TGB blade 300 User manual

BLADE250/300
SERVICEMANUAL
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This service manual contains the technicaldata of each component inspection and
repair for the BLADE 250/300 ATV. The manual is shown with
illustrations andfocused 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 250/300, are different from that
of the photos, picturesshown in thismanual, the actual vehicleshallprevail.
Specifications are subject tochange without notice.
ServiceDepartment
TAIWAN GOLDENBEECO.,LTD.
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HOW TOUSE THISMANUAL
This service manual describes basic information of different system parts and
systeminspection & service for BLADE 250/300 ATV. In addition,
please refer tothe manual contents in detailed for the modelyou serviced in
inspection and adjustment.
The first chapter covers general information and trouble diagnosis.
The secondchapter covers service maintenance information and specialtools
manual.
The third tothe 11thchapterscoverengineand driving systems.
The 12thchapter iscooling system.
The 13thto the16thchapter iscontained thepartsset of assembly framebody.
The 17thchapter iselectrical equipment.
The 18thchapter iswiring diagram.
Please see index ofcontent for quickhavingthe specialpartsand system
information.
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CONTENTS
PageContent Index
1-1~1-19 GENERALINFORMATION 1
2-1~2-14 SERVICEMAINTENANCEINFORMATION 2
3-1~3-8 LUBRICATIONSYSTEM 3
4-1~4-12 FUELSYSTEM 4
5-1~5-6 ENGINEREMOVAL 5
6-1~6-16 CYLINDER HEAD/VALVE 6
7-1~7-8 CYLINDER/PISTON 7
8-1~8-14 V”TYPE BELTDRIVINGSYSTEM/KICK-STARTER 8
9-1~9-12 FINALDRIVINGMECHANISM 9
10-1~ 10-10 ALTERNATOR 10
11-1~ 11-8 CRANKSHAFT/ CRANKCASE 11
13-1~ 13-9 BODYCOVER 13
14-1~ 14-14 FRONTBRAKEAND FRONTWHEEL 14
15-1~ 15-10 STEERING/FRONTSUSPENSION 15
16-1~ 16-18 REARBRAKE/REARWHEEL/REAR CUSHION 16
17-1~ 17-22 ELECTRICALEQUIPMENT 17
18-1~ 18-2 ELECTRICALDIAGRAM 18
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SERIAL NUMBER Homepage Contents
Framenumber
Enginenumber
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1. GENERALINFORMATION
Symbolsand Marks............................. 1-1
GeneralSafety..................................... 1-2
Service Precautions............................ 1-3
Specifications...................................... 1-9
SymbolsandMarks
Specifications..................................... 1-10 1
TorqueValues.................................... 1-11
TroublesDiagnosis............................ 1-13
Lubrication Points.............................1-18
Symbolsandmarks areused inthis manualtoindicatewhat and wherethespecialserviceareneeded,in
casesupplementalinformationisproceduresneeded forthesesymbols andmarks,explanations will be
addedtothe textinsteadof usingthesymbols ormarks.
Warning
Meansthatseriousinjuryorevendeathmay resultifproceduresarenot
followed.
Caution
Meansthatequipment damages may resultifproceduresarenotfollowed.
Engine oil
Limits touseSAE 10W-30API SGclass oil. Warrantywillnotcoverthe
damagethat caused bynotapplywiththelimited engine oil.
(Recommended oil: KINGMATEG-3oil)
Grease KingMateG-3is recommended.
Gear oil
Locking sealant
KingMategearoil serials arerecommended. (BramaxHYPOIDGEAROIL
#140)
Apply sealant;mediumstrengthsealant shouldbeused unlessotherwise
specified.
Oil seal Apply withlubricant.
Renew Replacewithanewpart beforeinstallation.
Brake fluid
Userecommended brakefluidDOT3orWELLRUNbrakefluid.
Special tools
Specialtools
Correct
Meaningcorrect installation.
Wrong
Meaningwronginstallation.
Indication Indicationof components.
