TGB - BLADE 250 ATV Service Manual

BLADE 250


SERVICE MANUAL

---

Homepage
Contents






FORWARD



This service manual contains the technical data of each component inspection and
repair for the
BLADE 250 ATV. The manual is shown with illustrations and
focused on “Service Procedures”, “Operation Key Points”, and “Inspection
Adjustment” so that provides technician with service guidelines.


If the style and construction of the ATV, BLADE 250, are different from that of the
photos, pictures shown in this manual, the actual vehicle shall prevail.
Specifications are subject to change without notice.









Service Department

TAIWAN GOLDEN BEE CO., LTD.

---

Homepage
Contents

HOW TO USE THIS MANUAL



This service manual describes basic information of different system parts and
system inspection & service for
BLADE 250 ATV.
In addition, please
refer to the manual contents in detailed for the model you serviced in inspection
and adjustment.


The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance information and special tools
manual.
The third to the 11th chapters cover engine and driving systems.
The 12th chapter is cooling system.
The 13th to the 16th chapter is contained the parts set of assembly frame body.
The 17th chapter is electrical equipment.
The 18th chapter is wiring diagram.
Please see index of content for quick having the special parts and system
information.

---

Homepage






CONTENTS


Page Content
Index

1-1 ~ 1-18 GENERAL INFORMATION
1

2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION
2

3-1 ~ 3-8
LUBRICATION SYSTEM
3

4-1 ~ 4-12 FUEL SYSTEM
4

5-1 ~ 5-6
ENGINE REMOVAL
5

6-1 ~ 6-16 CYLINDER HEAD/VALVE
6

7-1 ~ 7-8
CYLINDER/PISTON
7

8-1 ~ 8-14 “V” TYPE BELT DRIVING SYSTEM/KICK-STARTER
8

9-1 ~ 9-12 FINAL DRIVING MECHANISM
9

10-1 ~ 10-10 ALTERNATOR
10

11-1 ~ 11-8 CRANKSHAFT/ CRANKCASE
11

13-1 ~ 13-9 BODY COVER
13

14-1 ~ 14-14 FRONT BRAKE AND FRONT WHEEL
14

15-1 ~ 15-10 STEERING/FRONT SUSPENSION
15

16-1 ~ 16-18 REAR BRAKE/REAR WHEEL/REAR CUSHION
16

17-1 ~ 17-22 ELECTRICAL EQUIPMENT
17

18-1 ~ 18-2 ELECTRICAL DIAGRAM
18

---

Home page
Contents

SERIAL NUMBER




Frame number


















Engine number

---

Homepage
Contents


1. GENERAL INFORMATION




Symbols and Marks............................. 1-1
Specifications..................................... 1-10
1


General Safety ..................................... 1-2
Torque Values .................................... 1-11


Service Precautions ............................ 1-3
Troubles Diagnosis............................ 1-13


Specifications ...................................... 1-9
Lubrication Points ............................. 1-18


Symbols and Marks

Symbols and marks are used in this manual to indicate what and where the special service are needed, in
case supplemental information is procedures needed for these symbols and marks, explanations will be
added to the text instead of using the symbols or marks.




Means that serious injury or even death may result if procedures are not
Warning
followed.

Caution
Means that equipment damages may result if procedures are not followed.



Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the
Engine oil
damage that caused by not apply with the limited engine oil.

(Recommended oil: KING MATE G-3 oil)

Grease
King Mate G-3 is recommended.




King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL
Gear oil

# 140)


Apply sealant; medium strength sealant should be used unless otherwise
Locking sealant

specified.

Oil seal
Apply with lubricant.。


Renew
Replace with a new part before installation.

Brake fluid
Use recommended brake fluid DOT3 or WELLRUN brake fluid.

Special tools
Special tools


Correct
Meaning correct installation.

Wrong
Meaning wrong installation.

Indication
Indication of components.


Directions
Indicates position and operation directions


Components assembly directions each other.

Indicates where the bolt installation direction, --- means that bolt
cross through the component (invisibility)





1-1

---

To this chapter contents

1. GENERAL INFORMATION






General Safety



Carbon monoxide
Battery
If you must run your engine, ensure the place is

Caution
well ventilated. Never run your engine in a closed

area. Run your engine in an open area, if you have
• Battery emits explosive gases; flame is strictly
to run your engine in a closed area, be sure to use
prohibited. Keeps the place well ventilated
an extractor.
when charging the battery.

Caution
• Battery contains sulfuric acid (electrolyte)

which can cause serious burns so be careful
Exhaust contains toxic gas which may cause one
do not be spray on your eyes or skin. If you
to lose consciousness and even result in death.
get battery acid on your skin, flush it off

immediately with water. If you get battery acid
Gasoline
in your eyes, flush it off immediately with water
Gasoline is a low ignition point and explosive
and then go to hospital to see an
material. Work in a well-ventilated place, no flame
ophthalmologist.
or spark should be allowed in the work place or
• If you swallow it by mistake, drink a lot of
where gasoline is being stored.
water or milk, and take some laxative such as

castor oil or vegetable oil and then go to see a
Caution
doctor.

