User Manuals: TGB BLADE 600 Heavy Duty ATV

User Manuals: TGB BLADE 600 Heavy Duty ATV

Manuals and User Guides for TGB BLADE 600 Heavy Duty ATV. We have 1 TGB BLADE 600 Heavy Duty ATV manual available for free PDF download: Service Manual

TGB BLADE 600 Service Manual

TGB BLADE 600 Service Manual (307 pages)

Brand: TGB | Category: Offroad Vehicle | Size: 24 MB

Table of Contents

General Information
3
How to Use the Manual
3
Table of Contents
4
Engine Number
5
Frame Number
5
Serial Number
5
General Information Contents
6
Symbols and Marks
6
General Safety
7
Service Precautions
8
General Information
14
Lubrication System
14
Specifications
14
- Engine Torque Values
  18
- Standard Torque Values for Reference
  18
Torque Values
18
- Frame Torque Values
  19
- Engine Hard to Start or Can Not be Started
  20
- Engine Run Sluggish
  21
- Clutch, Driving and Driving Pulley
  23
- Poor Handling
  23
- Brake Fluid
  25
- Grease
  25
- Oil and Lubrication Points
  25
- Gear Oil
  26
- Maintenance Information Contents
  27
- Precautions in Operation
  27
Periodical Maintenance Schedule
28
Acceleration Operation
29
Air Cleaner
29
Fuel Lines
29
Spark Plug
29
Valve Clearance
30
Carburetor Idle Speed Adjustment
31
Emission Adjustment in Idle Speed
31
Cylinder Compression Pressure
32
Ignition System
32
Drive Belt
33
Maintenance Information
33
Air Bleed Operation
34
Brake System (Disk Brake)
34
- Filling out Brake Fluid
  34
- Brake Light Switch/Starting Inhibitor Switch
  35
- Brake Lining Replacement
  35
- Brake Lining Wear
  35
- Clutch Shoe Wear
  36
Cushion
36
Headlight Beam Distance
36
Appointed Tire Pressure
37
Nuts, Bolts Tightness
37
Steering Handle
37
Wheel/Tire
37
Special Tools List
38
- Lubrication System Contents
  43
- Mechanism Diagram
  43
- General Information
  44
- Engine Oil
  45
- Engine Oil Strainer Clean
  45
- Replace the Oil Filter
  45
- Oil Pump Disassembly
  46
- Oil Pump Removal
  46
- Oil Pump Inspection
  47
- Oil Pump Re-Assembly
  47
- Oil Pump Installation
  48
- Fuel Injection System Components
  49
- Fuel Injection System Contents
  49
Fuel Injection System Components
50
Fuel System
50
General
50
Precautions in Servicing
50
Connector/Coupler
51
Ecu/Various Sensors
51
Fuse
51
Electrical Circuit Inspection Procedure
52
- Open Circuit Check
  52
- Continuity Check
  53
- Voltage Check
  53
- Short Circuit Check
  54
Parts Location
56
Wiring Diagram
57
ECU Terminal
58
System Troubleshooting Customer Compliant Analysis
59
EFI System Components Inspection
61
- T-Map Sensor
  61
- ECT Sensor Inspection
  62
- ECT Sensor Removal/Installation
  63
- TP Sensor Inspection
  64
- Vehicle Speed Sensor
  65
- Injector
  66
- Injector Inspection
  67
- Injector Installation
  67
- Injector Removal
  67
- Crank Position Sensor
  68
- Ignition Coil
  69
- Throttle Body Removal, Disassembly and Assembly
  70
- Pressure Regulator Removal/Installation
  71
- Roll over Sensor Inspection, Removal and Installation
  72
- ECU Removal and Installation
  73
- Power Input Line
  73
Fuel Line Inspection
74
Fuel Pressure Inspection
74
Fuel Flow Inspection
76
- Fuel Pump Inspection
  76
- Fuel Filter Installation
  77
- Fuel Filter Replacement
  77
- Fuel Pump Relay Connection
  77
- Fuel Pump Removal
  77
- Fuel Tank/Reservoir Removal
  78
- CPS Sensor Circuit Malfunction
  79
- Sensor Circuit Troubleshooting
  79
- Sensor Inspection
  79
- T-MAP Inspection
  81
- T-MAP Sensor Circuit Malfunction
  81
- TP Sensor Circuit Malfunction
  83
- ECT Sensor Circuit Malfunction
  87
- Ignition System Malfunction
  90
Troubleshooting
90
Fault Diagnosis
100
- Can Not Start the Engine or Difficult to Start Inspection
  101
- Idle Flameout Diagnosis
  102
Integrated Fault Diagnosis Program
103
Fault Diagnosis Note
104
- Fault Code and the Sensors of the Table
  105
- Method of Use
  107
Use Diagnosis Tool
107
- Vehicle Info
  108
- Current
  109
- Diagnostic Trouble Code
  109
- History
  109
- Freeze Data
  110
- Erase DTC
  111