Directions
Indicatespositionand operation directions
Components assemblydirectionseachother.
Indicates wheretheboltinstallation direction, --- means thatbolt
cross through thecomponent (invisibility)
1-1
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Tothischaptercontents
1. GENERAL INFORMATION
GeneralSafety
Carbonmonoxide
If you mustrun yourengine,ensurethe placeis
well ventilated.Neverrunyourengine inaclosed
area.Run yourengine inanopenarea,if you have
torun yourengineinaclosedarea,be suretouse
an extractor.
Caution
Exhaust contains toxicgaswhichmay causeone
toloseconsciousness and evenresultindeath.
Gasoline
Gasoline isalowignitionpointandexplosive
material.Workinawell-ventilatedplace,no flame
orspark shouldbeallowed inthework placeor
wheregasolineis being stored.
Caution
Gasolineis highlyflammable,and mayexplode
undersomeconditions, keepitawayfrom
children.
Usedengineoil
Caution
Prolonged contactwithusedengine oil(or
transmissionoil)may causeskincanceralthough it
mightnot beverified.
Werecommend thatyou washyourhandswith
soapand waterrightaftercontacting.Keepthe
usedoilbeyondreachof children.
Hotcomponents
Caution
Components oftheengineandexhaust system
can becomeextremelyhotafterengine running.
They remainveryhot evenafterthe engine has
beenstopped forsometime. Whenperforming
serviceworkontheseparts,wearinsulated
glovesandwait untilcooling off.
Battery
Caution
‧ Battery emits explosivegases; flameis strictly
prohibited.Keeps theplacewellventilated
whenchargingthebattery.
‧ Battery contains sulfuric acid(electrolyte)
whichcan causeseriousburnssobe careful
do notbe sprayon youreyesorskin.If you
get batteryacidon yourskin,flushit off
immediately withwater.If you get batteryacid
inyoureyes,flushit off immediatelywithwater
andthengo tohospitaltosee an
ophthalmologist.
‧ If you swallowitby mistake, drinkalot of
waterormilk,and takesomelaxativesuchas
castoroil orvegetableoiland then gotoseea
doctor.
‧ Keep electrolytebeyondreachof children.
Brakeshoe
Donotusean airhoseoradry brushtoclean
components ofthebrakesystem; useavacuum
cleanerorthe equivalent toavoiddust flying.
Caution
Inhalingbrakeshoeorpad ashmay cause
disordersandcancerofthebreathingsystem
Brakefluid
Caution
Spillingbrakefluidonpainted, plastic,orrubber
parts may causedamage totheparts. Placea
cleantowelon theabove-mentioned parts for
protectionwhen servicing thebrakesystem.
Keep thebrakefluidbeyondreachof children.
1-2
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To thischaptercontents
1. GENERALINFORMATION
ServicePrecautions
● AlwaysusewithSANYANGgenuineparts and
recommendedoils.Usingnon-designedpartsfor
SANYANGATVmaydamagetheATV.
● Specialtools aredesignedforremoveand
installof componentswithout damagingthe
parts beingworked on.Using wrong toolsmay
result inparts damaged.
● Whenservicing this ATV,useonlymetrictools.
Metricbolts,nuts,andscrewsarenot
interchangeablewiththeEnglishsystem, using
wrongtools and fasteners may damage this
vehicle.
● Cleanthe outsideof the parts orthecoverbefore
removing it fromthe ATV. Otherwise,dirtand
depositaccumulated onthe part'ssurfacemay fall
intothe engine, chassis,orbrakesystemtocause
damage.
● Washand clean parts withhigh ignitionpoint
solvent,andblowdrywithcompressedair.Pay
specialattentiontoO-ringsoroilsealsbecause
most cleaning agentshavean adverseeffect on
them.
● Neverbend ortwist acontrolcabletoprevent
unsmoothcontroland prematurewornout.
● Rubberpartsmaybecomedeterioratedwhen old,
and pronetobe damaged by solventandoil.
