TGB EST 1000 Manuals

TGB EST 1000 Manuals

Manuals and User Guides for TGB EST 1000. We have 1 TGB EST 1000 manual available for free PDF download: Service Manual

TGB EST 1000 Service Manual

TGB EST 1000 Service Manual (270 pages)

Brand: TGB | Category: Offroad Vehicle | Size: 18.74 MB

Table of Contents

Table of Contents
3
General Information
3
Serial Number
4
Frame Number and Engine Number
4
General Information
4
- Maintenance Information
  5
- Specification
  5
- Periodical Maintenance Schedule
  6
- Acceleration Operation
  7
- Air Cleaner
  7
- Fuel Lines
  7
- Spark Plug
  7
- Valve Clearance
  8
- Cylinder Compression Pressure
  9
- Ignition System
  9
- Drive Belt
  10
- Brake System (Disk Brake)
  11
- Brake Light Switch/Starting Inhibitor
  12
- Cushion
  13
- Headlight Beam Distance
  13
- Nuts, Bolts Tightness
  14
- Steering Handle
  14
- Wheel/Tire
  14
- Special Tools List
  15
Precautions in Operation
19
General Information
19
Lubrication System
19
- Oil Level Verification
  20
- Oil Filter Change
  20
- Inspection
  21
- Engine Oil Pressure
  21
- Oil Filter
  22
- Oil Filter Removal
  22
- Oil Filter Inspection
  22
- Oil Filter Installation
  22
- Oil Pressure Switch
  23
- Engine Oil Pressure Valve
  23
- Oil Pressure Switch Activation
  23
- Oil Pressure Switch Test
  23
- Oil Radiator
  24
- Oil Pump
  25
- Oil Pump Final Test
  26
- Engine Oil Strainer
  27
- Valve Removal
  27
- Valve Installation
  27
- Cleaning and Inspection
  27
- Fuel Tank and Fuel Pump
  28
Fuel System
28
- Fuel System
  29
- Fuel Filters
  30
- Fuel Pump Assembly
  30
- Fuel Tank Vent System
  30
- System Description
  30
- Fuel Pump Pressure Test
  31
- Rapid Fuel Pressure Drop
  31
- Slow Fuel Pressure Drop
  31
- Test Conclusion
  31
- Fuel Hose and Clamp
  32
- Fuel Hose Replacement
  32
- Fuel Tank
  32
- Oetiker Clamp Replacement
  32
- Fuel Pump
  33
- Fuel Pump Quick Test
  33
- Fuel Tank Inspection
  33
- Fuel Tank Installation
  33
- Fuel Pump Removal
  34
- Fuel Pump Resistance Test
  34
- Fuel Pressure Inspection
  35
- Fuel Pump Installation
  35
- Fuel Gauge Meter
  36
- Fuel Gauge Meter Input Voltage Test
  36
- Fuel Gauge Meter Resistance Test
  36
- Fuel Tank Vent Valve
  37
- Observe Cup
  37
- Test for Normal Operation
  37
- Fuel System Diagnostic Flow Chart
  38
- Troubleshooting
  38
- Fuel Injection System Components
  39
- Fuel Injection System Components
  40
- General
  40
- Precautions in Servicing
  40
- Connector/Coupler
  41
- Ecu/Various Sensors
  41
- Fuse
  41
- Electrical Circuit Inspection Procedure
  42
  - Open Circuit Check
    42
  - Continuity Check
    43
  - Voltage Check
    43
  - Short Circuit Check (Wire Harness to Ground)
    44
  - Specifications
    45
  - Torque Values
    45
- Parts Location
  46
- Wiring Diagram
  47
  - With EPS
    47
  - Without EPS
    48
- ECU Terminal
  49
- EFI System Components Inspection
  50
  - T-Map Sensor
    50
  - ECT Sensor
    51
  - TP Sensor
    53
  - Vehicle Speed Sensor
    54
  - Injector
    55
  - Crank Position Sensor
    57
  - Ignition Coil
    58
  - Throttle Body
    59
  - Roll over Sensor
    60
  - O2 Sensor
    61
  - Ecu
    62
  - Power Input Line
    62
  - CPS Sensor Circuit Malfunction