- Actuator
  112
- Live Data
  112
- Special Function
  113
Troubleshooting Table
115
Comprehensive Maintenance List
116
- Engine Removal Contents
  117
- Engine Removal
  118
Engine Removal
119
- Engine Installation
  125
- Engine Disassembly
  128
- Cylinder Head/Valve Contents
  130
Precautions in Operation
131
Troubleshooting
132
Cylinder Head Removal
133
Camshaft
136
Cylinder Head Inspection
136
- Rocker Arm
  137
- Rocker Arm Shaft
  137
- Valve Spring Free Length
  137
- Valve Stem
  137
- Valve Guide
  138
Valve Stem Replacement
139
Valve Seat Grinding
140
Valve Seat Inspection and Service
140
Valve Seat Width
140
Cylinder Head Reassembly
142
Cylinder Head Installation
143
Valve Clearance Adjustment
145
- Cylinder/Piston Contents
  146
- Trouble Diagnosis
  147
- Cylinder and Piston Inspection
  148
- Cylinder and Piston Removal
  148
- Remove Piston Rings
  149
- Piston Ring Installation
  151
- Cylinder Installation
  152
- Piston Installation
  152
- V-Belt Driving System Contents
  154
- Maintenance Description
  155
- Clutch Cover Inspection
  156
- Clutch Cover Installation
  156
- Clutch Cover Removal
  156
- Drive Belt Removal and Inspection
  157
- Drive Belt Installation
  158
- Drive Face Removal
  159
- Drive Face Inspection
  160
- Drive Face Reassembly/Installation
  160
- Driven Pulley Installation
  161
- Clutch Outer Inspection
  162
- Clutch Outer/Driven Pulley Disassembly
  162
- Driven Pulley Inspection
  163
- Driven Pulley Spring Inspection
  163
- Installation of Clutch Outer/Driven Pulley Assembly
  164
- Front Drive (Front Differential)
  166
Drive System
167
- Front Drive
  167
- Wheel Hub Inspection
  167
- Wheel Hub Removal
  167
- Drive Shaft Boot Removal
  168
- Drive Shaft Removal, Inspection and Installation
  168
- Front Differential
  168
- Drive Shaft Boot Installation
  169
- Front Differential Removal
  169
- Front Differential Disassembly
  170
- Front Differential Assembly
  173
- 2WD/4WD Mode Cable Adjustment
  174
- Lock Mode Cable Adjustment
  174
- Differential Motor Installation
  175
- Front Differential Installation
  175
- Rear Drive (Rear Differential)
  176
- Rear Differential Removal
  177
- Rear Differential Installation
  178
- Rear Differential Disassembly
  180
- Rear Differential Assemble
  182
- Lock Mode Assy. Disassemble
  183
- Lock Mode Assy. Assemble
  184
- Rear Differential Adjustment
  185
- Pivot Gear Disassemble
  186
- Differential Motor Removal and Installation
  187
- Pivot Gear Assemble
  187
- Alternator/Starting Clutch Contents
  188
Precautions in Operation
189
- A.C.G. Set Removal
  190
- Left Cover Bearing Inspection
  190
Left Crankcase Cover Removal
190
Flywheel Removal
191
Alternaotor/Starting Clutch
192
- One Way Clutch Installation
  193
- One Way Clutch Removal
  193
- Flywheel Installation
  194
- A.C.G. Set Installation
  195
- Left Crankcase Cover Installation
  195
Crankshaft/Crankcase
198
- L Case
  198
- R Case
  198
- Oil Seal
  199
- Oil Separator
  199
- Bearing Reasembly
  200
- Drive Belt Cover
  201
- Drive Belt Cover Reassembly
  201
- L Crank Case Assembly
  202
- L Crank Case Cover
  202
- L Crank Case Reassembly
  203
- Balancer
  204
- Crankshaft
  204
- Oil Pump
  206
- Cam Chain
  207
- Clutch Shoe
  207
- Oil Pump Drive Gear
  207
- Clutch Case
  208
- Neutral Switch
  208
- Air Defector and Fixed Drive Face
  209
- Movable Drive/Driven Face and Drive Belt
  209
- Clutch Cover
  210
- Oil Filter
  210
- Water Pump Gear
  211
- Generator
  212
- Gearshift
  213
- Left Crankcase Cover
  213
- Starter Driven Gear/Idle Gear
  213
- Speedometer Gearbox
  214
- Water Pump
  214
- Starter Cup
  215
- Gearshift for Parking
  216
Cooling System
218
- Trouble Diagnosis for Cooling System
  219
- Change of Coolant
  221
- System Test
  221
- Test on the Filler Cap
  221
- Check Reserve Tank
  222
- Radiator Check and Removal
  222
- Radiator Disassembly, Assembly and Installation
  223
- Check Water Pump Seal / Cooling System Divulges Inspection
