ignition voltage P0480 Fan relay Fan relays P0505 Idle control actuator Idle control unit P0530 Light relay Headlamp relays...
  • Page 102 after the engine starts successfully. (2) When the current fault code is present At the time of engine operation, if the current fault occurs, the fault light changes from off to continuous on, alerting the driver that a fault has occurred. When the engine is extinguished, the current fault is converted into a historical fault and stored in the EFI ECU.
  • Page 103 (1) Connect the diagnostic instrument to the diagnostic interface on the EFI harness;...
  • Page 104 (2) Turn on the ignition switch; (3) Read the fault code; Check the maintenance manual to confirm the faulty part and type; Develop maintenance plans based on inquiry information and experience; (4) After troubleshooting, use the fault diagnostic instrument to clear the historical fault code. 5.
  • Page 105 (2) Check with a fault diagnostic instrument to confirm that there is no fault information record; (3) Confirm the existence of the fault phenomenon complained by the owner, and confirm the conditions under which the fault occurs. B. Then conduct visual inspection: (1) Check whether the fuel pipeline is leaking;...
  • Page 106 General diagnostic process: Item Detection steps Next steps Use a multimeter to check the voltage between the two terminal posts of the Replace battery to see if it is about 9-12V when the engine is started. battery The ignition switch is kept in the starting position, and check with a multimeter Check the wiring whether the terminal post of the positive terminal of the starting motor has a related...
  • Page 107 mechanical part. General diagnostic process: Item Procedure Next steps Connect the EFI system diagnostics, observe the "engine Overhaul the speed sensor speed" data item, start the engine, and observe whether circuit and speed sensor there is a speed signal output. Remove the spark plug cap, attach the spark plug, put the spark plug on the engine body, start the engine, and Overhaul the ignition system...
  • Page 108 Remove the injector from the intake pipe (the oil circuit Overhaul injector lines and and wiring harness connectors are not removed), start the injectors engine, and check for fuel injection. (iii). Difficult to start. General fault parts: 1. Fuel contains water; 2. Fuel pump; 3. Coolant temperature sensor; 4. Injector; 5. Ignition coil;...
  • Page 109 Remove the spark plug cap, attach the spark plug, put the spark plug on the engine body, start the Overhaul the ignition system engine, and check for strong spark. Gently add the throttle and observe if it starts Clean the throttle and idle airways easily.
  • Page 110 5. Air intake; 6. Idle speed regulator; 7. Ignition timing; 8. Spark plug; 9. Engine mechanical part; 10. Coolant temperature (cylinder temperature) sensor. General diagnostic process: Item Procedure Next steps remark Check that the air filter is not blocked and that Overhaul the air intake there is no air leakage in the intake system.
  • Page 111 Troubleshoot engine mechanics (pay attention Check the engine cylinder pressure to see if there check whether is sufficient cylinder pressure. engine valve clearance is too small) Check that the ignition sequence and ignition Overhaul ignition timing timing of the engine meet the specifications. Check the injector for leaks, blockages, or out-of- Replacement of faults specification flow.
  • Page 112 4. Ignition timing. General diagnostic process: Item Procedure Next steps Check if the throttle cable is stuck or too tight, causing the throttle adjust to not close completely. Overhaul the air intake Check the intake system for air leaks. system Remove the idle regulator and check for carbon deposits in the Cleaning of related throttle body, idle regulator, and idle bypass airway.
  • Page 113 General diagnostic process: Item Procedure Next steps remark Overhaul the air Check the air filter for blockages. intake system Connect the fuel pressure gauge, start the engine, and Overhaul the oil check whether the fuel pressure of the engine is about supply system 250kPa under full working conditions.
  • Page 114 Check that the fuel label (and whether it contains Change the fuel ethanol) meets the requirements of the whole vehicle. Check that the ignition sequence and ignition timing of Overhaul ignition the engine meet the specifications. timing Repair or replace Check whether the exhaust pipe is exhausted smoothly.
  • Page 115 2. Press the push-in connector button with both fingers at the same time to pull out the push-in connector. 3. Disconnect the injector connector...
  • Page 116 4. Disassemble the bolt and remove the injector. 5. Assemble according to the above reverse process during assembly.
  • Page 117 Fourth, the disassembly and assembly of the throttle body 1. Remove the fuel tank 2. Disconnect the plug 3. Disconnect the throttle line (1).
  • Page 118 4. Loosen the clamp between the air filter and the throttle body (2), and loosen the clamp connecting the throttle body and the intake manifold (3). 5. Remove the throttle body (4). 6. Assemble according to the above reverse process during assembly.

