TGB EST 1000 User manual

EST1000
SERVICEMANUAL
TAIWANGOLDENBEE CO.,LTD.

Thisservice manualcontainsthetechnicaldataofeachcomponent
inspectionandrepairsfor the Blade1000.The manualis
shown withillustrations andfocusedon ServiceProcedures”,
OperationKeyPoints”,and InspectionAdjustment”sothatprovides
technicianwithservice guidelines.
If the styleandconstructionoftheBlade1000aredifferent
fromthatof thephotos,picturesshown inthismanual,theactual
vehicleshall prevail.Specificationsaresubjecttochangewithout
notice.
Thisservice manualdescribesbasicinformationof differentsystem
partsandsysteminspection&service forBlade1000.In
addition,please refertothemanualcontentsindetailedforthe
modelyouservicedininspectionandadjustment.
Please seethecontentforquick havingthe specialpartsandsystem
information.

1. GENERAL INFORMATION
1-2
PAGE CONTENT
1
GENERALINFORMATION
2
SERVICEMAINTENANCEINFORMATION
3 LUBRICATIONSYSTEM
4-1
FUELSYSTEM
4-2
FUELINJECTIONSYSTEM
5-1
ENGINEASSEMBLY
5-2
ENGINETOPEND
5-3
ENGINEBOTTOM END
5
-
4
TRANSMISSIONBEARBOX
5
-
5
CONTINUOUSLY VARIABLETRANSMISSION
6 DRIVESYSTEM
7-1
STEERINGSYSTEM &SUSPENSION
7-2
ELECTRICPOWERSTEERING
7-3
BRAKESYSTEM &BODYCOVER
8-1
ELECTRICSYSTEM
8-2 ELECTRICDIAGRAM

1. GENERAL INFORMATION
1-3
SERIALNUMBER
FrameNumberandEngineNumber
TST*000001*

2.MAINTENANCEINFORMATION
2
-
1
PrecautionsinOperation 2-1
PeriodicalMaintenanceSchedule 2-2
FuelLines 2-3
Acceleration Operation 2-3
AirCleaner 2-3
SparkPlug 2-3
ValveClearance 2-4
CarburetorIdleSpeedAdjustment 2-5
Ignition System 2-6
CylinderCompressionPressure 2-6
DriveBelt 2-7
BrakeSystem(DiskBrake) 2-8
BrakeLight Switch/StartingInhibitor
Switch 2-9
HeadlightBeamDistance 2-10
ClutchDiscWear 2-10
Cushion 2-10
SteeringHandle 2-11
Wheel/Tire 2-11
Nuts,BoltsTightness 2-11
SpecialTools List 2-12
Specification Fuel Tank Capacity
2300c.c.
Oil &FilterChange
2000 c.c.
Oilchange
1800c.c.
EngineOil
NewEngine
2300c.c.
BearBox Capacity
900cc
Front Capacity
350 c.c.
TransmissionGearoil
Rear Capacity
500 c.c.
Engine +Radiator
2600c.c.
Capacity of coolant
Reservoirupper 1100c.c.
Clearanceof throttlevalve
1~3mm
Type
NGKDCPR8E
Spark Plug Gap
0.7~0.8 mm
Idling speed 1250±100 rpm
Cylindercompression pressure 9 ±1kgf/cm²
Valveclearance
IN:0.10 ±0.02mm EX:0.15 ±0.02
mm
Front AT25x8-12 AT26x8-14
Tiredimension
Rear AT25x10-12 AT26x10-14
Tirepressure 7psi
Battery 12V18Ah(type: MFbattery)
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2. MAINTENANCEINFORMATION
2
-
2
Periodical MaintenanceSchedule
MONTHS 1 3 6 12
Kms INITIAL200 EVERY1000 EVERY2000 EVERY4000
INTERVAL
ITEM
MILES INITIAL120 EVERY600 EVERY1200 EVERY2400
MufflerBoltsand ExhaustPipeNuts T T T T
ValveClearance I - I I
AirCleaner - C C R
AirCleanerVentTube I I I
EngineIdleRPM I I I I
- - I I
SparkPlus ReplaceEvery6000KM(4000MILES)
EngineOil R - R R
Oil Filter R - R R
R - R R
FrontDifferentialSetOil ReplaceEvery6000KMorEvery6Months
R - R R
FinalGearOil ReplaceEvery6000KMorEvery6Months
C.V.TBelt - - I I
- I I I
FuelTube ReplaceEvery4Years
ThrottleCablePlay I I I I
Brakes I I I I
- - I I
Brake Hose ReplaceEvery4Years
- I I I
Brake Fluid ReplaceEvery2Years
Tires - I I I
Suspensions - - I I
Steering System I I I I
ChassisBoltsandNuts T T T T
General Lubrications - L L L
Greasenipple - - L L
Code:C ~Cleaning (replacedifnecessary)I~Inspection,cleaning,andadjustment
L~LubricationR ~ReplacementT~Tighten
HaveyourATVchecked, adjusted,and recordedmaintenancedataperiodicallybyyourTGB
AuthorizedDealertomaintaintheATVat the optimumcondition.
