TNG Little Sport, Owner'S Manual

Page 1: ...Revised 11 07 Owner s Manual Little Sport 49cc LS492 ...

Page 2: ...ATING YOUR VIN The serial numbers of the frame and engine are used for vehicle registration The frame VIN and label are located on the leg shield Then engine is located on the back of the engine Frame Engine ...

Page 3: ...rts catalogs are available for you to view at our web site www tngscooters com We continuously keep a large inventory of parts and accessories in stock to support our TNG dealers service centers and ultimately TNG scooter owners Your local TNG dealer knows your scooter the best and always is interested in your satisfaction We advise your local TNG dealer make all repairs on your scooter You can fi...

Page 4: ...en to avoid damage to the scooter NOTE A NOTE provides key information to make procedures easier to spot This Owner s Manual should be considered as a permanent part of the scooter as it contains important information for operation and maintenance of the scooter It should remain with the scooter at all times This Owner s Manual contains the most current product information at the time of approval ...

Page 5: ...ATION Page 6 D SAFETY INSTRUCTIONS Page 7 E SPECIFICATIONS Page 13 F COMPONENT DESCRIPTIONS FUNCTIONS Page 14 G PRE RIDE CHECKLIST Page 19 H PROPER OPERATION Page 22 I SERVICE MAINTENANCE SCHEDULE Page 27 J WINTERIZING Page 36 K TROUBLESHOOTING Page 41 L FULL WARRANTY INFORMATION Appendix ...

Page 6: ...ted in this warranty section For complete warranty information see the Warranty Appendix NOTE Your scooter performs best when run weekly Running the engine for a minimum of 20 30 minutes per week ensures that your battery remains fully charged and the fuel system doesn t foul NOTE ForthebestperformancefromyourTNGscooterhaveaTNGdealerperformallservicemaintenance Failure to follow the service mainte...

Page 7: ...edgeable with all road signs WARNING Failure to follow any SAFETY INSTRUCTION could cause severe injury or even death to the scooter operator passenger or a bystander Protective Gear Riding a scooter leaves the rider exposed Therefore wearing appropriate protective gear can prevent or diminish injuries from accidents 1 An Approved Helmet The majority of serious scooter injuries and deaths are the ...

Page 8: ...full attention to the road Goggles can protect your eyes in the same manner Never use eyeglasses or sunglasses in place of a face shield or goggles 3 Clothing Bright clothing should be worn by the driver so as to be easily seen by other motorists Jacket and pants should cover your arms and legs completely but not too loose to flap in the wind or catch on the levers or wheels which could result in ...

Page 9: ...aintenance procedures described in this manual Test your brakes after operation in wet conditions If necessary apply the brakes several times to let friction dry out the linings Never attempt wheelies jumps and other stunts as these could cause damage to the scooter and loss of control Always keep both hands on the handlebars and feet on the floor board during operation Never consume alcohol or dr...

Page 10: ...engers Loading WARNING This scooter is rated for 2 people total weight of the rider and the passenger must not exceed 330 lbs Do not exceed 17 5 lbs of cargo Attach the load securely since a loose load can catch in the wheel or rack causing skidding You should avoid carrying passengers or large loads until you have gained sufficient experience riding alone Extra weight changes handling stability b...

Page 11: ...er as you approach a stop Maintain a larger cushion of space ahead and to the sides Wait for larger gaps when you want to cross enter or merge with traffic LOADS A scooter is not really designed to carry cargo However small loads can be carried safely if they are positioned and fastened properly The rear luggage rack can carry 11 lbs max The compartment under the seat can carry 6 5 lbs max No more...

Page 12: ...o your eyes see doctor immediately or call American Association of Poison Control Centers at 1 800 222 1222 for assistance If you spill gasoline on your clothes change and wash the affected area immediately with soap Modification Any modifications to this scooter or removal of original equipment without approval from TNG Scooters may cause it to be unsafe for use and may trigger severe accident Mo...

