Royal Alloy TG300S ABS User manual

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Dear Users,
Thank you for choosing the Royal Alloy brand scooter – TG300S. In order to make your driving safer and more
comfortable, please read and fully understand the contents of this manual.
This manual explains the structure, characteristics and maintenance of the motorcycle, as well as the main
information such as the structure and maintenance of the engine EFI system, so that you can carry out regular
maintenance operations of your vehicle. Since it is not possible to contain a complete mechanical concept in this
manual, the user should have basic mechanical knowledge when repairing motorcycles. Repairing or inspecting
vehicles without knowing it can be inefficient or even dangerous, so be very cautious so as not to damage parts
or injure individuals. It is highly recommended that you contact your local dealer for repairs and maintenance.
The Company reserves the right to make any modifications to the Product as a result of its updates. Subject to
change, the actual vehicle shall prevail without notice. Major technical changes and changes to repair procedures
are communicated to our sales outlets and international subsidiaries in a timely manner, and these changes will be
perfected in subsequent editions of the manual.
The following important information will appear in this manual:
Reminder: means the specific procedures implemented to prevent damage to the vehicle.

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Warning: Specific procedures implemented to prevent injury to persons.
INDEX
(1) Overview of characteristics ----------------------------------------------------------------------------------------- 4
(2) Tools ------------------------------------------------------------------------------------------------------------------------ 17
(3) Maintenance ------------------------------------------------------------------------------------------------------------- 22
(4) Electrical system ------------------------------------------------------------------------------------------------------- 48
(5) Engine removal --------------------------------------------------------------------------------------------------------- 55
(6) Engine disassembly --------------------------------------------------------------------------------------------------- 72
(7) EFI system ---------------------------------------------------------------------------------------------------------------- 89
(8) Braking system-------------------------------------------------------------------------------------------------------- 110
(9) Cooling system-------------------------------------------------------------------------------------------------------- 125
(10) Final inspection ----------------------------------------------------------------------------------------------------- 130

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(1) Overview of characteristics
Repair rules
Vehicle identification
Technical parameters
Description of the variable speed system
Lubrication system description
Fuel system description
Cooling system instructions
Chassis and suspension system description
Front and rear wheel description
Description of the braking system
Electrical system description
Tightening torque

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Repair rules
1. Must use parts and lubricants recommended by us or our company; Parts and lubricants that do not meet our
design specifications may damage the motorcycle. Recommended oil brand model: Motul Scooter Expert
Semi-synthetic 4-stroke SAE 10W/40-SJ.
2. When reassembled, new elastic washers, gaskets, O-rings, stand-up pins and retaining rings must be replaced.
3. When tightening bolts and nuts, start with a large diameter or from the inner bolt. Then increase the number
of steps diagonally, unless a special order is specified to tighten to the specified torque.
4. After decomposition, clean the parts in a clean solvent; Lubricate any smooth surfaces before assembly.
5. After reassembly, check that all parts are installed and operated correctly.
6. Unclog all cables and harnesses.
7. Please go to our authorized dealer for repair, unless the owner has special tools and repair data and is a
qualified mechanic.

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Vehicle Identification:
Frame number: engraved under the right pedal.
Engine number: engraved on the rear gearbox.

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NOTE: These numbers are necessary for vehicle registration identification and changing the identification
number may be severely punished by law, in particular modifying the chassis number will immediately void the
warranty
Technical details
Vehicle parameters
Engine parameters
Model
TG300S
Engine model
1P75MN
Vehicle size (mm).
1845×670×1115
Engine idling
1700(1±10%)
Track (mm).
1390
Engine type
Single-cylinder horizontal
water-cooled four-valve
overhead cam
Seat height (mm).
780
Bore ×stroke
(mm).
75*63
Minimum ground
clearance (mm).
145
Total displacement
(mL).
278（300cc）
Net weight (kg).
145
Compression ratio
11:1
Maximum load (kg, rider-
passenger luggage).
210
Maximum net
power (kW/r/min).
18.5/7250

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Front tyre
specifications/inflation
pressure
110/70-12
32 PSI
Maximum net
torque (Nm/r/min).
24.5/6000
Rear tyre
specifications/inflation
pressure
120/70-12
34 PSI
Startup mode
Electric start
Front brake
Disc brakes
Ignition method
EFI (Magneti Marelli).
Rear braking
Disc brakes
Valve clearance
(mm).
Intake valve: 0.10
Exhaust valve: 0.15
Battery capacity
12V 9Ah
Lubrication
method
Pressure/splash
Horn
90-100dB(A)
spark plug
NGK CR8EKB
Clutch
Automatic
centrifugal dry
clutch
02.0±
02.0±

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Description of the variable speed system
Items
Description
Variable speed transmission
CVT + V-belt + final gear reduction gearbox
CVT gear ratio
2.3～0.815：1
Final gear ratio
7.823
Overall gear ratio of the rear wheels
of the engine
6.38～18