Check theseparts beforeinstallation tomakesure
that they areingood condition,replaceif
necessary.
● When loosening acomponentwhichhas
different sized fasteners, operatewitha
diagonalpatternand work frominside out.
Loosen thesmallfastenersfirst.Ifthe bigger
onesareloosenfirst,smallfasteners may
receivetoomuchstress.
● Storecomplex componentssuchas
transmissionparts intheproperassembleorder
and tiethemtogetherwithawireforeaseof
installation later.
● Notethe reassemblepositionof theimportant
components beforedisassembling themto
ensuretheywillbereassembledincorrect
dimensions (depth, distanceorposition).
● Components nottobereusedshouldbe
replacedwhen disassembled includinggaskets
metalsealrings, O-rings,oilseals, snap rings,
and splitpins.
1-3
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Tothischaptercontents
1. GENERAL INFORMATION
● Thelengthofboltsand screws forassemblies,
coverplates orboxes isdifferentfromoneanother,
be surethey arecorrectlyinstalled.Incaseof
confusion, Insertthebolt intothe holetocompare
its lengthwithotherbolts,if its lengthout sidethe
holeisthesamewithotherbolts,itis acorrect
bolt. Bolts forthesameassembly shouldhavethe
samelength.
● Tightenassemblies withdifferentdimension
fastenersas follows: Tighten all the fasteners
withfingers, thentightenthe bigones with
specialtoolfirstdiagonally frominsidetoward
outside,important components shouldbe
tightened 2to3times withappropriate
increments toavoidwarpunlessotherwise
indicated. Boltsandfastenersshouldbe kept
cleanand dry. Donot apply oiltothe threads.
● Whenoilsealis installed,fillthegroovewith
grease,installthe oilsealwiththenameof the
manufacturerfacing outside,andcheck theshaft
on whichtheoilsealistobe installedfor
smoothness and forburrs that may damage the
oilseal.
● Removeresiduesofthe oldgasketorsealant
beforereinstallation,grind withagrindstoneif
thecontact surfacehas anydamage.
● Theends of rubberhoses(forfuel, vacuum, or
coolant)shouldbepushed asfaras they can go
totheirconnections sothatthereis enough room
belowthe enlarged endsfortightening the
clamps.
Groove
Clamp
Connector
● Rubberand plasticbootsshouldbe properly
reinstalledtotheoriginalcorrect positionsas
designed.
Boots
● Thetoolshouldbe pressedagainst two(inner
and outer) bearing raceswhen removingaball
bearing. Damage may resultif thetoolispressed
against only onerace(eitherinnerraceorouter
race).Inthis case, the bearingshouldbe
replaced. Toavoiddamaging thebearing, use
equalforceonbothraces.
Manufacturer'sname
1-4
Bothoftheseexamplescanresultin
bearing damage.
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To thischaptercontents
1. GENERALINFORMATION
● Lubricatethe rotationfacewithspecified
lubricantonthelubricationpoints before
assembling.
● Checkifpositionsand operation forinstalled
parts isincorrect and properly.
● Makesureservicesafetyeachotherwhen
conducting by twopersons.
● Notethat donotletparts fall down.
● Afterservicecompleted, makesureall
connectionpoints is secured.
Battery positive(+)cableshouldbeconnected
firstly.
● Andthe twoposts ofbattery havetobegreased
afterconnected thecables.
● Makesurethat thebattery post capsare
located inproperlyafterthe battery posts had
beenserviced.
● If fuseburned,it has tofindout thecauseand
solved it. Andthenreplacewithspecified
capacity fuse.
● Beforebattery removaloperation,it has to
removethebatterynegative(-)cablefirstly. Notre
toolslikeopen-endwrenchdo notcontact with
body topreventfromcircuitshortandcreate
spark.
Capacity
verification
1-5
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ontents
1. GENERAL INFORMATION
● Whenseparating aconnector, itlockerhastobe
unlockedfirstly. Then, conduct theservice
operation.
● Donotpullthe wiresasremoving aconnector
orwires. Holdthe connectorbody.
