Royal Alloy TG300 ABS User manual

TL

Preface
2
Preface
Thank you for choosing your Royal Alloy TG300 scooter. Royal Alloy products embody high technology with
reliability and have been designed utilising RA Engineering Co., Ltd and its partners’ many years of experience in
manufacturing scooters for travel, commuting, leisure and sporting activities. This is why this model takes a leading
position in the market sector.
This manual explains the use, operation, basic inspection and maintenance etc for your scooter. If you have any
further questions about the operation and maintenance, please contact your dealer.
The scooter is designed to fully meet the exhaust emissions standards prevailing on the date of manufacture.
To keep the compliance to the exhaust emissions standards, please carry out the maintenance schedule and
instructions in this manual in cooperation with your dealer.
The following important information will appear in this manual:
Caution:
Refer to procedures that must be followed. Otherwise, your personal safety may be endangered.
Note:
Refer to procedures that must be followed to avoid damaging the scooter
Warning:
Refer to procedures that must be followed to avoid injury to you, or other persons or damage to the scooter.

Preface
3
Note
This manual should be regarded as part of the scooter and should be always with the scooter, even when
it is resold.
Note
Our company is working hard towards improvement of product design and quality. This manual
contains the latest product information at the time of print. However, it is possible that the manual may
have slight differences with your scooter. If you have any question, please contact your dealer.
Warning
Read this manual carefully before riding the scooter.

Contents
4
Precautions for Safe Riding ......................................... 6
Names of Different Parts .............................................. 7
The Serial Number ....................................................... 9
Functions of Controllers ............................................. 10
Instrument Panel Indications ................................ 10
Ignition Switch ...................................................... 11
Switches on the Handlebars(Left) ........................ 12
Switches on the Handlebars(Right) ...................... 13
Fuel Tank Cap ....................................................... 14
Coolant tank cap ................................................... 15
Seat Lock(一) ........................................................ 16
Front Luggage Box ............................................... 16
Fuel and Oil Recommendations ................................ 17
Fuel ....................................................................... 17
Engine Oil ............................................................. 17
Transmission Oil ................................................... 17
Running-in of New Scooter ......................................... 18
Inspection before Riding ............................................. 19
Inspection of Braking effect and free play ............ 20
Inspection the Front Brake and Anti-Dive Linkage20
Inspection of the Tyres .......................................... 20
Inspecting the Quantity of Fuel ............................. 21
Inspecting the Quantity of Engine Oil ................... 21
Inspecting the Transmission Oil Level .................. 22
Inspection of the Ignition Unit and the Lights ...... 22
Riding Tips ................................................................... 23
Start the Engine ..................................................... 23
Setting off .............................................................. 23
Inspection and Maintenance ...................................... 25
The first maintenance ............................................ 25
Maintenance Schedule ........................................... 26
Battery ................................................................... 28
Spark Plug ............................................................. 28
Contents

Contents
5
Fuel Hose .............................................................. 30
Air Filter ............................................................... 30
Tyres ..................................................................... 32
Fuses ..................................................................... 33
Troubleshooting .......................................................... 34
Storage Procedures ..................................................... 35
Specifications ............................................................... 36

Precautions for Safe Riding
6
Precautions for Safe Riding
Please obey all local traffic regulations and consider safety
prior to riding. It is advised to control your speed and to
stay within safe limits.
Practice before Riding
Before riding the scooter in traffic, it is recommended that
you practice your riding at a spacious and traffic-free place
so that you are skilled enough to ride safely and are familiar
with the scooter’s controls. Practice is essential for safety.
Please observe any special training and or government test
required before using your scooter on the public highways.
Knowing Your Safety Speed Limit
Safe speed limit varies in accordance with the road
conditions, riding skill and the weather. Be aware of local
and national speed limits.
Be Careful on Rainy Days
It is dangerous to ride on damp or wet roads. Therefore,
high speed should be avoided and special care should be
taken when turning. Bear this in mind, the braking distance
on rainy days can be twice as much as on dry days.
Correct Wearing of Safety Helmet
Wear a safety helmet whenever you ride, and make sure
you fasten the strap securely whenever you wear the
helmet.
Safety clothing Recommendation
Bright-coloured and well-fitting garments are
recommended. Mind that the clothes should allow the limbs
to move freely.
Clothes of thick materials and shoes with short heels are
also recommended.
Indispensable Maintenance and inspection
Caution High Temperature
The high temperature of the muffler may cause burns.
Please park your scooter to prevent the accidental chance of
persons coming into contact with the muffler.
No modifications allowable
Modification to the unit is not allowed and may not
guarantee a safe driving.
The following items are indispensable:
² Make safety checks before every
journey.
² Half-yearly thorough inspection.
² One-year thorough serving.
² Those listed in the Maintenance
Schedule.

