TGB BLADE 550i IRS 4X4 User manual

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ONE / TWO － UP
BLADE 550i IRS 4X4
BLADE 550i EPS IRS 4X4
BLADE 550i EPS SE IRS 4X4
Recreation Utility Ve icle
Assembly Manual

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Foreword
This Assembly Manual contains the
information required for the correct assembly
of this TGB vehicle prior to delivery to the
customer. Since some external parts of the
vehicle have been removed at TGB factory for
the convenience of pac ing, assembly by the
TGB dealer is required. It should be noted that
the assembled vehicle should be thoroughly
cleaned, chec ed, and adjusted prior to
delivery to the customer.
If the style and construction of the TGB vehicle
are different from that of the photos, pictures
shown in this manual, the actual vehicle shall
prevail. Specifications are subject to change
without notice.
NOTICE
The service specifications given in this
assembly manual are based on the model as
manufactured. Modifications and significant
changes in specifications and/or procedures
will be forwarded to authorized
dealers.
The procedures below are described in the
order that the procedures are carried out
correctly and completely. Failure to do so can
result in poor performance and possible harm
to the vehicle and/or rider.
Particularly important information is
distinguished in this manual by the following
notations.
Warning
Means that serious injury or even death may
result if procedures are not followed.
Caution
Means that equipment damages may result if
procedures are not followed.
Please see the content for quic having the
special parts and system information.

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Table of Contents
PAGE CONTENT
4 Symbols Used on Outer Cover
5 Crate Handling
5-6 Uncrating
7-9 Parts Chec
10 Assembly (Shock Absorber)
11 Assembly (Wheels)
11 Assembly (Handlebar)
11 Assembly (Speedometer)
12 Assembly (Shift ever)
12 Assembly (Rear Carrier)
12 Assembly (Battery)

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Symbols Used on Outer Cover
(1) Indicates correct upright position of the transport pac age.
(2) Transport pac age must be ept away from rain.
(3) Contents of the transport pac age are fragile, therefore the pac age must be handled with care.
(4) Up to 4 of the transport pac ages can be piled up.
(5) Do not insert from the symbol position of the transport pac age.
(6) Indicates correct insert position of the transport pac age.
(1)
(2)
(3)
(4)
(5)

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Crate Handling
Warning
1. Always handling the crated vehicle by a for lift, include stac ing/un-stac ing and storing.
2. Never stac ing up over the indicated high shown on the crate outer cover.
Caution
1. Insert the for according to the indication position where shown on the crate outer cover.
2. Insert the for as shown below, the for must be horizontal into the crate pallet. The operation
with angles will damage the vehicle and created components.
Uncrating
Warning
Crates have sharp edges and may have nails or screws that can cause cuts and injury. Always wear
protective gloves, boots and eye protection when uncrating to prevent injury.
1. Remove 4 corner cage ends (A), and rivets
(B), and then remove the outer cover.
A
B

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2. Remove top cage braces (C), and be careful
to avoid damage to the vehicle plastics and
the seat leather during the action.
3. Remove the bolts (D), and then lay down LH
& RH side diagonal braces (E) to disengage
its soc ets from the pallet.
Warning
Remove the bolts while holding the frame.
4. Lay down Front & Rear diagonal braces (F)
to disengage its soc ets from the pallet.
5. Remove the bolt and rear carrier brac et (G)
which be fixed the vehicle on the pallet.
C
D
E
F
G

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Parts C eck
Note
There may be minor differences in appearance between these illustrations and the actual
vehicle parts.
Remove the parts and chec the crate base and pac aged materials carefully for lost parts.
Chec the parts against the illustrations. In the following charts under Remar s, D=diameter in
millimeters, and L=length in millimeters, and P=Pitch. In the following charts under
Qty,( )component of assembly parts.
NO Part Name Qty Remar
1 Front Wheel Assy. 2 AT 25 x 8 - 12 or AT 26 x 8 - 14
Rear Wheel Assy. 2 AT 25 x 10 - 12 or AT 26 x 10 - 14
Wheel Nut 16
Rubber Cap 4
2 Battery 1 12V 18AH
3 Rear Carrier Comp. 1
Bolt 4 D=8, L=18, P=1.25
1
2
3