● Makesureif the connectorpins arebent,
extrudedorloosen.
● Insert the connectorcompletely.
If therearetwolockerson twoconnectorsides,
makesurethe lockersarelockedinproperly.
Checkifany wireloose.
● Checkif the connectoriscoveredby thetwin
connectorboot completelyand secured
properly.
● Beforeterminalconnection,check if the bootis
crackorthe terminalis loose.
1-6
● Insertthe terminalcompletely.
Check if theterminaliscovered bythe boot.
Donot letboot openfacingup.
● Securewiresandwireharnessestothe frame
withrespectivewirebands at thedesignated
locations. Tightenthe bands sothat onlythe
insulated surfaces contact the wiresorwire
harnesses.
● Wirebandandwireharnesshavetobe
clampedsecured properly.
● Donot squeezewiresagainsttheweldorits
clamp.
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1. GENERALINFORMATION
● Donotletthewireharness contactwithrotating,
movingorvibrating components as routing the
harness.
● Keep wireharnesses faraway fromthehot
parts.
NeverTouch
● Routewireharnesses toavoidsharpedgesor
cornersandalsoavoidtheprojectedendsof
bolts and screws.
● Routeharnesses sothattheyneitherpull too
tightnorhaveexcessiveslack.
● Protect wiresorwireharnesseswithelectrical
tapeortubeiftheycontact asharpedgeor
corner.Thoroughly clean thesurfacewhere
tapeistobe applied.
● Securethe rubberbootfirmlyas applyingit on
wireharness.
● Neverusewiresorharnesseswhichinsulation
hasbeenbroken. Wrapelectricaltapearound
thedamaged parts orreplacethem.
● Neverclamporsqueezethewireharnessas
installingothercomponents.
Never clampor
squeeze thewire
harness
Never tootight
1-7
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1. GENERAL INFORMATION
● Donotletthewireharnessbeentwistedas
installation.
● Wireharnessesrouted along thehandlebar
shouldnot bepulled tootight orhaveexcessive
slack, be rubbed againstorinterferewithadjacent
orsurroundingparts inallsteering positions.
● Beforeoperatingatest instrument,operator
shouldread theoperationmanualofthe
instrument.And then, conduct test in
accordancewiththe instruction.
● Withsand papertoclean rust onconnector
pins/terminalsiffound. Andthen conduct
connectionoperation later.
Cleanrust
Doyouknow howtosetthe
instrumenttoits
measurement position and
the insert locationsof its
twoprobes?
1-8
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1. GENERALINFORMATION
Specifications
MAKER TGB MODEL UA25A
Overall Length 2160mm Front Doublearm
Overall Width 1160mm
Suspension
System Rear UnitSwing
Overall Height 1175mm Front AT22x7-10 (onroad)
WheelBase 1300mm
Tire
Specifications Rear AT22x10-10(on road)
Front 940mm Rim Aluminum
Wheeltread
Rear 890mm Front Disk(Ø180mm)
Front 137kg BrakeSystem Rear Disk (Ø220mm)
Rear 118kg Max. Speed Above86 km/hr
Curb
Weight Total 255kg Performance
ClimbAbility Below25ﾟ
Passengers/weight Two/150 kg
Front 179kg
Primary
Reduction Belt
Rear 244kg
WeightDimension
Total
Weight Total 423kg
Secondary
Reduction Gear/ Sprocket
Type 4-StrokeEngine Clutch Centrifugal,drytype
Installationand
arrangement Vertical,below center,incline
Reduction
Transmission C.V.T.,autospeed
change
FuelUsed Above92 unleaded Speedometer 0~300 km/hr
Cycle/Cooling 4-stroke/Watercooled Horn 93~112dB/A
Bore Ø71 mm Muffler
Expansion &Pulse
Type
Stroke 63 mm
ExhaustPipePosition
and Direction
Leftside,and
Backward
Cylinder
Number/
Arrangement
SingleCylinder Lubrication System
Forcedcirculation&
splashing
Displacement 249.4cc SolidParticulate
Compression Ratio 10.5:1 CO Below7.0g/km
Max. HP 14.7kw /6500rpm HC Below1.5g/km
Max. Torque 23.5Nm/ 5500rpm
Exhaust
Concentration
Nox Below0.4g/km
Ignition C.D.I. E.E.C.