Page 13: ...Beam 35W 35W Most Economical Speed 30 mph Front Running Light 3W Noise 80dB A Brake Tail Lights 21W 5W Engine Type 2 Stroke Turn Signal Light 10W Cylinder Arrangement Single Cylinder Turn Signal Indicators Dash 3W Displacement 49cc Instrument Illumination 3W Ignition Type CDI Fuses 15 Amps Transmission CVT Fuel Type 90 Octane Front Brake Disc Fuel Capacity 1 5 gals Rear Brake Drum Tire Size Front ...

Page 14: ...hrottle Control 8 Ignition Switch 14 Front Storage 20 Horn Turn Signal 3 Rear Brake Lever 9 Handle 15 Electric Start Hi Lo Beam Switch 4 Battery 10 Fuel Tank Cover 16 Storage Hook 21 Side Stand 5 Storage Compartment 11 Seat Lock 17 Speedometer 22 Engine Kill Switch 6 Muffler 12 Air Filter 18 Oil Warning Light ...

Page 15: ...Seat Lock TABLE 1 1 NOTE Steering can only lock when the handle bar is turned left CAUTION Make sure key is in OFF position after riding or opening seat When key is left in ON position and engine is off you will drain your battery ...

Page 16: ...o cancel turn signal push in the button on the switch White Lo Hi Beam Switch and Hi Beam Indicator When illuminated high beam is selected See page 14 for Lo Hi beam switch location See page 14 for indicator location CAUTION Be sure to always use LO BEAM light when facing oncoming traffic Speedometer See page 14 Indicates the operating speed Odometer See page 14 Indicates accumulated distance in k...

Page 17: ...avoid possible damage Horn Button see page 14 To sound the horn press this button Engine Stop Switch see page 14 Set the switch to on before starting the engine Set the switch to off for EMERGENCY STOP For example if the scooter overturns or you cannot decrease speed with the throttle Rear Brake Lever Front Brake Lever see page 14 To decrease speed and stop the scooter from moving To apply rear br...

Page 18: ...t is locked before riding CAUTION Do not store anything susceptible to heat inside storage compartments Do not let humidity spread from storage compartment Do not put anything valuable or breakable in storage compartment The compartment is not waterproof Use plastic bags to store stuff when washing the scooter Luggage Rack WARNING Luggage rack can carry 11 lbs max Do not exceed maximum 17 5 lbs fo...

Page 19: ...d before riding Do not overfill the tank as it may overflow when the fuel warms up and expands Avoid spilling fuel on a hot engine CAUTION Wipe off the spilled fuel immediately as fuel may deteriorate the paint on the scooter or any plastic parts Always use 90 octane or higher gasoline when refueling the scooter G PRE RIDE CHECKLIST 1 Check the fuel level Remove the gas cap by turning the cap coun...

Page 20: ...to the ON position Move the turn signal control to the left and right positions Check the front and rear turn signal lamps flash as well as the turn signal indicators on the instrument panel 4 Check the Tires Measure the pressure in each tire The correct pressures are Front 29 PSI Rear 33 PSI Visually inspect the tires for damage and wear Look for nails glass or stones what are cutting into the ti...

Page 21: ... begins to slow the rear wheel The lever should travel between 10 to 20 mm before the wheel begins to drag 7 Check the Brake Fluid Level See Page 29 8 Check the Spark Plug The spark plug will need to be checked if you find the scooter hard to start The gap should be between 0 023 0 032 inches The electrode should be a light brown color Incorrect gap can cause many problems for the scooter engine M...

Page 22: ...s rated for two persons total weight with rider and passenger must not exceed 330 lbs 1 ENGINE STARTING PROCEDURE Normal Start Place scooter on the center stand Turn the ignition key to the ON position While holding brake lever firmly push the electric start Repeat 5 second intervals of starter motor activation and 5 second rest Do NOT twist throttle open to start NOTE It is recommended to always ...