    63
- Sensor Circuit Mal. Troubleshooting
  63
- Fault Diagnosis
  84
  - Can Not Start the Engine or Difficult to Start Inspection
    85
  - Idle Flameout Diagnosis
    86
- Integrated Fault Diagnosis Program
  87
- Diagnosis Tool for Overhaul
  88
- Fault Diagnosis Note
  88
- Fault Code and the Sensors of the Table
  89
- Use Diagnosis Tool
  90
  - Method of Use
    91
  - Live Data
    95
  - Actuator
    96
  - Special Function
    97
- Troubleshooting Table
  98
- Comprehensive Maintenance List
  99
Engine Removal and Installation
101
Engine Assembly
101
- Engine Installation
  102
- Engine Mounts
  102
- Lifting and Remove the Engine
  102
- Final Assembly Procedure
  102
- Air Intake System
  103
- Air Cleaner Element
  104
- Air Filter Element Replacement
  104
- Air Cleaner Removal
  104
- Exhaust System
  105
- Muffler Removal
  106
- Muffler Installation
  106
- Exhaust Pipe
  107
- Exhaust Pipe Removal
  107
- “Y” Exhaust Pipe Inspection
  107
- “Y” Exhaust Pipe Installation
  107
- Cooling System
  108
- Radiator
  108
- Water Pump
  108
- Thermostat Removal
  109
- Thermostat Installation
  110
- Radiator Inspection
  110
- Thermostat Test
  110
- Radiator Cooling Fan Relay
  111
- Radiator Removal
  111
- Radiator Installation
  111
- Relay Installation (Radiator Cooling Fan)
  111
- Radiator Cooling Fan
  112
- Relay Operation Test (Radiator Cooling Fan)
  112
- Relay Continuity Test (Radiator Cooling Fan)
  112
- Radiator Cooling Fan Operation
  112
- Radiator Cooling Fan Fuse Location
  113
- Radiator Cooling Fan Test
  113
- Water Pump Housing Inspection
  114
- Radiator Cooling Fan Removal
  114
- Water Pump Housing Installation
  114
- Water Pump Housing Removal
  114
- Water Pump Impeller Removal
  115
- Water Pump Impeller Inspection
  115
- Water Pump Impeller Installation
  115
- Rotary Seal and Oil Seal Removal
  115
- Rotary Seal and Oil Seal Installation Oil Seal
  116
- Rotary Seal
  116
- Water Pump Shaft/Seal Removal
  118
- Water Pump Shaft/Seal Inspection (Disassembled Engine)
  118
- Water Pump Shaft/Seal Installation (Disassembled Engine)
  118
- AC Generator System
  120
- ACG Cover Removal
  121
- ACG Cover Inspection and Cleaning
  121
- ACG Cover Installation
  121
- Stator Static Test: Continuity
  122
- Stator Static Test: Insulation
  122
- Stator Dynamic Test: AC Voltage
  122
- Stator Removal
  123
- Stator Inspection
  123
- Stator Insulation
  123
- Rotor Removal
  123
- Rotor Installation
  124
- Rotor Inspection
  124
- Unidirectional Clutch Removal
  125
- Unidirectional Clutch Inspection
  125
- Unidirectional Clutch Installation
  125
- Starting Clutch Gear Removal
  126
- Starting Clutch Gear Inspection
  126
- Starting Clutch Gear Installation
  126
- Starter Drive Gear Removal
  126
- Intake Manifold
  127
Engine Top End
127
- Cylinder Head
  128
- Cylinders and Pistons
  129
- Maintenance
  130
- Valve Adjustment
  130
- Intake Manifold Removal
  131
- Intake Manifold Inspection
  131
- Intake Manifold Installation
  131
- Cylinder Head Cover Removal
  132
- Cylinder Head Cover Inspection
  132
- Cylinder Head Cover Installation
  132
- Rocker Arm Removal
  132
- Rocker Arm Shaft
  133
- Rocker Arm Installation
  133