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Lubrication system description
Items
Quantity
The total capacity of
engine lubricating oil is
1300ml
Grade: SAE10W-40-SJ
Change the
oil only
1200ml
Change the
oil and filter
element
1250ml
Remove the
engine and
fill it with oil
1300ml
Total capacity of
transmission lubricating
oil 250ml Grade: 75W-80
Change the
transmission
oil
200ml
Remove the
engine and
fill it with oil
250ml

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Fuel
Items
Description
Fuel grade
Unleaded gasoline above 95#
Fuel tank capacity
10.5L
Cooling system description
Items
Description
Coolant capacity
When
replaced
1.15L
When
disassembling
1.20L
Recommended antifreeze
Coolant or ethylene glycol antifreeze of the
same quality is mixed with distilled water at a 1:1
rate, the freezing point reaches -40 ° C
, and the
boiling point reaches 108 ° C.

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Chassis and suspension system description
Items
Description
Chassis
High-strength steel tubular chassis with
single bar at the front and double brackets
at the rear
Forward tilt
26.30°
Front suspension
Adjustable preload, hydraulic, retractable
fork
Front suspension travel
70mm
Rear suspension
Adjustable preload, hydraulic, double-
acting shock absorbers
Rear suspension travel
85mm
Front and rear wheel description
Items
Description
Rim material
Aluminum alloy
Front wheel tyres
Tubeless 110/70-12
Rear wheel tyres
Tubeless 120/70-12
Front tyre inflation pressure
32/220（Psi/KPa）

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Rear tyre inflation pressure
34/234（Psi/KPa）
Description of the braking system
Items
Description
Braking system
ABS
Front wheel brakes
¢220mm disc hydraulic brake
Rear wheel brakes
¢220mm disc hydraulic brake
Brake fluid
FMVSS DOT4+
Electrical system description
Items
Description
Battery capacity
12V-9Ah
Fuse
20-15-15-15A
Permanent magnet alternator
12 V - 330W at 8000 rpm
spark plug
NGK CR8EKB
Lamps/warning
lights
High/low beam
12V 20/10W LED
Front position light
(daytime light)
LED

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Tail light (daytime
light)
LED
License plate lights
LED
Brake lights
LED
Front and rear turn
signals
LED
appearance
Indicator dial light
LED
Turn warning lights
LED
High beam warning light
LED
Engine oil pressure
warning light
LED
Low oil warning light
LED
EFI fault warning light
LED

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Tightening torque
Fastening parts
Quantity
Thread specifications
Torque: Nm
Engine hanger mounting nut
1
M10
45
Engine mounting nut
1
M10
45
Front axle nut
1
M12
60
Rear axle nut
1
M14
100
Bolts are mounted on the rear
shock absorber
2
M10
40
Bolts are installed under the rear
shock absorber
2
M8
25
Fixed bolts above the front shock
absorber
2
M6
12
Fixed bolts under the front shock
absorber
2
M12
60
Steering post lock nut
1
M25
70
Orient the mounting nut
1
M10
45
Front brake disc fastening bolts
3
M8
25
Rear wheel fastening bolts
5
M12
60
Rear brake disc fastening bolts
5
M8
25

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Other specifications of bolt reference: GB1231-2006 bolt torque standard
Engine section:
Fastening parts
Quantity
Thread specifications
Torque: Nm
Head bolt A
4
M8
24～26
Head bolt B
2
M6
10～12
Camshaft cover fixing bolts
8
M6
10～12
Timing sprocket bolts
2
M8
25～30
Exhaust pipe joint fixing bolts
2
M7
12～14
Oil filter cover
2
M6
9～12
Closing bolts
3
M6
9～12
Intake manifold bolts
3
M6
9～12
Crankcase drain bolts
1
M28
24～30
Gearbox drain bolt
1
M6
10～12
Front clutch nut
1
M12
70～80
Rear clutch nut
1
M12
55～65
Magneto rotor fixing nut
1
M8
23～27
Water temperature sensor
1
M12
20～24
spark plug
1
M10
12～14

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Other specifications of bolt reference: GB1231-2006 bolt torque standard
(2) Tools
1. Special tools: (The following tools are only operated by professional technicians, and the owner is not allowed
to operate without authorization).
Item
The name of the
dedicated tool
Tool
number
Image
1
Valve spring
compressor
Z01

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2
Crankshaft
positioning bolts
(top dead center
positioning)
Z02
3
Clutch drive wheel
limiter
Z03
4
Bearing punches of
various
specifications
Z06.1---
Z06.8

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5
Oil seal punches of
various
specifications
Z07.1--
Z07.9
6
Magneto rotor
extractor
Z04
7
Spark plug sleeve
Z05
8、
Troubleshooter
Z08
9、
Shock absorbers
adjust the handles
Z09

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2. General tools:
Item
Description
1
T" sleeves: 8#, 10#, 12#,
14#
2
Toolbox 1