  224
- Removal of Water Pump
  224
- Thermostat Installation
  225
- Thermostat Removal and Inspection
  225
- Thermostat Technical Data
  225
- Oil Radiator Check and Installation
  226
- Blade Model Mechanism Diagram
  228
Body Cover
228
- Blade Model Maintenance
  229
- Target Model
  237
- Body Covers Dissemble Sequence
  238
- Brake
  243
- Front Brake
  243
Rear Brake/Rear Wheel/Rear Cushion
244
- Brake Specifications
  245
- Brake System Service Notes
  246
- Brake Light Switch Continuity Test
  247
- Brake Light Switch Location
  247
- Brake Light Switch Replacement
  247
- Master Cylinder Inspection
  248
- Master Cylinder Installation
  248
- Master Cylinder Removal
  248
- Caliper Installation
  249
- Caliper Removal
  249
- Brake Disc Inspection
  250
- Brake Disc Replacement
  250
- Brake Pads Replacement
  250
- EPS Model
  251
- Steering System
  251
- Non EPS Model
  252
- Steering System General
  253
- Handlebar Cover Inspection
  254
- Handlebar Cover Installation
  254
- Handlebar Cover Removal
  254
- Procedures
  254
- Handlebar Inspection
  255
- Handlebar Installation
  255
- Handlebar Removal
  255
- Steering Shaft Removal
  256
- Steering Tie-Rod Assembly
  257
- Tire Inspection and Replacement
  258
- Tire Pressure
  258
- Wheel and Tire General
  258
- Wheels Removal and Installation
  258
- Front Suspension
  259
- Front Suspension General
  260
- Shock Absorber Removal
  260
- Lower Arm Installation
  261
- Lower Arm Removal
  261
- Shock Absorber Installation
  261
- Upper Arm Installation
  262
- Upper Arm Removal
  262
- Rear Suspension
  263
- Rear Suspension General
  264
- Tension Bar Installation
  265
- Tension Bar Removal
  265
- EPS (Electric Power Steering)
  268
- (EPS) Electric Power Steering General
  269
- De-Rating Explanation
  269
- EPS Assist Mode
  269
- System Descriptio
  269
- EPS System Description
  270
- EPS Unit
  270
- EPS Unit Protection
  270
- Steering Torque Sensor
  270
- How to Change EPS Mode
  271
- How to View EPS Mode Selection
  271
- EPS Unit System Description
  272
- Torque Offset Reset Adjustment
  272
- EPS Unit Power Fuse Test
  274
- EPS Unit Input Voltage Test
  275
- EPS Unit Communication Link (CAN)
  276
- EPS Unit Ground Circuit Test
  276
- PS System Load Test
  277
- EPS Unit Current Test
  278
- EPS Unit Removal
  279
- Control Unit Removal
  281
- Steering Lower Bearing Seat
  281
- Fuse Installation
  282
- Fuse Removal
  282
- Electrical System Contents
  283
- Maintenance Data
  284
- Technical Specification
  284
- Trouble Diagnosis
  285
  - Battery Charging
    286
  - Battery Removal
    286
  - Charging Circuit
    287
- Charging System
  287
  - Current Leakage Inspection
    287
  - Inspection on Charging Voltage
    288
  - Inspection on Regulator Rectifier
    289
  - C.D.I Unit
    290
  - Ignition Circuit Diagram
    290
- Ignition System
  290
  - Ignition Coil Replacement
    291
  - Inspection of Pulse Generator
    291
  - Inspection on Ignition Coil
    291
  - Inspection on Starter Relay
    292
  - Starting Circuit Diagram
    292
- Starting System
  292
  - Installation of Starter Motor
    293
  - Removal of Starter Motor
    293
  - Meters Removal
    294
- Light / Bulb
  295
  - Replacing Bulb for Headlight
    295
  - Replacing Bulb of Position Light
    296
  - Replacing the Front Winker Light Bulb
    296
  - Rear Winker Light
    297
  - Replacing Bulb of License Light
    297
  - Replacing Bulb of Taillight
    297
  - Handle Switches
    298
  - Start Switch
    298
- Switch / Horn
  298
  - Hazard Switch
    299
  - Headlight Switch
    299
  - Horn Switch
    299
  - Winker Switch
    299
  - Lock Switch
    300
  - Front Brake Switch
    301
  - Horn
    301
  - Rear Brake Switch
    301
- Fuel Unit
  302
- Function of Over-Ride
  302
- Cooling Fan Switch
  303
- Thermo Unit
  304
- Water Temperature Indicator Light
  304

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