TGB Xmotion 125 User manual

Xmotion 125/250
OWNER-MANUAl
MAINTENANCE HANDBOOK
TAIWAN GOLDEN BEE CO.,LTD.
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TABLE OF CONTENT
1. REGULAR INSPECTION
1-1 Delivery Introduction -----------------------------------------------------2
1-2 Inspection Before Running ---------------------------------------------4
1-3 Regular Maintenance Schedule -------------------------------------- 5
1-4 General Inspection -------------------------------------------------------6
1-5 Notes for Inspection ----------------------------------------------------- 7
2. MAINTENANCE INFORMATION
2-1 Specification Sheet -----------------------------------------------------8
2-2 Safety Precautions--------------------------------------------------------10
2-3 Special Tools --------------------------------------------------------------11
2-4 List of Grease & Oil Adopted ----------------------------------------- 24
2-5 Circuit Drawings --------------------------------------------------------- 25
2-6 Troubleshooting ----------------------------------------------------------27
2-7 Tighting Torque of Screws --------------------------------------------27
2-8 Troubleshooting ----------------------------------------------------------30
3. DESCRIPTION OF PARTS AND COMPONENTS
3-1 Engine ---------------------------------------------------------------------39
3-2 Electric System ---------------------------------------------------------- 126
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4. DISASSEMBLY REPAIRMENT
4-1 Notice for Disassembly Repairment ----------------------------- 137
4-2 Removal and lnstallation of Engine -------------------------------138
4-3 Removal and Inspection of Electric Items -----------------------199
4-4 Removal and Inspection of Body Parts ----------------------------206
4-5 Brake System ----------------------------------------------------------- 214
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CHAPTER I
REGULAR INSPECTION
1-1 Delivery Introduction 1-4 General Inspection
1-2 Inspection Before Running 1-5 Notes for Inspection
1-3 Regular Maintenance Schedule _______________________
1-1 Delivery Introduction
To inform customers of correct methods to use: To practically and correctly
ride a scooter according to the Instruction of Manual and Maintenance
Handbook. Customers should also try in person according to this manual.
1. Starting:
A. Turn the power switch to "ON."
B. Hold the front or rear brake and press the "START" button.
C. If the scooter is not started, release the "START" button and try again after a few
minutes. Each start should be less than five seconds to avoid battery consumption.
Note: This is an AUTO-CHOKE scooter, thus there is no choke lever.
The fuel is controlled only by throttle grip.
The accelerator has to return to its original place when the scooter is not in use.
D. If the scooter can not be started by the "START" button, try the kick starter.
2. Fuel:
Inform customers to refill the fuel to no more than 80% of the tank capacity only.
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1-1 Delivery Introduction 3
. Lubricant Adopted:
A. WARNING : The engine oil must be refilled when the oil warning lamp lights, otherwise the
engine will be burned-out due to insufficient lubrication. Recommended oil : TGB Genuine
EXTRA 4X OIL.
B. Genuine TGB HYPOID GEAR OIL(or SAE85W-140) will be adopted as gear oil to be
changed on a periodical basis. Gear oil and engine oil are different in their nature.
Attention should be paid to avoid mistake when used.
4. Regular Inspection and Maintenance:
Inform customers of the importance of inspection before running and regular inspection.
A. Inspection Before Running: Riders should perform nspection by themselves before
running.
B. Regular Inspection: Regular inspection should be performed after the first month and
the sixth month and every six months afterwards.
5. Description of Warranty System:
Clearly identify the content of warranty in accordance with the warranty paper.
A. Content and term of warranty.
B. Maintenance items not guaranteed.
C. Items should be followed by customers.
Instruct customers to carry the OWNER'S Manual with them when they come for regular
inspection and maintenance. It is because such inspection should be recorded onto the
Manual.
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1-2 Inspection Before Running
Items to be Inspected Before Running by Customers:
ITEM CONTENT GUIDELINE
1. Starter
Is the oil volume
proper?
1 .Check Oil Warning Lamp to see if the oil
volume is proper?
2 .Fuel
Is the fuel volume
sufficient?
1 .Check fuel volume to see if it is enough
to the destination.
3. Lamp &
Direction
Indicator
Is the lamp condition
well? Is there any
dirt?
1 .Check if the lighting condition of head
lamp, tail lamp, licence lamp, brake lamp,
direction indicator and other lamp is well.
2. Lamps should be kept clean and
undamaged.
4. Back Mirror
Is the reflecting
image well?
1. Look at the back mirror from the
seat to check if the rear view is clear.
5. License Plate &
Reflector
No dirt and damage
should appear.
1. License plate should be installed, letters
and numbers should be kept clear and
clean. 2. Dirt and damage should not
appear on the reflector.
6 . Brake
Check the distance of
brake handle lever
and the brake effect.
1 .Operate the handle lever slowly to the
brake begin to effect in order to inspect the
moving distance. 2.Test the brake with low
speed running to see the brake effect of
front and rear brakes.