Names of Different Parts
7
Names of Different Parts
Read the following labels carefully before using the motorcycle.
1.Exhaust/Muffler pipe
4.Seat
7.Front turning lamps
2.Rear light/Brake light/number plate light
5.Acceleration grip &right switch
8.Side reflector
3.Rear rack
6.Head lamp
9.Front right shock absorber
Warning
Rear rack has a maximum payload of 5 kgs
5
2
1
3
4
6
7
9
8

Names of Different Parts
8
1. Rear brake lever
5. Rear indicator lamps
9. Main stand
2. Rear-view mirrors
6. Rear shock absorber
10. Side stand
3. Left grip switch
7. Rear disc brake
11.Front disc brake
4. Glove box
8. Air filter
12.Front left shock absorber
1
7
2
6
4
5
3
8
9
10
11
12

The Serial Number
9
The Serial Number
Engine number
Engine number is stamped on the rear of the crankcase
assembly.
Note
Remember your engine number in mind for
convenience in purchasing correct spare parts from your
distributor.
Chassis number
Chassis number is stamped on the frame right side
frame rail.
Engine number
Chassis number
Please write down the serial numbers below for future
reference.
Chassis Serial No. :
Engine Serial No. :

Functions of Controllers
10
5
6
7
8
9
10
11
12
13
14
4
Functions of Controllers
Instrument Panel Indications
1 - Engine RPM Indicator
The indicator will show the engine RPM.
2 - Fuel gauge
This shows the fuel volume remaining in the fuel tank.
When the pointer points to “F”, the fuel tank is full. When
the pointer moves to “E” or lower, it means the fuel level
is low and refilling is necessary.
3 – TRIP
The trip registers the single distance that the scooter has
been ridden.
4 – DATE&TIME
Dispaly the date & time.
5/13- LH Direction Indicator & RH Direction Indicator
When the turning switch lever is set to left, the LH
Direction Indicator will flash. When the turning switch
lever is set to right, the RH Direction Indicator will flash.
6/12 – LEFT&Right set button,functions (See below):
Short press the left button“SET”:KPH and MPH change.
Long press the Right button“MODE”:TRIP clear.
1
2
3
4
15
16

Functions of Controllers
11
Long press the left button“SET”:
Long press the left key to enter the clock setting mode.
At this time, the month digit flashes. short press the right
button “MODE” to adjust. short press the left button
“SET” to shift. set the month、 day 、year、 minute AM
/ PM in turn. after setting, long press the left button“SET”
to save and exit. if there is no other operation more than
15s in this operation, it will automatically save and exit.
7 - High beam/ Low beam indicator
8 - Water temperature indicator
9 - ABS indicator
If this warning light appears during running please
consult your dealer.
10 - Engine fault indicator warning light
If this warning light appears during running please
consult your dealer.
11- Oil indicator
*STOP ENGINE* if this warning light appears during
running check oil level if found to OK. Then please
consult your dealer.
14 – Odometer
The odometer registers the total distance that the scooter
has been ridden.
15 - Water temperature gauge
16 – Speedometer
The speedometer shows the speed at which you are riding
in MPH or KPH.
Ignition Switch
Rotate the key to turn power ON or OFF.
Warning
Before open the ignition switch, To prepare an
adequate battery, and connected firmly, can not
have any loose.
ON
The engine can be started.
Possible to drive.
It is not possible to remove the key.
OFF
The engine cannot be started.
The engine is stopped.
The key can be inserted or removed.
LOCK
The steering bars can be locked to one direction.
The key can be inserted or removed.

Functions of Controllers
12
When you leave the scooter, you may lock the steering
handlebars to help prevent your scooter from being stolen.
1. Turn the handlebars to the left.
2. Insert the key (if it is not in the ignition) from OFF
position. Press the key in and turn it anti-clockwise to
LOCK position.
3. Pull out the key.
To unlocking the handlebars, insert the key from LOCK
position, and turn it (without pressing) clockwise to OFF
position.
Switches on the Handlebars(Left)
1. Beam Switch
This switch is used to change the headlamp beam.
When you turn the switch to:
Note
² Rotate the handlebars to ensure that they are
unlocked.
² Tip, you may turn the handlebars slightly
rightward and try again.
1
2
3

Functions of Controllers
13
HIGH
The high beam is turned on.
LOW
The low beam is turned on.
(Low beam is for normal riding)
2. Horn Button
Press this button to sound the horn.
3. Turning Indicator Switch
This switch is used to turn on/off the left/right
indicators to show the other vehicles that you want to
turn left or right. When you press the lever to:
Right
The right signal lamps flash.
Left
The left signal lamps flash.
Centre
Push in the switch at the centre position to
cancel the turn-signal operation.
Please turn off the lamps when they are no longer
necessary, otherwise you may cause problems to drivers in
front of or behind you.
Switches on the Handlebars(Right)
4. Starter Button
This button is used to start the engine. Turn the
ignition key to ON, squeeze the rear brake lever (6)
and press the button (4).
5.Throttle Grip
!Throttle grip is used to control engine speed. Rotate it
towards you to increase engine speed; Turn it away from
you to decrease the engine speed.
6. Brake Levers
By operating the brake levers, you can control the
6
5
4