  • Page 119: Braking System

    (7) Braking system: The scooter is equipped with a two channel ABS brake system: one front disc brake, one rear disc brake, ABS integrated unit. Operate the right brake lever to apply pressure to the front caliper. Operate the left brake lever to apply pressure on the rear caliper.
  • Page 120 First, the front brake calipers and brake discs are removed: 1. Place scooter on main stand, loosen and remove the bolts (1). Tightening torque M8: 25Nm.
  • Page 121 2. Loosen and remove the front wheel axle bolt (2) and remove the front wheel. Tightening torque M12: 60Nm. 3. Loosen and remove 3 bolts (3), remove the brake disc (A) and the ABS rotor (B). Reminder: The bolt thread part of Figure 4 is coated with Loctite brand 243 thread glue when reassembling; Tightening torque M8: 25Nm.
  • Page 122 4. Loosen and remove 2 nuts and 2 built-in bolts (4). Remove 2 friction pads (5).
  • Page 123 Reminder: Do not operate the brake lever after the friction pad(s) is/are removed, otherwise the caliper plunger will come out and cause brake fluid leakage. 6. The inspection and replacement of friction pads and brake discs are described in Part III below. Note: Reassembly is carried out according to the reverse process above.
  • Page 124 2. Loosen but do not remove the bolt (2).
  • Page 125 3、Loosen and remove the bolts (3).
  • Page 126 4. Loosen but do not remove the 2 bolts (4) and remove the silencer. 5. Loosen and remove the bolts (5 and 6), and remove the right rear shock absorber (7).
  • Page 127 6. Loosen and remove the bolts (8, 9) and nuts (10), and remove the rear flat fork (11). NUT (10) TIGHTENING TORQUE: 100NM...
  • Page 128 7. Hold the left brake lever (12), loosen and remove the 5 bolts (13), and remove the rear wheel. Tightening torque Reminder: The bolt thread part of Figure 4 is coated with Loctite brand 243 thread glue when reassembling; Tightening torque: 60Nm.
  • Page 129 8: Loosen and remove the 2 bolts (14) to remove the brake disc and rear calipers. Tightening torque M8: 25Nm.
  • Page 130 10. Remove the clamp (15), pull out the pin shaft (16), remove the spring plate (17), and pay attention to the spring plate (17) to assemble it in the direction of the drawing. Remove the friction hoof block (18). Reminder: Do not operate the brake lever after the friction shoe block is removed, otherwise the caliper plunger will come out and cause brake fluid leakage.
  • Page 131 12. The inspection and replacement of friction shoe blocks and brake discs are described in Part III below. Note: Reassembly is carried out according to the reverse process above. Third, the front and rear friction shoe block and brake disc inspection 1.
  • Page 132 (3) Use a dial indicator to measure the runout of the brake disc, and replace it if it exceeds the tolerance limit (0.3mm). 2. Rub the shoe block to check and replace (1) Figure 2 is the front brake friction shoe block, and Figure 3 is the rear brake friction shoe block. (2) Measure the thickness of friction materials with vernier depth calipers (Figure 2 and Figure 3), as long as the thickness of one friction material is reduced to 1.5mm, two friction shoe blocks need to be replaced at the same time.
  • Page 133 1. Front brake fluid system (1) Pull out the rubber cap of the bleed valve (1). (2) Insert a plastic transparent tube (3) into the bleed valve (2), and a container is connected to the other end of the tube (3) to collect the discharged brake fluid. (3) Quickly press and release the right brake lever several times, and then press the right brake lever hard without letting go.
  • Page 134 lever until the end of the stroke. (5) Repeat the above operation until there are no bubbles in the brake fluid entering the container. Reminder: During the operation, always check the brake fluid level in the upper pump reservoir, and add it in time can not be drained, otherwise bubbles will be generated in the pipeline.
  • Page 135 2. Rear brake fluid circuit The same as the removal process of the brake fluid circuit. 3. Brake fluid replacement 1. Replace the front brake fluid (1) Pull out the rubber cap of the bleed valve (1);...
  • Page 136 (2) Insert a clear plastic through tube (3) into the bleed valve (2), and a container is connected to the other end of the tube (3) to collect the discharged brake fluid. (3) Quickly press and release the right brake lever several times, and then press the right brake lever hard without letting go.

  • Page 137: Cooling System

    4. Replace the rear brake fluid Same as previous brake fluid replacement process. 5. Cooling system 1. System composition:...
  • Page 138 Second, coolant replacement 1. Drain the coolant...
  • Page 139 (1) Remove 6 bolts (1) and remove the right guard plate (2) and the left guard plate (3). (2) Loosen the clamp bolt (4) and slide out the water pipe (5) to collect the coolant into the container prepared in advance.
  • Page 140 Reminder: Removing the expansion box cap helps coolant drain. Raising the front wheels at least 55cm above the ground allows sufficient drainage of coolant in the system circuit.
  • Page 141 2. Fill with coolant (1) Replace the outlet pipe (5) and tighten the clamp bolt (4). (2) Fill the expansion box with coolant until the liquid level reaches the "MAX" reference scale (3) Fill the tank with coolant until it is topped up and covered with the tank lid (2).
  • Page 142 (4) Start the engine and run at idle until the fan works. (5) Turn off the engine and cool down sufficiently (about 12 hours). (6) Check the liquid level position of the expansion tank and water tank again, if necessary to add to the correct liquid level.

  • Page 143: Final Inspection

    Final inspection After the repair and maintenance of the whole vehicle, before normal riding, perform the following checks: 1. Visual inspection 1. The paint surface of the leaky parts 2. Assembly of leakage plastic parts 3. Bumping, scratching 2. Second, tightening torque inspection 1.
  • Page 144 1. Key switch 2. Headlights: high beam, low beam, position light, warning light 3. Adjust the low-beam light line of the headlamp according to the regulations 4. Front and rear brake switches and brake lights 5. Left and right turn switches and left and right turn signals 6.
  • Page 145 3. Sensitivity of throttle control 4. Stability of acceleration and braking 5. The effect of front and rear braking: TG125S with/without ABS, TG300S with ABS 6. The effect of front and rear shock absorption 7. Whether there is abnormal noise and or vibration 6.

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