StartingSystem Electricalstarter P.C.V.
Engine
Airfiltration Sponge
Catalyticreactioncontrol
system
1-9
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1. GENERAL INFORMATION
Specifications
MAKER TGB MODEL UA25C
Overall Length 2160mm Front Doublearm
Overall Width 1160mm
Suspension
System Rear UnitSwing
Overall Height 1205mm Front AT25x8-12 (onroad)
WheelBase 1300mm
Tire
Specifications Rear AT25x10-12(on road)
Front 940mm Rim Aluminum
Wheeltread
Rear 890mm Front Disk(Ø180mm)
Front 145kg BrakeSystem Rear Disk (Ø220mm)
Rear 129kg Max. Speed Above86 km/hr
Curb
Weight Total 274kg Performance
ClimbAbility Below25ﾟ
Passengers/weight Two/150 kg
Front 186kg
Primary
Reduction Belt
Rear 256kg
WeightDimension
Total
Weight Total 442kg
Secondary
Reduction Gear/ Sprocket
Type 4-StrokeEngine Clutch Centrifugal,drytype
Installationand
arrangement Vertical,below center,incline
Reduction
Transmission C.V.T.,autospeed
change
FuelUsed Above92 unleaded Speedometer 0~300 km/hr
Cycle/Cooling 4-stroke/Watercooled Horn 93~112dB/A
Bore Ø71 mm Muffler
Expansion &Pulse
Type
Stroke 63 mm
ExhaustPipePosition
and Direction
Leftside,and
Backward
Cylinder
Number/
Arrangement
SingleCylinder Lubrication System
Forcedcirculation&
splashing
Displacement 249.4cc SolidParticulate
Compression Ratio 10.5:1 CO Below7.0g/km
Max. HP 14.7kw /6500rpm HC Below1.5g/km
Max. Torque 23.5Nm/ 5500rpm
Exhaust
Concentration
Nox Below0.4g/km
Ignition C.D.I. E.E.C.
StartingSystem Electricalstarter P.C.V.
Engine
Airfiltration Sponge
Catalyticreactioncontrol
system
1-10
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1. GENERAL INFORMATION
Specifications
MAKER TGB MODEL ATV300C.C.
Overall Length 2155mm Front Doublearm
Overall Width 1170mm
Suspension
System Rear UnitSwing
Overall Height 1175mm Front
AT22x7-10
AT25x8-12
AT23x8-12
WheelBase 1300mm
Tire
Specifications
Rear
AT22x10-10
AT25x10-12
AT23x10-10
Front 890mm Rim Aluminum
Wheeltread
Rear 940mm Front Disk(Ø180mm)
Front 156kg BrakeSystem Rear Disk (Ø220mm)
Rear 129kg Max. Speed Above86 km/hr
Curb
Weight Total 285kg Performance
ClimbAbility Below25ﾟ
Passengers/weight Two/150 kg
Front 190kg
Primary
Reduction Belt
Rear 260kg
WeightDimension
Total
Weight Total 450kg
Secondary
Reduction Gear/ Sprocket
Type 4-StrokeEngine Clutch Centrifugal,drytype
Installationand
arrangement Vertical,below center,incline
Reduction
Transmission C.V.T.,autospeed
change
FuelUsed Above92 unleaded Speedometer 0~300 km/hr
Cycle/Cooling 4-stroke/Watercooled Horn 93~112dB/A
Bore Ø75 mm Muffler
Expansion &Pulse
Type
Stroke 65 mm
ExhaustPipePosition
and Direction
Leftside,and
Backward
Cylinder
Number/
Arrangement
SingleCylinder Lubrication System
Forcedcirculation&
splashing
Displacement 287.2cc SolidParticulate
Compression Ratio 8.8: 1 CO Below7.0g/km
Max. HP 15kw/ 6500rpm HC Below1.5g/km
Max. Torque 24.7Nm/ 5500rpm
Exhaust
Concentration
Nox Below0.4g/km
Ignition C.D.I. E.E.C.