Page 23: ...ve the ignition switch in the ON position for extended periods of time The battery may become depleted to the point that the vehicle cannot be started To preserve the scooter each starting attempt should be less than 5 seconds To maximize the engine life warm up the engine for 2 to 3 minutes prior to riding No fast acceleration when the engine is still cold NOTE The engine will not start unless ei...

Page 24: ...rs Put on your turn signal before pulling away from the curb Look over both shoulders for oncoming traffic be sure that it is safe to pull out into the traffic Release the rear brake and accelerate the scooter slowly to take off 6 USING THE BRAKES The brakes work best when the front and rear brakes are applied simultaneously To apply the brake release the throttle quickly and squeeze the front bra...

Page 25: ...and steer the scooter to the side of the road Gently apply the front brake using the right brake lever and at the same time gently applying the rear brake using the left brake lever Extend your left foot just before coming to a complete stop so as to keep the scooter upright when it stops Turn off the ignition key and dismount the scooter on the left side Use your right foot to extend the side sta...

Page 26: ... 300km to achieve the best performance from the scooter Limit full throttle operation and avoid any condition that may result in engine overheating Always keep the speed below 40 mph Do not overload the scooter or carry a passenger during this period Change oil at 300 km use Opti 2 to maintain engine warranty CAUTION Have your TNG Scooter dealer check the vehicle if any engine trouble occurs durin...

Page 27: ...00 km or Every 6 Months Fuel Line I Fuel Filter R Air Filter I I I Spark Plug R Oil Filter R R Carburetor R R Drive Belt REPLACE EVERY TWELVE MONTHS Transmission Oil I R Braking System I I Wheels I I Wheel Bearings I I Steering Bearings I I I Rear Shock Absorber I I ...

Page 28: ...ler perform all service maintenance Failure to follow the service maintenance schedule may void your warranty coverage RECOMMENDED If regular driving is in arid or coastal condition air filter and engine oil may need to be replaced more frequently TIRE PRESSURE TREAD Measure the pressure of each tire The correct pressures are Front 29 PSI Rear 33 PSI Visually inspect the tires for damage and wear ...

Page 29: ...til you reach the acceptable level See Fig 2 Turn it counterclockwise to soften brake HYDRAULIC BRAKE FLUID LEVEL Front Brake Check the fluid level by looking at the reservoir See Fig 3 The fluid level must be between the two lines If it is below the lower line check the brake line and cylinder for a possible leak Check the brakes for excessive wear The middle groove of the brake should still be v...

Page 30: ... any water or air into the brake system when changing the fluid Do not spill any brake fluid on any other scooter parts as the fluid can damage metal and paint Always replace the brake fluid with type DOT 3 brake fluid RECOMMENDATION An authorized TNG Dealer or Service Center should complete all brake fluid adjustments ...

Page 31: ...over WARNING Do not change spark plug while engine is hot CAUTION Incorrect gap can cause problems to the scooter engine Make sure it is correct If the spark plug is fouled or damaged replace it with Autolight 4194 or like plug RECOMMENDATION Most spark plugs are self cleaning After replacing its best to ride the scooter for a minimum of 10 min Stop the scooter on a level surface and turn the engi...

Page 32: ...on its center stand on a level surface Let the engine warm up for three minutes and 1 then shut the engine off Remove the oil fill plug and the oil drain plug and allow the oil to drain completely 2 Inspect the sealing washer on the drain plug and if it s OK reinstall the drain plug 3 Refill the gearbox until full 4 Reinstall the oil fill plug 5 WARNING Use caution when changing oil to avoid burns...

Page 33: ...air cleaner cover See page 14 for air box location Lift out the air filter screen and cartridge Clean the screen and cartridge with compressed air Reassemble the air filter components and back end of the scooter CAUTION If riding in an excessively dusty location the air filter should be inspected more often than the recommended When remounting the air cleaner cover components onto the scooter Be c...