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FOR 2-UP MODEL
NO Part Name Qty Remar
1 Front Wheel Assy. 2 AT 25 x 8 - 12 or AT 26 x 8 - 14
Rear Wheel Assy. 2 AT 25 x 10 - 12 or AT 26 x 10 - 14
Wheel Nut 16
Rubber Cap 4
2 Battery 1 12V 18AH
3 Rear Carrier Comp. (2-UP) 1
Bolt 4 D=8, L=18, P=1.25
Passenger Hand Holder 2
Soc et Bolt 11 D=8, L=20
Spring Washer 11 φ8.2 x 11.4 x 2.0t
Seat Bac Cushion Comp. 1
Brac et 1
Rubber Bush 1
Spring Washer 1 Φ6.2 x 11.5 x 1.5t
Screw 1 D=6
1
2
3

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NO Part Name Qty Remar
4 Shift Lever Holder 1
Spring 1
Shift Lever Pull Rod Assy. 1
Bolt 1 D=5, L=8
5 Owner’s Manual 1
6 Tool Bag 1
7 Shoc Absorber Bolts 4 D=10, L=48, P=1.25
Shoc Absorber Nuts 4 D=10, P=1.25
8 Speedometer Brac et Bolts 4 D=6, L=16, P=1.0
9 Right Glove Box Cover 1
Left Glove Box Cover 1
4
5
6
7
9

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Assembly
After opening the crate, lift the vehicle out from the pac ing crate, and place the vehicle on a
suitable rac , or using jac s to raise the vehicle for assembling process.
Warning
Torque wrench tightening specifications must be adhered to.
Warning
1. When raising your vehicle ma e sure to observe the following to reduce the possibility of death or
serious injury.
2. Lift up the vehicle using a floor jac such as the one shown in the illustration.
3. Always use floor jac and ATV jac stands on a solid, flat, level surface.
4. Do not start the engine while the vehicle is supported by floor jac .
5. Do not raise the vehicle while someone is in the vehicle.
6. When raising the vehicle, do not place any objects on top of or underneath the floor jac .
1. Front Shoc Absorber
Install the below flange bolt (A) from front
to rear, and then tighten the nut (B) to
450~550 kgf-cm torque.
2. Rear Shoc Absorber
Install the below flange bolt (A) from rear
to front, and then tighten the nut (B) to
450~550 kgf-cm torque.
B
A
A
B

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3. Wheels
Install the wheel, ma e sure the air valve is
facing out, and the arrow mar (if exist) on
the tire point toward to rotating direction
of the wheel. Tighten the nuts (C) with
6 0~720 kgf-cm tighten torque and then
plug the rubber cap (D).
Warning
Install the nut with its tapered side towards
the wheel.
4. Handlebar
Loosen the fixed bolts of the handlebar
holder, and pull handlebar to ma e the top
cover of the bra ing cylinder (E) parallel to
the ground. Re-tighten the front bolts (F) of
the holder first and then the rear bolts (G).
The tighten torque specification is 300~350
kgf-cm.
5. Speedometer
Remove the brac et of speedometer (H),
upside down the brac et, and re-fixed it
bac to the steering shaft. Place the
speedometer upon the handle and fixed to
the brac et by the four bolts (I).
FOR HEADLAMP EQUIPPED MODEL
Remove the 6 screws on the bac part to
disassemble the headlamp assy. And
remove the 2 bolts (J) fixed on the
handlebar holders, place the bac parts on
the handlebar holders and fix by the 2
bolts. And then re-assembly the two parts
of headlamp with the 6 screws.
C
D
E
F
G
H
I
J

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6. Shift Lever
Insert the pull rod assy. (K) into the gear
shifter shaft, placed the spring (L) and lever
holder (M) into the shaft, and push the
holder down until the fixing bolt (N) can be
thread in and tighten.
7. Rear Carrier
Ma e the front support tube of the rear
carrier through the 2 holes on the top of
rear vehicle plastic fender. And bolted to
the mounting points of frame (O) and to
the rear hand hold (P).
FOR 2 - UP MODEL
For ease of operation, seat bac cushion (Q)
and passenger hand holder (R) can be
pre-assembled before the rear carrier being
fitted to the vehicle.
Caution
When install the passenger hand holder,
ma e the high end forward to front to get
better comfort.
8. Battery
Remove the battery mounting brac et (S)
and place the battery in the positioning,
ma e the positive (+) be on the left side of
the vehicle, and then re-tighten the brac et
to secure the battery. Connecting the red
cable (T) to positive (+), and then
connecting the two blac cables (U,V) to
negative (-).
Caution
Follow the preparation guide in the battery
pac age to ready the battery before
mounting to the vehicle.
L
M
N
S
T
U
V
K
O
P
Q
R