- Cylinder Head Inspection
  134
- Cylinder Head Removal
  134
- Cylinder Head Installation
  135
- Camshaft Removal
  135
- Camshaft Inspection
  136
- Camshaft Installation
  137
- Valve Spring Removal
  137
- Valve Spring Inspection
  137
- Valve Spring Installation
  138
- Valves
  138
- Valve Stem Seal
  138
- Valve Stem and Valve Guide
  139
- Clearance
  139
- Valve Face and Seat
  140
- Valve Installation
  140
- Cylinder Removal
  141
- Cylinder Inspection
  141
- Cylinder Taper
  141
- Cylinder out of Round
  141
- Cylinder Installation
  142
- Piston Removal
  142
- Piston Inspection
  143
- Piston/Cylinder Clearance
  143
- Connecting Rod/Piston Pin Clearance
  143
- Piston Installation
  144
- Ring Inspection
  145
- Ring/Piston Groove Clearance
  145
- Ring Installation
  146
- Timing Chain
  147
- Timing Chain Tensioner Removal
  149
- Timing Chain Tensioner Inspection
  149
- Timing Chain Tensioner Installation
  149
- Camshaft Timing Gears Removal
  150
- Timing Gear Inspection
  150
- Timing Gear Installation
  151
- Camshaft Timing Cylinder (Rear)
  151
- Camshaft Timing Cylinder (Front)
  152
- Timing Chain Removal (ACG Side)
  153
- Timing Chain Removal (CVT Side)
  153
- Timing Chain Inspection
  154
- Timing Chain Installation
  154
- Timing Chain Guide (Tensioner Side)
  154
- Bottom End
  155
- Engine Drive Shaft
  155
- Crankcase
  156
- Crankshaft
  156
- Water Pump, Oil Pump
  157
- Oil Seal Replacement (Engine Drive Shaft)
  158
- Engine Drive Shaft Removal
  158
- CVT Vent Backboard Oil Seal Removal
  159
- Engine Drive Inspection
  159
- Engine Drive Shaft Installation
  159
- Vent Backboard Oil Seal Inspectio
  160
- CVT Vent Backboard Oil Seal Installation
  160
- CVT Vent Backboard Removal
  160
- CVT Vent Backboard Inspection
  160
- Plain Bearing Replacement (CVT Vent Backboard Cover)
  161
- Plain Bearing Installation
  161
- CVT Vent Backboard Installation
  162
- Drive Gear Removal
  162
- Drive Gears Inspection
  162
- Crankcase Disassembly
  163
- Drive Gear Installation
  163
- Crankcase Cleaning
  164
- Crankcase Inspection
  164
- Main Bearing Inside Diameter (CVT/ACG)
  165
- Plain Bearing Replacement (Main)
  165
- Crankcase Assembly
  166
- Crankshaft Inspection
  166
- Connecting Rod Big End Axial Play
  167
- Connecting Rod Big End Radial Play
  167
- Connecting Rod Big End Radial Clearance
  167
- Crankshaft Radial Play ACG/CVT Side
  167
- Crankshaft Installation
  168
- Crankshaft Assembly
  168
Transmission Bear Box
169
- VSS Location
  171
- VSS Wire Identification
  171
- VSS Input Voltage Test
  171
- VSS Signal Test
  171
- VSS Removal
  172
- VSS Installation
  172
- Gear Switch Input Test
  172
- Gearbox Removal
  173
- Gearbox Case
  173
- Gear Switch Installation
  173
- Gear Switch Removal
  173
- Gearbox Bearings
  174
- Gearbox Inspection
  174
- Gearbox Installation
  174
- Gear Camshaft Comp
  175
- Parking Gear
  175
- Output Secondary Gear Shaft and 17 Tooth Gear
  175
- Transmission Gear
  175
- Shift Lever
  176
- Shift Lever
  177
- Continuously Variable Transmission (CVT)
  180
- Drive Pulley
  182
- Drive Belt
  182
- Tuner Haft Cover Removal
  183
- Governor Cup Removal
  184
- Governor Cup Installation
  184