The abovemaintenancescheduleisestablishedbytakingthe monthly1000 kilometersasa
referencewhichevercomesfirst.
Remarks:
1. Clean orreplacetheaircleanerelement moreoftenwhenthe ATVisoperatedon dusty
roadsorintheHeavily-pollutedenvironment.
2.Maintenanceshouldbeperformed moreoftenif theATVis frequentlyoperatedinhigh
speedandaftertheATVhasaccumulated ahighermileage.
3.Preventivemaintenance
a.Ignition system Performmaintenanceandcheckwhencontinuousabnormalignition,
misfire,after-burn,overheating occur.
b.Carbondepositremoval Removecarbondepositsincylinderhead,pistonheads,
exhaustsystemwhenpowerisobviouslylowerthan normal.
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2.MAINTENANCEINFORMATION
2
-
3
Fuel Lines
Checkalllines, and replaceit when theyare
deterioration, damage orleaking.
Forremoval,refertochapter4FuelPump.
Warning
Gasolineis alowignitionmaterialsoanykind
offireisstrictlyprohibited as dealing it.
Acceleration Operation
Haveawideopenofthrottlevalveas handlein
anypositionandreleaseittolet back original
(fullclosed)position.
Checkhandleif its operation issmooth.
Checkaccelerationcableandreplaceit if
deteriorated, twisted ordamaged.
Lubricatethecableifoperationisnot smooth.
Measurethe throttleleverfreeplayinits flange
part.
Removerubberboot,loosen fixing nut, and
then adjust itby turningthe adjustmentscrew.
Tighten the fixingnut,and checkacceleration
operation condition.
Freeplay:1~3mm.
AirCleaner
Openaccesscover.
Counterclockwiseturnthe lidandpull out
theelement
Loosenthe screwand separatethe element.
Clean thesponge withnon-flammableor
high-flashpointsolventandthensqueezeitfor
dry.
Caution
Neverusegasoline oracidorganizedsolvent
tocleanthe element.
Forinstallation,reversetheremovalprocedure.
SparkPlug
Recommended sparkplug:
NGK /DCPR8E
Removesparkplugcap.
Clean dirtaroundthe sparkplug hole. Remove
sparkplug.
Measurespark pluggap.
Sparkpluggap ： 0.7 ~ 0.8mm
Carefullybend groundelectrode oftheplugto
adjust thegap ifnecessary.
Holdsparkplugwasherand install thespark
plug byscrewing it.
Tighten the plug byturning1/2turnmorewith
plug socketafterinstalled.
Tightentorque:2.0 ~0 .2kgf-m
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2. MAINTENANCEINFORMATION
2
-
4
Valve Clearance
Caution
Checks and adjustment must be performed
when theenginetemperatureisbelow35 ℃ .
Removefront fender,top coverandaircleaner.
Removecylinderhead cover.
TurncamshaftboltinC.W. direction andletthe
Printingmarkon thecamshaft sprocket align
withcylinderhead marksothatpiston is placed
at TDC position incompressionstroke.
Caution
Donotturnthe boltinC.C.W.directionto
preventfromcamshaftboltlooseness.
Valveclearanceinspectionandadjustment.
Check &adjustvalveclearancewithfeeler
gauge.