Page 34: ...month using a battery charger for a minimum of 6 hours Additionally it is important that your scooter be stored in a dry area and protected from extreme temperatures Battery Replacement The scooter battery is self sustained by electric current generated by the alternator within the scooter 1 It s a good idea to replace the battery every three years Always turn the ignition system off prior to repl...

Page 35: ... fuses CAUTION When removing the fuse from the fuse box do not squeeze the fuse puller or it will release the fuse When inserting the new fuse be sure that it fits snugly into the fuse socket A loose fit will cause intermittent electrical problems and possible overheating of the fuse contacts Always replace the open fuse with another of the same type When washing your scooter be sure not to get wa...

Page 36: ...areas that should be considered when preparing to put your TNG Scooter into storage The five areas of focus are Battery 1 Fuel System 2 Engine 3 Tires 4 Cover 5 1 BATTERY Maintaining the state of charge of your scooter battery during an extended period of storage is essential to insure the maximum service life of the battery If at all possible remove the battery from the vehicle Clean the battery ...

Page 37: ...rge to 100 every month If stored in a warm area above 60 F recharge the battery every two weeks Before you connect your charger to the battery make sure that you know how your battery charger operates Some chargers will not stop charging when the battery reaches 100 while others will stop automatically Some automatic chargers will begin charging again when the battery level drops while others will...

Page 38: ...wo ways this can be accomplished A DRY FUEL SYSTEM This technique is suitable if you are going to store your bike in a heated location where condensation due to temperature fluctuations is not a problem This requires you to fully drain the entire fuel system including the fuel tank and carburetor Generally you will need to remove the float bowl of the carburetor and then blow all of the fuel out o...

Page 39: ...at spot or cracked sidewall does not develop With nearly all TNG Scooters when the bike is on the center stand the front wheel is on the ground while the rear wheel is slightly off the ground You may simply be able to lift he front wheel of the scooter off the ground and place something under the frame of the scooter and have both wheels off the ground Make sure that the scooter is stable and cann...

Page 40: ... rust and corrosion to the cylinder wall To reduce the chance of getting rust or corrosion perform the following steps Remove the spark plug Squirt about 2 ounces of 2 cycle oil into the cylinder This applies to both 2 and 4 cycle engines With the spark plug still out turn the engine over a few times Reinstall the spark plug 5 COVER TNG Scooters come standard with a nylon weather cover Placing the...

Page 41: ...osition Depress Either Brake Lever Push Start Button on the Right Handle Bar If the Engine Doesn t Turn Over Charge or Replace the Battery ENGINE IS DIFFICULT TO START 1 Check for Fuel in Carburetor Out of Fuel Fill Fuel Tank Fuel Filter or Petcock Blocked Clean or Replace Fuel Switch or Petcock With Fuel Check Spark Plug ...

Page 42: ...k Plug 3 Spark Plug No Spark Spark Plug Wet or Fouled Remove Plug Prime Kick the Start Pedal without Fuel Ignition Re install Spark Plug Intermittent Spark Plug Lead Replace Lead Spark Plug Dirty or Wrong Gap Replace Plug or Correct Gap Loose Spark Plug Tighten Spark Plug Spark Plug OK Check Carburetor ...

Page 43: ...e Lubricating Oil Air Inlet System Blocked or Leaky Remove Blockage or Leak KNOCKING SOUND IN CYLINDER Causes Solutions 1 Engine Overheating Check Replace Lubricating Oil 2 Spark Plug Defective Replace the Spark Plug 3 Ignition Timing Too Early Adjust Ignition Timing 4 Carbon Build up In Cylinder Remove Carbon Build up In Exhaust Pipe Muffler Remove Carbon Build up ...

