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