StandardValue: IN0.10 0.02 mm
EX 0.15 0.02mm
Loosen fixing nut andturntheadjustment nut
foradjustment.
Caution
Re-checkthe valveclearanceaftertightened
thefixing nut.
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2.MAINTENANCEINFORMATION
2
-
5
Ignition System
Forignitionsystem, refertochapter5electric
system.
CylinderCompressionPressure
Warmup engine.
Turnoff theengine.
Removethetop cover.
Removetheside cover.
Removeany one of thespark plug cap and
sparkplug.
Install compression gauge.
Fullopen thethrottlevalve,androtatethe
engine bymeansofstartermotor.
Caution
● Rotatetheengineuntilthereading inthe
gaugeno moreincreasing.
● Usually, the highest pressurereadingwillbe
obtained in4~7seconds.
Compressionpressure:9.0 2bar
Checkfollowingitemsifthepressureistoo low:
● Incorrect valveclearance.
● Valve leaking.
● Cylinderheadleaking,piston, piston ring
andcylinderwornout.
Ifthepressureistoohigh, itmeans carbon
depositsincombustion chamberorpiston head.
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2. MAINTENANCEINFORMATION
2
-
6
Drive Belt
Removeside cover.
Removefootrest.
Removeboltsof theclutchcover.
Checkifthe beltis crack orwornout.
Replacethebelt ifnecessaryorinaccordwith
theperiodicalmaintenancescheduletoreplace
it.
Widthlimit:31.0mm orabove
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2.MAINTENANCEINFORMATION
2
-
7
Brake System
BrakeSystemHose
Makesurethebrakehoses forcorrosionor
leaking oil.
BrakeFluid
Check brakefluidlevelinthebrakefluid
reservoir.
Ifthelevelislowerthanthe LOWERlimit, add
brakefluidtoUPPERlimit.Alsocheck brake
systemforleakingiflowbrakelevelfound.
Caution
●
Inordertomaintainbrakefluidinthereservoir
inhorizontalposition,do notremovethecap
until handlestop.
● Donot operatethe brakeleverafterthe
cap hadbeen removed.Otherwise,the
brakefluidwillspread out ifoperated the
lever.
● Donot mix non-compatiblebrakefluid
together.
FillingOut BrakeFluid
Tightenthedrainvalve,andadd brakefluid.
Operatethebrakeleversothat brakefluid
contents insidethe brakesystemhoses.
AirBleedOperation
Connect atransparent hosetodraining valve.
Holdthebrakeleverandopen airbleeding valve.
Performthis operation alternativeuntilthereis
noairinside thebrakesystemhoses.
Caution
Beforeclosingthe airbleedvalve,do not
releasethe brakelever.
AddedBrakeFluid
Add brakefluidtoUPPERlimitlever.
Recommendedbrakefluid: DOT3orDOT4
WELLRUNbrakefluid.
Caution
Nevermix orusedirty brakefluidtoprevent
fromdamagebrakesystemorreducingbrake
performance.
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2. MAINTENANCEINFORMATION
2
-
8
Brake LiningWear
Theindentmarkon brakeliningisthewear
limitation.
Replacethebrakeliningifthewearlimitmark
closed totheedge of brakedisc.
Caution
● Tocheck frontbrakelining must be remove
front wheelfirst.
● It isnot necessary toremovebrakehose
when replacingthe brakelining.
Brake Lining Replacement(referchapter
7-3)
Makesurethe brakeliningcondition. Replace
thelining ifthebrakelining wearlimitation
grooveclosetothe brakedisc.
Caution
● Donotoperatethebrakeleverafterthe
clipperremovedtoavoidclippingthe brake
lining.
●
Inordertomaintainbrakepowerbalance, the
brakeliningmust bereplacedwithoneset.
Brake LightSwitch/Starting
InhibitorSwitch
Thebrakelight switchistolightup brakeli
ghtas
brakeapplied.
Makesurethat electricalstartercanbe operated
only underbrakeapplying.
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2.MAINTENANCEINFORMATION
2
-
9
HeadlightBeamDistance
Turnonmainswitch.
Headlight beamadjustment.
Turntheheadlightadjustment screwtoadjust
headlight beamhigh.
Caution
● Toadjusttheheadlightbeamfollows related
regulations.