Page 44: ...ton in Cylinder Exhaust System Remove Carbon Build up 4 Piston Cylinder Excessively Warn Replace Piston Cylinder 5 Ignition Timing Incorrect Adjust Timing 6 Clutch Slipped Adjust Clutch 7 Belt is Loose Replace Belt BLACK OIL EXHAUST FROM EXHAUST PIPE Causes Solutions 1 Carburetor Not Atomizing Fuel Properly Check Adjust Carburetor 2 Air Cleaner Blocked Clean Air Filter ...

Page 45: ...at Excessive Speeds Ride at More Economical Speeds FUEL DRAINING FROM CARBURETOR OVERFLOW TUBE Causes Solutions 1 Float Bowl Residue Clean the Float Bowl 2 Float Bowl Needle Valve Not Completely Closed Replace Needle Valve 3 Occasional Fuel Overflow Tap the Fuel Bowl Lightly PETCOCK FUEL FILTER LEAKS Causes Solutions 1 Fuel Switch Loose Tighten the Fuel Switch 2 Broken Seal Replace Fuel Switch ...

Page 46: ...ted States Canada or Mexico who is authorized by CMSI to sell CMSI products Dealer must be signed up and be familiar with CMSI warranty policy WARRANTY VERIFICATION METHOD Owner and dealer sign Owner Registration Card at time of purchase This information is kept in CMSI s warranty system and can be requested thru an authorized dealer In the case of a transfer of ownership during the warranty perio...

Page 47: ...d or replaced under warranty are warranted only during the balance of the applicable warranty period THE AUTHORIZED DEALER To give you complete warranty documentation when you pick up your vehicle To perform warranty repairs on any CMSI product that qualifies for such repairs The selling dealer shall sign the Acceptance Certificate and a Card of Delivery upon delivery of the vehicle The Card of De...

Page 48: ...ricant at the time of purchase of the new scooter and use only that lubricant during the entire warranty period An authorized CMSI dealer is your best source for scheduled maintenance on your vehicle If warranty repairs are needed your dealer may ask you for documentation which may consist of one or more of the following A Maintenance Record showing the odometer mileage and service date Each entry...

Page 49: ...omponents Parts Labor less than 50cc 24 months 24 months less than 170cc lesser of 30 months or 12 000 Km 24 months 170cc to 280cc lesser of 5 years or 18 000 Km 24 months 280cc and above lesser of 5 years or 30 000 Km 24 months Basic non engine Parts Labor 50cc and below 24 months 24 months 51cc and above 24 months 24 months Body Parts Parts Labor all models 12 months 1 month Battery Parts Labor ...

Page 50: ...or consequential expenses storage DURATION OF IMPLIED WARRANTIES Any Implied Warranties including the implied warranty of merchantability and fitness for a particular purpose are limited to the duration of this written warranty STATE LAWS MAY VARY The previously listed limitations or exclusions may not apply to a motor scooter because of state laws Some states may not allow limitations on how long...

Page 51: ...due to a defect in material or factory workmanship Parts or accessories affected or damaged by Lack of required maintenance Owner abuse or misuse Accident and or collision Normal wear Neglect Improper installation Unsuitable use in an application for which the part was not designed The incorporation or use of unsuitable attachments or parts The unauthorized alteration of any part The incorporation...

Page 52: ...ding peeling blistering chipping or rusting Plastic body parts and panels See Warranty Time Table USE FOR THE FOLLOWING ACTIVITIES SHALL VOID COVERAGE Racing Competition Rental or other commercial uses Towing another vehicle trailer or similar device Alteration to the engine or drive train Any operation or use outside of that described in this Owner s Manual Alteration of the odometer so that the ...

Page 53: ...Warranty Time Table TO QUALIFY FOR THIS WARRANTY The vehicle must originally have been purchased from a dealer within the United States Canada or Mexico who is authorized by CMSI to sell CMSI products Prior to delivery to the purchaser setup and pre delivery service must be performed by a dealer or service center who is authorized by CMSI to deliver it vehicles DISTRIBUTOR S LIMITED WARRANTY MOTOR...