StartingSystem Electricalstarter P.C.V.
Engine
Airfiltration Sponge
Catalyticreactioncontrol
system
1
-
1
1
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1. GENERALINFORMATION
TorqueValues
Thetorque valueslistedinabovetableareformoreimportanttightentorque values. Pleasesee standard
valuesfornot listedinthetable.
StandardTorqueValues forReference
Type TightenTorque Type TightenTorque
5mmbolt 、 nut 0.45~0.6kgf-m 5mm screw 0.35~0.5kgf-m
6mmbolt 、 nut 0.8~1.2kgf-m 6mm screw 、 SHnut 0.7~1.1kgf-m
8mmbolt 、 nut 1.8~2.5kgf-m 6mmbolt 、 nut 1.0~1.4kgf-m
10 mmbolt 、 nut 3.0~4.0kgf-m 8mmbolt 、 nut 2.4~3.0kgf-m
12 mmbolt 、 nut 5.0~6.0kgf-m 10mmbolt 、 nut 3.5~4.5kgf-m
EngineTorqueValues
Item Q’ty ThreadDia.(mm) TorqueValue(kgf-m) Remarks
Cylinderstud bolt 4 10 1.0~1.4
Cylinderheadnut 4 8 3.6~4.0
Cylinderheadright bolt 2 8 2.0~2.4
Cylinderheadsidecoverbolt 2 6 1.0~1.4
Cylinderheadcoverbolt 4 6 1.0~1.4
Cylinderheadstudbolt(inletpipe) 2 6 1.0~1.4
Cylinderheadstudbolt(EX.pipe) 2 8 2.4~3.0
Airinjectpipe bolt 4 6 1.0~1.4
Airinjectreedvalvebolt 2 3 0.07~0.09
Tappetadjustmentscrewnut 4 5 0.7~1.1 Apply oil tothread
Sparkplug 1 10 1.0~1.2
Tensionerlifterbolt 2 6 1.0~1.4
Carburetorinsulatorbolt 2 6 0.7~1.1
Oil pumpscrew 2 3 0.1~0.3
Waterpumpimpeller 1 7 1.0~1.4
Engineleftcoverbolt 9 6 1.1~1.5
Engineoildraining bolt 1 12 3.5~4.5
Engineoilstrainercap 1 30 1.3~1.7
Mission drainingbolt 1 8 1.1~1.5
Mission fillingbolt 1 12 3.5~4.5
Shiftdrumfixing bolt 1 14 3.5~4.5
Clutchdrivingplatenut 1 28 5.0~6.0
Clutchouternut 1 14 5.0~6.0
Drivefacenut 1 14 8.5~10.5
ACG. Flywheelnut 1 14 5.0~6.0
Crankcasebolts 7 6 0.8~1.2
Mission casebolt 7 8 2.6~3.0
1-12
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1. GENERAL INFORMATION
FrameTorqueValues
Item Q’ty ThreadDia.(mm) TorqueValue(kgf-m) Remarks
Handlebarupperholderbolt
4 6 2.40
Steeringshaftnut
1 10 5.00
Steeringtie-rod nut
4 10 5.00
Knucklenut
2 10 5.00
Steeringshaftholderbolt
2 8 3.40
Tierodlocknut
4 10 3.60
Handlebarunderholdernut
2 8 4.00
Front wheelnut
8 10 2.40
Frontaxlecastlenut
2 14 5.00
Rearaxle castle nut
2 14 5.00
Rearwheel nut
8 10 2.40
Enginehangernut
4 12 8.50
Rearaxle holderbolt
4 12 9.20
Drivegearbolt
2 10 4.6
Driven gearnut
4 10 4.6
Swingarmpivotbolt
1 14 9.20
Frontsuspensionarmnut 4 10 5.00
Front / Rearcushion mountingbolt 6 10 4.60
Brakelevernut
2 6 1.00
Brakehosebolt
13 10 3.50
Brakecaliperbolt
6 6 3.25
Brakediskmountingbolt
11 8 4.25
Air-bleed valve
3 5 0.50
Exhaustmufflermountingbolt
2 8 3.00
Exhaustmufflerconnectionnut
2 7 1.20
1-13
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1. GENERALINFORMATION
Troubles Diagnosis
A.Enginehardto startorcannot bestarted
Check andadjustment Faultcondition Probablecauses
Loosen carburetordrain bolt to
checkifthereisgasolineinside
thecarburetor
Fuelsupplied tom
carburetor sufficient
Remove spark plug, installit
into spark plugcap, and performa
sparktest against engineground.