● Improperheadlight beamadjustment will
makeincomingdriverdazzledorinsufficient
lighting.
Cushion
Warning
● Donot ridethe ATVwithpoorcushion.
● Looseness,wearordamagecushionwill
makepoorstabilityanddrive-ability.
Front cushion
Press downthe front cushion forseveraltimesto
checkit operation.
Check ifitis damage
Replacerelativepartsifdamage found.
Tightenallnuts and bolts.
RearCushion
Press downthe rearcushionforseveraltimes to
checkit operation.
Check ifitis damage
Replacerelativepartsifdamage found.
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2. MAINTENANCEINFORMATION
2
-
10
Steering Handle
Caution
Checkallwires andcablesif theyareinterfered
withtherotation ofsteeringhandlebar.
Liftthe front wheeloutofground.
Turnhandlefromright toleftalternativeand
check ifturning is smoothly.
If handleturning is unevenandbending, orthe
handlecanbe operated inverticaldirection, then
check thehandletopbearing.
Wheel/Tire
Caution
Tirepressurecheck shouldbe done ascold
engine.
Checkiftiresurfaceisticked withnails, stones or
othermaterials.
Appointedtirepressure
Tiresize FrontTire RearTire
Tirepressureascold 7 psi 7 psi
Checkiffront and reartires’pressureisin
normal.Measuretirethread depthfromtire
centralsurface.Replacethe tireifthe depthisnot
comewithfollowing specification:
Front tire: 1.5mm
Reartire: 2.0mm
Nuts,BoltsTightness
Performperiodicalmaintenanceinaccordwith
thePeriodicalMaintenanceSchedule
Checkifallboltsandnutson theframeare
tightened securely.
Checkallfixing pins,snap rings,hoseclamp,
andwireholdersforsecurity.
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2.MAINTENANCEINFORMATION
2
-
11
Special ToolsList
PARTSNO.: 440649
PARTSNAME:EXTENSIONPULLER/ REMOVER
PARTSNO. :440650
PARTSNAME:BUSHING(924739)REMOVER
PARTSNO.:440651
PARTSNAME:BEARING(924384)REMOVER φ15
PARTSNO. :440652
PARTSNAME:BEARING(924384)REMOVER
φ20
PARTSNO.:440653
PARTSNAME:BEARING(924384)REMOVER φ45
PARTSNO. :440656
PARTSNAME:LCRANKCASEOILSEAL
REMOVER
PARTSNO.:552303
PARTSNAME:PISTON&RODCONNECTING
HOLDER
PARTSNO. :440662
PARTSNAME:CYLINDERHEADVALVEGAP
ADJUSTER
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2. MAINTENANCEINFORMATION
2
-
12
PARTSNO.:440667
PARTSNAME:CYLINDERHEADVALVEAND
SPRINGINSTALLER/REMOVER
PARTSNO.:440671
PARTSNAME:WETCLUTCHSCREWNUT
FIXER
PARTSNO.:560001
PARTSNAME:FLYWHEELREMOVER
PARTSNO.:560002
PARTSNAME:FLYWHEEL INSTALLER
PARTSNO.:560003
PARTSNAME:RIGHTCRANKCASEMECHNICAL
SEAL INSTALLER/REMOVER
PARTSNO.:560004
PARTSNAME:DRIVE PULLEYFIXINGROD
PARTSNO.:560005
PARTSNAME:DRIVENPULLEYFIXINGTOOL
PARTSNO.:560006
PARTSNAME:DRIVE PULLEYREMOVER
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2.MAINTENANCEINFORMATION
2
-
13
PARTSNO.:560007
PARTSNAME:DRIVENPULLEYEXTENDTOOL
FORREMOVEBELT
PARTSNO. :560008
PARTSNAME:BEARINGREMOVER(W/
440649 Ø20mm)
PARTSNO.:560009
PARTSNAME:DEARDIFF.NEEDLEBEARING
REMOVER(W/440649 Ø20mm)
PARTSNO. :560010
PARTSNAME:REAR DIFF.BEARINGSPACER
INSTALLER
PARTSNO.:552312
PARTSNAME:EPS STEERINGBEARINGSEAT
SOCKET
PARTSNO.:560011