Functions of Controllers
14
speed of the scooter to slow down or stop. The brake is
applied by squeezing the brake lever gently towards the
grip. The rear brake light will be illuminated when the
lever is squeezed inward.
7. Side Stand
To use the side stand, depress the end of the stand until
it rotates towards the front of the scooter and stops. Please
note: If the side stand is not fully retracted the engine will
not start.
8. Main Stand
To use the main stand, depress it by foot and lift the
rear of the scooter backwards using the rear rack until the
stand is securely in place with the rear wheel off the
ground.
Fuel Tank Cap
To access the fuel cap open up the seat .To open the fuel
cap, insert the ignition key into the cap and turn the fuel
cap tab clockwise. Please note: Don’t use the key to
rotate the cap as this make cause the key to break，shuold
the key and lock cover were rotated at the same time.
Close the fuel cap use the same way.
There has a Operation Notice deccal nerrby the fuel cap.
Operation Notice
When the key is inserted,the oil fillingport can
be opened or closed unless the key and lock
cover were rotated at the same time.
7 8

Functions of Controllers
15
Coolant tank cap
The coolant tank cap is in the left of vehicle.
Note
When the key is inserted,the oil fillingport can be
opened or closed unless the key and lock coverwere
rotated at the same time.
Warning
² Never open coolant tank cap when the scooter is
hot.
² Hot coolant can cause burns and may cause
injury.

Functions of Controllers
16
Seat Lock
To open and close the seat as follows:
1. The seat release button is located on the left
hand side and to the rear of the seat, push the
button in and the seat will open.
2. To close the seat gently lower the seat down
onto the locking pin.
Front Luggage Box
Caution
² Do not keep breakables in the luggage box.
² Do not keep valuable item in the luggage box.
² Do not place fuel and oil in the luggage box.
² Only store water proof items in luggage box

Fuel and Oil Recommendation
17
Fuel and Oil Recommendations
Fuel
Use unleaded fuel with an octane number Unleaded Euro
95 or higher. Unleaded fuel can extend spark plug life and
exhaust component life. We recommend using the highest
octane pump fuel available.
Engine Oil
Use of high quality 4-stroke engine oil will extend the
longevity of the engine. Grade SE or SD engine oil in API
method are recommended with a viscosity of SAE10W-40.
If this oil is not available, please purchase appropriate
substitutes according to the data listed below.
Transmission Oil
Use good quality SAE 75W-80 synthetic motor oil.
Specifications – API, GL4, GL5

Running –in of New Scooter
18
Running-in of New Scooter
The first 600 miles (1000km) are the most important in the
life of your scooter. Correct running-in operation during
this period will help ensure maximum life and
performance from your new scooter. The parts are
manufactured from high quality materials, and machined
parts are finished to close tolerances. Correct running-in
operation allows the machined surfaces to lap each other
and bedding together smoothly. Freeing up of the internal
parts is achieved after approximately 60 running hours,
and during this running-in period the engine will loosen up
and performance will improve.
Maximum Throttle Operation Recommendation
This table shows the maximum recommended throttle
operation during the break-in period. Change below to
miles
Initial 100 miles (160 km)
Less than 1/2 throttle
Initial 250 miles (400 km)
Less than 3/4 throttle
Vary the engine Speed
The engine speed should be varied and not held at a
constant speed. This allows the parts to be “loaded” with
pressure, and then unloaded, allowing the parts to cool.
This aids the bedding together process of the parts. It is
essential that some stress should be placed on the engine
component during running-in to ensure this bedding
together process. Do not, apply extensive load on the
engine during this period.
Avoiding Constant Low Speed
It is not beneficial when running in the engine to operate it
at a constant low speed. Allow the engine to accelerate
freely within the recommended maximum limits. Do not,
however, use full throttle for more than 10 minutes during
the first 1000 miles (1600km).

Inspection before Riding
19
Allow the Engine Oil to Circulate before Riding
Allow sufficient idling time after warm or cold engine start
up before applying load or revving up the engine. This
allows time for the lubricating oil to reach all critical engine
components.
Performing the First Service
The 600 miles (1000 km) service is the most important
service your scooter will receive. During running-in all of
the engine components will have bedded together and all the
other parts will have seated in. All adjustments will be
restored, all fasteners will be tightened, and the old oil will
be replaced. Timely performance of the 600 mile6 (1000km)
service will ensure optimum service life and performance
from the engine.
Inspection before Riding
Before riding the scooter, be sure to check the following
items. Never underestimate the importance of these checks.
Perform all of them before riding the machine.
Warning
Ensure that the battery is fully charged and that the
battery is secure and the battery terminals/connectors are
secure. A battery with loose connections will damage
electrical components including the ECU.
WHAT TO
CHECK
CHECK FOR
Steering
1) Smoothness
2) No restriction of movement
3) No play or excessive movement
Brakes
1) Correct brake lever free play
2) No obstruction in braking.
Tyres
1) Correct pressure
2) Adequate tread depth
3) No cracks or cuts
Fuel
Enough fuel for the planned distance of
the journey
Lighting
Operate all lights —headlamp, side lamp,
tail lamp, brake lamp, turning indicator
lamps
Caution
The 600 miles (1000km) service should be performed as
the outlined in the inspection and maintenance section in
this manual. Pay attention to the caution and warning in
that section.