1.Is the air pressure
proper?
1 .Check if the air pressure of tire is
sufficient with a gauge or by sight.
2.Groove should be
deep enough.
1 .Check if the groove of tires is enough.
3.Unusual wear is not
desired.
1 .Check landing flat of tire to see if
any unusual wear appears.
4.Breaking and damage
are not desired.
1 .Check landing flat and side to see if
any breaking or damage appear.
7. Tire
5.Metal, stone and
other articles are
not desired.
1 .Cneck if any cracking, stone or any
other article sticks into the tire.
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1-3 Regular Maintenance Schedule
The chart below lists the recommended intervals for all the returned periodic service work
necessarily to keep the motorcycle operating at peak performance and utmost efficiency.
Mileages are expressed in terms of kilometers and months. These intervals judged by
odometer reading or month whichever comes first.
\~^^^^ Maintenance
N, ^^\ kilometer
300KM
Every
1000KM
Every
3000KM
Every
6000KM
Every
12000KM
Item
^^ Maintenance Interval
Check Items \
NEW 1 Month 2 Month 3 Month 4 Month
Remarks
01 Air cleaner element(Remark) I C C
02 Oil filter(Screen) C R
03 Engineoil R I Replacement for every 3000KM
04 Tire,pressure I I
05 Battery I I
06 Sparkplug I I R
07 Carburetor(idlespeed) I I
08 Steeringbearing andhandles I I
09 CheckTransmission forleakage I I
10 Check crankcase for leakage I I
11 Transmission oil R
Replacement for every 5000KM
(5 Month)
12 DriveBelt/roller I R
13 Fuel tank switchandlines I I
14 Throttle valve operation andcable I I
15 Enginebolts andnuts I I
16 Cylinder head,cylinder,andpiston I
17 Exhaust system/cleaningcarbon I
18 Cam chain/ignition time I I
19 Valveclearance I I
20 Shockabsorbers I I
21 Front/rearsuspension I I
22 Main/sidestands I I/L
23 Crankcase Blow - bysystem(PCV) I I
24 Coolant I I R
25 Cooling fan, lines I I
26 Clutchdisk I
27 Brakemechanism/brakelining(pad) I I
28 Bolts/nuts foreachcomponents I I
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*The above maintenance schedule is established by taking the monthy 1000 kilometers as
areference which ever comes first.
Code : I ~ Inspection, cleaning, and adjustment R ~ Replacement
C ~ Cleaning(replaced if necessary) L ~ Lubrication
Remark : 1. Clean or replace the air cleanr element more often whe the scooter is operated on
dusty roads or in the Heavily - polluted environment.
2. Maintenance should be performed more often if the scooter is frequently operated
in high speed and after the scooter has accumulated a higher mileage.
1-4 General Inspection General Inspection and Adjustment
* means adjustable.
Note: The ignition of this scooter by the use of crank-shaft which is 4 ignitions/revolution.
Special attention should be paid while setting the turning speed of Engine by Tachometer.
Brake
Disc
Tail Light/Turn
Signal Light
Gear Oil
Spark Plug
Raer Brake
Brake Disc
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Fuses
Head Light
Tire
Air Filter
HeadLig
Tail Light/Turn
Signal Light
Raer
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1-5 Notes for Inspection
ITEM INSPECTION DETAILS
1
Be aware of smoke and fire while performing maintenance.
2
New Packing, Gasket, O Ring, locking pin should be used while
assembling.
3
Only designated TGB oils should be used on spare parts.
4
Clean the vehicle before maintenance to avoid dirt or mud on
disconnected parts.
5
The locking sequence of Bolt and Nut should be from inside to
outside, or in diagonal step. Reverse the sequence to loose.
6
Special tools should be used when necessary.
7
Attention should be paid to avoid damage or loss of disconnected parts. Clean
and grease properly before the assembly. No grease on Bolt's Thread.
8
Reconfirm each function after the assembly.
9
Special attention should be paid to the battery's electrolyte
and brake oil which will stam clothes.
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CHAPTER 2
MAINTENANCE INFORMATION
2-1 Specification Sheet
CU8 (X-Motion 125)
Air Filter Paper Type
Length (mm) 2130 Fuel Capacity 11L
Width (mm)
840
Type CVK164 Dimen
Height (mm) 1380 Venturi (mm)
25
sion
Wheelbase (mm) 1500
Front
55
Fuel
System
Carburetion
Rear
95
Unload
mass
Total
150
Type C.D.I.
Ma
s
Front
102
Spark CR8E
Rear
198
Ignition
Pointgap (mm) 0.8+0.1
s
Total mass
2 person/
150 kg
Total
300
Electric
system
Battery Type GTX14-BS
Front 120/70-14 type Automatic Tire
Rear 140/60-13 Clutch type Centrifugal type
Engine Type
4 Stroke 4V electroplated
ceramic cylinders engine
Transmission type
CVT
Fuel Type Petrol Type Automatic
Number of Cylinder Single cylinder
R1
0.79~2.72
Bore X Stroke (mm ) 57 X 48.8
Gear Box
Gear
Ratio
R2
9.67
Cylinder Capacity 124.5 c.c.