Nofuel is supplied to
carburetor
No fuel in fueltank
Check ifthepipes,fuel tanktocarburetor
and intakevacuum,areclogged.
Float valve clogged
Lines infueltankevaporation
system clogged
Malfunctionof fuel pump
Loosen ordamagedfuel pump
vacuum hose
Fuelfilterclogged
Malfunctionof spark plug
Spark plug foul
Check if sparks Weak sparks, no sparkat
all
Performcylinder compression
pressure test.
Malfunctionof CDI set
Malfunctionof AC generator
Ignitioncoilis inopenor shortcircuit
Ignitioncoilleadsopenorshort circuit
Malfunctionof main switch
Cylinder compression
pressurenormal
Re-start byfollowing the starting
procedures
Lowcompression
pressureor no pressure
Piston ring seized
Malfunction of cylinder valves
Worn cylinder and piston ring
Cylindergasketleak
Sandhole incompressionparts
No ignition There aresomesigns of
ignition;nut engine can
notbestarted
Malfunctionof throttle valveoperation
Airsucked intointake manifold
Incorrect ignitiontiming
Remove thesparkplug again
andcheckit.
Dryspark plug Wet sparkplug
Fuellevelin carburetor too high
Malfunctionof throttle valveoperation
Throttlevalve openingtoowide
Remove carburetorafter30
minutesandconnect ahose
onto fuel rich circuit.Thenblow
thehosewithair
Blowing innormal Blowing clogged
Malfunctionof automatic by-starter
1-14
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1. GENERAL INFORMATION
B.Enginerun sluggish(Speeddoesnotpick up, lackofpower)
Checkandadjustment Faultcondition Probablecauses
Trygradualacceleration and
checkengine speed
Engine speedcan be
increased.
Check ignition timing (Using
ignitionlamp)
Engine speed cannot be
increased.
Air cleaner clogged
Poorfuel supply
Linesinfuel tankevaporation
system clogged
Exhaustpipeclogged
Fuelnozzle clogged in carburetor.
Fuelnozzle clogged in carburetor.
Ignitiontiming correct Incorrect ignitiontiming
Malfunctionof CDI
Malfunctionof AC alternator
Checkcylindercompression
pressure(usingcompression
pressuregauge)
Compressionpressure
correct
Check if carburetor jet is
clogged
No compressionpressure
Cylinder&piston ring worn out
Cylindergasket leaked
Sand hole in compressionparts
Valve deterioration
Seized piston ring
Noclogged Clogged
Remove foreign
Remove spark plug
Nofoulor discoloration Fouled and discoloration
Check if engine over heat
Normal Engine overheat
Continuallydriveinacceleration
orhighspeed
Noknock Knock
Remove dirt
Incorrect spark plug heatrange
Piston and cylinderworn out
Leanmixture
Poorfuel quality
Too muchcarbon deposited
in combustionchamber
Ignitiontiming too advanced
Poorcircuitonthecooling system
Too muchcarbon deposited
in combustionchamber
Leanmixture
Poorfuel quality
Ignitiontiming too advanced
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