Gasoline is highly flammable, and may explode
• Keep electrolyte beyond reach of children.
under some conditions, keep it away from

children.
Brake shoe

Do not use an air hose or a dry brush to clean
Used engine oil
components of the brake system; use a vacuum

cleaner or the equivalent to avoid dust flying.
Caution


Caution
Prolonged contact with used engine oil (or

transmission oil) may cause skin cancer although it
Inhaling brake shoe or pad ash may cause
might not be verified.
disorders and cancer of the breathing system
We recommend that you wash your hands with

soap and water right after contacting. Keep the
Brake fluid
used oil beyond reach of children.


Caution
Hot components


Spilling brake fluid on painted, plastic, or rubber
Caution
parts may cause damage to the parts. Place a

clean towel on the above-mentioned parts for
Components of the engine and exhaust system
protection when servicing the brake system.
can become extremely hot after engine running.
Keep the brake fluid beyond reach of children.
They remain very hot even after the engine has

been stopped for some time. When performing


service work on these parts, wear insulated

gloves and wait until cooling off.
















1-2

---

To this chapter contents


1. GENERAL INFORMATION




Service Precautions


● Always use with SANYANG genuine parts and
● Never bend or twist a control cable to prevent
recommended oils. Using non-designed parts for
unsmooth control and premature worn out.
SANYANG ATV may damage the ATV.


● Rubber parts may become deteriorated when old,
● Special tools are designed for remove and
and prone to be damaged by solvent and oil.
install of components without damaging the
Check these parts before installation to make sure
parts being worked on. Using wrong tools may
that they are in good condition, replace if
result in parts damaged.
necessary.

● When loosening a component which has
different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.
● Store complex components such as
transmission parts in the proper assemble order
and tie them together with a wire for ease of

installation later.
● When servicing this ATV, use only metric tools.
Metric bolts, nuts, and screws are not
interchangeable with the English system, using
wrong tools and fasteners may damage this
vehicle.

● Clean the outside of the parts or the cover before
removing it from the ATV. Otherwise, dirt and
deposit accumulated on the part's surface may fall
into the engine, chassis, or brake system to cause
damage.

●

Note the reassemble position of the important
● Wash and clean parts with high ignition point
components before disassembling them to
solvent, and blow dry with compressed air. Pay
ensure they will be reassembled in correct
special attention to O-rings or oil seals because
dimensions (depth, distance or position).
most cleaning agents have an adverse effect on
● Components not to be reused should be
them.
replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.










1-3

---

To this chapter contents

1. GENERAL INFORMATION





● The length of bolts and screws for assemblies,
● Remove residues of the old gasket or sealant
cover plates or boxes is different from one another,
before reinstallation, grind with a grindstone if
be sure they are correctly installed. In case of
the contact surface has any damage.
confusion, Insert the bolt into the hole to compare
its length with other bolts, if its length out side the
hole is the same with other bolts, it is a correct
bolt. Bolts for the same assembly should have the
same length.

● The ends of rubber hoses (for fuel, vacuum, or
coolant) should be pushed as far as they can go
to their connections so that there is enough room
below the enlarged ends for tightening the
clamps.


Groove

Clamp
● Tighten assemblies with different dimension
Connector
fasteners as follows: Tighten all the fasteners


with fingers, then tighten the big ones with

special tool first diagonally from inside toward

outside, important components should be

tightened 2 to 3 times with appropriate
● Rubber and plastic boots should be properly
increments to avoid warp unless otherwise
reinstalled to the original correct positions as
indicated. Bolts and fasteners should be kept
designed.
clean and dry. Do not apply oil to the threads.










Boots





● The tool should be pressed against two (inner
● When oil seal is installed, fill the groove with
and outer) bearing races when removing a ball
grease, install the oil seal with the name of the
bearing. Damage may result if the tool is pressed
manufacturer facing outside, and check the shaft
against only one race (either inner race or outer
on which the oil seal is to be installed for
race). In this case, the bearing should be
smoothness and for burrs that may damage the
replaced. To avoid damaging the bearing, use
oil seal.
equal force on both races.



Manufacturer's name


















Both of these examples can result in

bearing damage.


1-4

---

To this chapter contents


1. GENERAL INFORMATION




● Lubricate the rotation face with specified
● After service completed, make sure all
lubricant on the lubrication points before
connection points is secured.
assembling.
Battery positive (+) cable should be connected
firstly.
● And the two posts of battery have to be greased
after connected the cables.



● Check if positions and operation for installed
parts is in correct and properly.


● Make sure that the battery post caps are
located in properly after the battery posts had

been serviced.
● Make sure service safety each other when
conducting by two persons.

● If fuse burned, it has to find out the cause and
solved it. And then replace with specified

capacity fuse.
● Note that do not let parts fall down.


Capacity
verification











● Before battery removal operation, it has to

remove the battery negative (-) cable firstly. Notre

tools like open-end wrench do not contact with


body to prevent from circuit short and create

spark.


















1-5

---