Transmis -
sion
Starter Electric &Kick raked angle ( °)
Cooling System Liquid Front
28
Lubrication system Forced circulation & splashing
Tire Pressure (psi)
Rear
32
Reference and setting range(IN )
0.12±0.02 mm
Left
Reference and setting range(EX)
0.12±0.02 mm
Motion
system
Turn angel ( °)
Right
...
MaxSpeed (km/hr) 105 km/h Front Disk
Idle speed (rpm ) 1800+100 rpm
Braking system
Rear Disk
Max Power ( Kw/rpm ) 9 kw/8750 rpm Front Hydraulic-pressed Spring type
Max Torque (Nm/rpm) 10.5Nm/8250rpm
Suspension
Rear Hydraulic-pressed Spring type
Compression Ratio 10.5 Front Hydraulic-pressed Spring
Oil Spec. SAE 10W-30
Buffer
Buffer
Rear Hydraulic-pressed Spring
Oil Capacity (L) 1L Frame Type Welding Tube
Engine
Gear Oil Spec., Capacity SAE 90, 0.11L
Front Lamp 35W/35W-12V
Rear Lamp 5W-12V
Brake Lamp 21W-12V
Lamp
Direction Lamp 21W-12V
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CUB(X-Motion 250)
Air Filter PaperType
Length (mm) 2130 FuelCapacity 11L
Width (mm)
840
Type
...
Height (mm) 1380 Venturi (mm)
...
Dimension
Wheelbase (mm) 1500
Front
60
Fuel
System
Carburetion
Rear
100
Unloadmass
Total
160
Type E.C.U.
Front
107
Spark CR8E
Rear
203
Ignition
Point ga (mm) 0.8±0.1
Mass
Totalmass2
person/ 150
kg
Total
310
Electric
system
BatteryType GTX14-BS
Front 120/70-14 type Automatic Tire
Rear 140/60-13 Clutch type Centrifugaltype
EngineType 4Stroke Transmissiontype
CVT
FuelType Petrol Type Automatic
NumberofCylinder Singlecylinder
R1
0.8~2.30
BoreXStroke(mm) 71 X63.3
GearBox
Gear
Ratio
R2
7.42
CylinderCapacity 249.4c.c.
Transm-
ission
Starter Electric rakedangle(°)
—
CoolingSystem Liquid Front
28
Lubricationsystem
Forced circulation&
splashing
Tire Pressure
(psi)
Rear
32
Referenceandsetting
range(IN)
0.1±0.02mm Left
—
Referenceandsetting
range(EX)
0.15±0.02mm
Motion
system
Turnangel ( °)
Right
—
Max Speed (km/hr) 128km/h Front Disk
Idle speed (rpm ) 1650±100rpm
Brakingsystem
Rear Disk
MaxPower ( Kw/rpm ) 17.2kw/8750rpm Front Hydraulic-pressedSpring type
MaxTorque(Nm/rpm) 22.7Nm/8250rpm
Suspension
Rear Hydraulic-pressedSpring type
CompressionRatio 10.8 Front Hydraulic-pressedSpring
OilSpec. SAE10W-30
Buffer
Buffer
Rear Hydraulic-pressedSpring
Oil Capacity (L) 1.4L FrameType WeldingTube
Engine
GearOilSpec.,Capacity SAE90, 0.18L
Front Lamp 35W/35W-12V
RearLamp 5W-12V
BrakeLamp 21W-12V
Lamp
DirectionLamp 21W-12V
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2-2 Safety Precautions
Warning: Engine Exhaust
Please keep good ventilation during engine operation. Do not operate engine in closed-room.
The toxic carbon-oxygen (CO) in exhaust may lead human to loss conscious and even death.
Warning: Gasoline
The gasoline is very easy to burn or explode. Forbid any fire during inspection of gasoline
tank or gasoline leak.
Warning: Battery H
2
and Battery Liquid
1. The battery liquid is toxic sodium liquid. Please do not contact the liquid with skin or eye. If
any contact happens, please wash with massive clean water and contact with doctor.
2. The released H
2
from battery is explosive. Please keep good ventilation during charging
battery and forbid any fire.
Watch: Brake Fluid
The brake fluid can damage the painting on plastic. Please cover the plastic parts with towel
or cloth during maintenance of brake disk. If the brake fluid is split on plastic component,
please remove the fluid and wash the surface with water right away.
Watch: High Temperature of Engine
The engine cover, cylinder, and exhaust pipe have high temperature after starting of engine.
Please wear glove in maintenance of parts during engine operation, or maintenance should
be waited until engine is cooled.
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2-3Special Tools
125 ce:
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