Page 54: ...ed Dealer for replacement use To qualify for this warranty The tire must have been purchased from an Authorized CMSI Dealer The tire was part of the original factory equipment The tire must have been used for its designed purpose THE OBLIGATION OF CMSI INC To replace any tire which is proven to be defective in material or factory workmanship under normal use until the tire center tread is worn to ...

Page 55: ...SI Inc Dealer REPLACEMENT CHARGES UP TO 50 TREAD WEAR Tire No charge for a new direct replacement tire Labor No charge for mounting and balancing to the tire s original purchaser if the tire was factory or dealer installed You pay for mounting and balancing if the tire was not sold installed REPLACEMENT CHARGES AFTER 50 TREAD WEAR Tire 50 charge for a new direct replacement tire Labor 50 charge fo...

Page 56: ...ted without inner tubes Tires which have been repaired Tires whose sidewalls have been modified by the addition or removal of material Tires with superficial weathering checking or cracking Tires used in racing or other competition DISTRIBUTOR S LIMITED WARRANTY REPLACEMENT PARTS WARRANTY TIME PERIOD See Warranty Coverage Table on page 4 of Warranty Section Coverage begins The date of purchase fro...

Page 57: ...led by an Authorized CMSI Dealer Parts No charge Labor You pay for removal installation charges THIS REPLACEMENT PARTS WARRANTY DOES NOT COVER The following exclusions apply specifically to replacement parts in addition to the exclusions listed Tires Refer to Distributor s Limited Warranty Motorcycle Tires The motorcycle in which the part is installed The color match of painted components CMSI mak...

Page 58: ...at a safety defect exists in a group of vehicles it may order a recall and remedy campaign For this reason it is very important for you to notify CMSI of any change of address or ownership NHTSA cannot become involved in individual problems between you your dealer or CMSI To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 202 366 0123 in Washington DC area ...

Page 59: ... or 12 000 kilometers whichever comes first provided that there has been no abuse neglect or improper maintenance of your vehicle Your emission control system may include parts such as the carburetor the ignition system catalytic converter and engine computer if it is so equipped Also included may be hoses belts connector and other emission related assemblies Where a warrantable condition exists C...

Page 60: ...warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance You are responsible for presenting your vehicle to the CMSI authorized dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days As the vehicle owner you should be aware that CMSI may deny your warranty coverage i...

Page 61: ...d and B Is free from defects in material and workmanship which cause such vehicle to fail to conform to applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board for the periods specified above I Coverage Warranty defects shall be remedied during customary business hours at any authorized CMSI dealer located within the United States of Ameri...

Page 62: ... conforming to CMSI specifications which adversely affect performance and or 5 Use in competitive racing or related events B Inspections replacement of parts and other services and adjustments for required maintenance C Any vehicle equipped with an odometer on which the odometer mileage reading has been changed so that actual mileage cannot be readily determined III Limited Liability A The liabili...

Page 63: ...THE VEHICLE FOR ANY PURPOSE SOMESTATESDONOTALLOWTHEEXCLUSIONORLIMITATIONOFCONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU B NO EXPRESS EMISSION CONTROL SYSTEM WARRANTY IS GIVEN BY CMSI EXCEPT AS SPECIFICALLY SET FORTH HEREIN ANY EMISSION CONTROL SYSTEM WARRANTY IMPLIED BY LAW INCLUDINGANYWARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS LIMITED TO THE EXPRESS E...

Page 64: ...IMITED MOTORCYCLE WARRANTY VI ADDITIONAL INFORMATION Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs However CMSI is not liable for these parts The owner is responsible for the performance of all required maintenance Such maintenance may be performed at a service establishment or by any individual The warranty perio...

Page 65: ...CMSI Inc Motorsports 8146 304th Ave SE P O B ox 969 Preston WA 98050 USA Phone 425 222 7738 Fax 425 222 7739 Inc Motorsports ...