TGB Hornet 90 Manuals

Manuals and User Guides for TGB Hornet 90. We have 1 TGB Hornet 90 manual available for free PDF download: Service Manual

TGB Hornet 90 Service Manual

TGB Hornet 90 Service Manual (87 pages)

TGB Hornet ATV Service manual

Brand: TGB | Category: Offroad Vehicle | Size: 1 MB

Table of Contents

Table of Contents
1
1 Regular Inspection

2
2 Maintenance Information

7
- Specification Sheet
  7
- Maintenance Data
  8
- Special Tools
  9
- List of Grease and Oil Adopted
  12
- Circuit Drawings
  13
- Tighting Torque of Screws
  14
  - Screw Torque of Body
    14
  - Screw Torque of Engine
    15
  - General Torque
    15
- Simplified Troubleshooting
  16
  - Troubleshooting for Failure in Starting the Engine
    17
  - Check Item
    19
  - Troubleshooting for Poor Skip of Spark Plugs
    20
  - Troubleshooting for No-Skip of Spark Plugs
    21
  - Troubleshooting for Slow Run (Troubled Engine)
    22
  - Poor Acceleration and Horse Power
    23
  - Cover and Seat
    25
    
    Description of Components and Assembly Contents
    25
    
    Cover and Seat
    26
    
    Air In-Take and Exhaust System
    27
    
    Combustion and Air Inlet-Outlet System
    27
  - Engine
    27
    
    Carburetor
    28
    
    Idle Jet
    28
    
    Manual Choke System
    28
    
    Forced Air-Cooled Engine
    29
    
    Lubrication & Cooling System
    29
    
    Oil-Pump
    29
    
    Belt Automatic Continuous Variable Transmission
    30
    
    Path of Power Transmission
    30
  - Transmission Mechanism
    30
    
    Continuous Variable Transmission
    31
    
    Drive Pulley
    31
    
    Driven Pulley
    31
    
    V-Belt
    31
    
    Running Curve
    32
    
    Electric Self-Starter
    33
    
    Reducing Gear
    33
    
    Starting Mechanism
    33
  - Electric System
    35
    
    Flywheel Magneto
    35
    
    Ignition and Charging Device
    35
    
    Battery Caution
    36
    
    Ignition Charging Device for the Ignition
    36
    
    Instruction for Filling Electrolyte
    36
  - Body
    37
    
    Frame & Fuel and Oil System
    37
    
    Fuel Tank
    37
    
    Manual Fuel Shutoff Control
    37
    
    Brake System
    38
    
    Front and Rear Suspension System
    38
  - Disassembly and Assembly of Engine
    39
  - Disassembly Repairment Contents
    39
  - Notice for Disassembly Repairment
    39
  - Removal and Assembly of Carburetor
    39
  - Removal and Lnstallation of Engine
    39
    
    Notice for Disassembly Inspection
    40
    
    Removal of Engine
    41
    
    Installation of Engine
    42
    
    Disassembly Sequence of Engine
    43
    
    Removal of Drive Pulley
    45
    
    Removal of Kick Starter Lever Assy
    45
    
    Removal of Muffler
    45
    
    Removal of Driven Pulley Assy
    46
    
    Removal of Flywheel Magneto
    47
    
    Removal of Starter Motor
    47
    
    Cylinder
    48
    
    Piston
    48
    
    Removal of In-Take Pipe
    48
    
    Removal of Oil-Pump
    48
    
    Removal of Reducing Gear
    49
    
    Removal of Crank Case
    50
    
    Inspection of Engine Components
    52
    
    Measurement of Compression Pressure of Engine
    52
    
    Inspection and Replacement of Reducing Gear Oil
    53
    
    Inspection of Crank Shaft
    54
    
    Inspection of Cylinder
    54
    
    Inspection of Piston
    54
    
    Inspection of Piston Pin/Ring
    54
    
    Assembly Sequence of Engine
    56
    
    Assembly of Crank Case
    58
    
    Assembly of Engine
    59
    
    Assembly of Reducing Gear
    60
    
    Assembly of Piston
    61
    
    Assembly of Cylinder
    62
    
    Assembly of Oil-Pump
    63
    
    Assembly of Reed Valve
    63
    
    Assembly of Starter Motor
    63
    
    Assembly of Flywheel Magneto
    65
    
    Assembly of Cooling Fan
    66
    
    Assembly of Movable Driven Pulley Assy
    67
    
    Assembly of Drive Pulley Assy
    69
    
    Assembly Kick Starter Lever Assy
    71
    
    Assembly of Muffler
    72
    
    Removal of Carburetor
    73
    
    Assembly of Carburetor
    74
    
    Idle Setting with an Air-Adjusting Screw
    74
    
    Inspection of Carburetor
    74
    
    Inspection of Electric Items
    75
    
    Inspection of Ignition Coil and C.D.I.
    75
    
    Notice for Inspection and Arrangement of Electric Components
    75
    
    Removal and Inspection of Ignition and Charging System
    75
    
    Electric Resistance of Coil Assy
    76
    
    Electric Resistance of Rectifier
    76
    
    Inspection of Coil Assy
    76
    
    Inspection of Rectifier
    76
    
    Removal and Inspection of Fuel Tank
    79
    
    Removal and Inspection of Oil Warning Indicator
    79
  - Removal and Inspection and Assembly of Body Parts
    80
    
    Removal and Inspection and Assembly of Steering Shaft Assy
    80
    
    Removal of Rear Axle
    82
    
    Assembly of Rear Axle
    83
    
    Inspection of Rear Axle
    83
    
    Inspection of Brake Parts
    84
    
    Removal of Front and Rear Wheel
    84
    
    Assembly of Brake and Wheel
    85
    
    Unpack and Assemble ATV
    86

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