- Tuner Haft Cover Installation
  185
- Drive Pulley Installation
  185
- Driven Pulley
  186
- Driven Pulley Assembly
  189
- Front Drive (Front Differential)
  191
Drive System
191
- Drive System
  192
- Front Drive
  192
- Wheel Hub
  192
- Front Drive Shaft
  193
- Drive Shaft Boot
  193
- Front Differential
  194
- Pinion Gear
  195
- Front Differential Installation
  195
- Differential Motor
  195
- Rear Drive (Rear Differential)
  196
- Rear Drive
  197
- Wheel Hub Inspection
  197
- Wheel Hub Installation
  197
- Rear Drive Shaft Installation
  198
- Rear Differential
  199
- EPS Model
  201
Steering System & Suspension
201
- Non EPS Model
  202
- Handlebar Cover
  204
- Steering Shaft Removal (Without EPS)
  206
- Steering Shaft Removal (with EPS)
  206
- Wheel and Tire
  207
- Front Suspension
  208
- Shock Absorber Installation
  210
- Lower a Arm Removal
  210
- Upper a Arm Removal
  211
- Upper a Arm Installation
  211
- Rear Suspension
  212
- Shock Absorber Removal
  213
- Tension Bar Removal
  214
- Tension Bar Installation
  214
- Lower a Arm Installation
  216
- EPS (Electric Power Steering)
  217
- EPS Unit
  219
- EPS Unit Protection
  219
- Steering Torque Sensor
  219
- EPS Mode
  219
- How to View EPS Mode Selection
  220
- How to Change EPS Mode
  220
- EPS Unit Power Fuse Test
  223
- EPS Unit Input Voltage Test (Power Side)
  224
- EPS Unit Input Voltage Test (Control Side)
  224
- EPS Unit Ground Circuit Test
  225
- EPS Unit Communication Link (CAN)
  225
- EPS System Load Test
  226
- EPS Unit Current Test
  227
- EPS Unit Removal
  228
- Steering Lower Bearing Seat
  230
- Fuse Removal
  231
- Front Brake
  232
- Rear Brake
  233
Brake System & Body Cover
233
- Brake Specifications
  234
- Brake System Service Notes
  235
- Brake Light Switch
  236
- Brake Light Switch Continuity Test
  236
- Brake Light Switch Replacement
  236
- Master Cylinder
  237
- Master Cylinder Removal (Hand Brake)
  237
- Master Cylinder Removal (Pedal Brake)
  237
- Caliper
  238
- Brake Pads
  239
- Top Cover, Side Cover, Footrest
  240
- Front Bumper
  240
- Body
  240
- Front Cover
  241
- Rear Cover
  241
Electric System
248
- Engine will Not Start (Engine Turns Over)
  250
- Engine Hard to Start
  250
- Engine Misfires, Runs Irregularly
  250
- Engine Continually Backfires
  250
- Ignition System
  251
- Ignition Switch
  252
- Inspection on Ignition Coil
  253
- Ignition Coil Ground Circuit Continuity Test
  253
- Ignition Coil Resistance Test
  253
- Spark Plug Analysis
  254
- Charging System
  255
- Output Voltage Test
  256
- Battery Voltage Test (no Load Applied)
  257
- Battery Load Test
  257
- Battery Removal
  257
- Battery Cleaning
  258
- Battery Storage
  258
- Battery Installation
  258
- Starting System
  259
- Starter Relay Winding Resistance Test
  261
- Starter Relay Operational Test
  261
- Starter Relay Ground Signal Test
  261
- Starter Relay Input Voltage Test
  261
- Starter Operation Test
  262
- Starter Installation
  262
- Starter Removal
  262
- Lights, Speedometer and Accessories
  264
- Headlight
  265
- Taillights/Brake Lights
  266
- Turn Signal Lamp
  267
- Horn
  267
- Schematic Diagram
  268

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