PARTSNAME:PLAINBEARINGINSTALLER
(LEFTCRANKCASE)
PARTSNO. :560012
PARTSNAME:PLAINBEARINGREMOVER
(LEFTCRANKCASE
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2. MAINTENANCEINFORMATION
2
-
14
PARTSNO.:560013
PARTSNAME:PLAINBEARINGINSTALLER
(RIGHTCRANKCASE)
PARTSNO.:560014
PARTSNAME:PLAINBEARINGREMOVER
(RIGHTCRANKCASE
PARTSNO.:560015
PARTSNAME:CRANKCASE COVERLH
PLAINBEARINGINSTALLER
(LEFTCRANKCASE)
PARTSNO.:560016
PARTSNAME:CRANKCASE COVERLH
PLAINBEARINGREMOVER
(LEFTCRANKCASE
PARTSNO.:560017
PARTSNAME:GOVERNORCUP
INSTALLER/REMOVERKIT
(DRIVEPULLEY)
PARTSNO.:560018
PARTSNAME:DRIVE PULLEYFIXINGSEAT
FORINSTALL ANDREMOVE
PARTSNO.:560019
PARTSNAME:HAFTSHEAVEPRESSINGTOOL
PARTSNO.:560020
PARTSNAME:DRIVENPULLEYFIXINGSEAT
FORINSTALL ANDREMOVE
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3.LUBRICATIONSYSTEM
3
-
1
PrecautionsinOperation
GeneralInformation
Thischaptercontains maintenance operation
forthe engine oilpumpand gearoilreplacement.
Specifications
Engine oilquantity
Overhaul: 2300c.c.
Filterchange:1800 c.c.
Change: 2000 c.c.
OilviscositySAE 10W-40
Torquevalue
Torquevalue oilfiltercover 1.2kgf-m
Engine oildrainbolt 2 .4kgf-m
Troubleshooting
Lowengineoil level
Oil leaking
Valveguideorseatwornout
Piston ring wornout
Camshaftworn out
Camshaftmain bearing worn out
Lowoilpressure
Lowengine oillevel
Cloggedin oilstrainer, circuits orpipe, oilradiatorgasket
Oilpumpdamage
Oilpressure valve, oilfilter
Dirtyoil
Nooil change inperiodical
Cylinderhead gasket damage
Pistonring wornout
Camshaftworn out
Camshaftmain bearing worn out
Items Standard(mm) Limit(mm)
Innerrotorclearance 0.15 0.20
Clearancebetweenouterrotorand body 0.15~0.20 0.25
Oil pump
Clearancebetweenrotorsideandbody 0.04~0.09 0.12
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3.LUBRICATIONSYSTEM
3
-
2
Oil Level Verification
NOTE: Strictlyfollow thisprocedure, otherwise
wrongoil levelmaybeindicated.
Ensurevehicleison a levelsurface.
▪Start engineand letidleforafewminutes.
▪Stopengine, wait afewminutestoallowoil to
flowdowntocrankcasethen checkoil level.
▪Fullyscrewindipsticktocheck oil level.
▪Removedipstick and read the oillevel.
▪Oillevelmustbe betweenminimumand
maximummarksondipstick.
▪Refill oilasnecessary. Donotoverfill.
▪Reinstalldipstick.
Oil FilterChange
▪Ensurethe vehicleis on alevelsurface.
▪Oiland oilfiltermust be replaced at thesame
time. Oil change andoilfilterreplacement
shouldbedone withawarmengine.
WARNING
Engineoil canbeveryhot. Waituntil engine
oil iswarm
▪Placeadrainpanunderthe enginedrainplug
area.
▪Clean the drainplugarea.
▪Unscrewdrainplugand discardthe gasket
ring.
▪Removedipstick.
▪Allowoiltodraincompletelyfromcrankcase.
NOTE:
Oilconditiongivesinformationaboutthe
engine condition.
▪clean themagneticdrainplugfrommetal
shavingsandresidue. Presenceofdebris
givesan indicationoffailure inside theengine.
Checkengine tocorrecttheproblem.
▪Install aNEWgasket ringon drainplug.
TORQUE: 2
.4kgf-m
UpperLevel
LowLevel
EngineType
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