TGB X-MOTION 250, Owner'S Manual

Page 1: ...Xmotion 125 250 OWNER MANUAl MAINTENANCE HANDBOOK TAIWAN GOLDEN BEE CO LTD PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 2: ...dopted 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 Q Q Rnrlv 1 1 J J UUUjf I J I 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 Inspec...

Page 3: ...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...

Page 4: ...ction 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...

Page 5: ...alled 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...

Page 6: ...e pressure I I 05 Battery I I 06 Spark plug I I R 07 Carburetor idle speed I I 08 Steering bearing and handles I I 09 Check Transmission for leakage I I 10 Check crankcase for leakage I I 11 Transmission oil R Replacement for every 5000KM 5 Month 12 Drive Belt roller I R 13 Fuel tank switch and lines I I 14 Throttle valve operation and cable I I 15 Engine bolts and nuts I I 16 Cylinder head cylind...

Page 7: ... 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...

Page 8: ...e 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 bat...

Page 9: ...ar 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 ...

Page 10: ...n Starter Electric raked angle Cooling System Liquid Front 28 Lubrication system Forced circulation splashing Tire Pressure psi Rear 32 Reference and setting range IN 0 1 0 02mm Left Reference and setting range EX 0 15 0 02 mm Motion system Turn angel Right Max Speed km hr 128 km h Front Disk Idle speed rpm 1650 100 rpm Braking system Rear Disk Max Power Kw rpm 17 2kw 8750 rpm Front Hydraulic pres...

Page 11: ...clean water and contact with doctor 2 The released H2 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 ...

Page 12: ...2 3 Special Tools 125 ce 11 PDF created with pdfFactory Pro trial version www pdffactory com ...

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Page 25: ...ssion Gear Oil for Scooters TGB Genuine EXTRA 4X OIL Engine Oil Apply in oil tank Three Bond 1322 Under M10 Screw For medium fixing for Flywheel Magneto TGB Supper Grease No I Apply in Oil Seal DOT 3 Brake Oil For Brake TGB Supper Grease No 2 Apply in Kick Starter TGB Supper Grease No 4 For Movable Drive Face Comp Cemedine 575 Apply in Handle Grip 24 PDF created with pdfFactory Pro trial version w...

Page 26: ... 0 D T O 3 3 0 Ui t Wfmmk CRITICAL CHARACTERISTIC Ifffitt SIGNIFICANT CHARACTERISTEC ...

Page 27: ...EN YELLOW 37 a BLACK GREEN 2 a RED 16 GREEN BLACK 3S a s BLACK YELLOW t 81 RED 1 w É YELLOW WHITE 3U Ë i WHITE BLUE 2 RED ia PINK 4U Ë w WHITE YELLOW 2 RED 19 M ff BLUE RED 42 K YELLOW BLUE J a RED 2 SKY BLUE 4H SS BLUE 4 s BROW 21 ff RED YELLOW 49 ORANGE S S Ê GREEN WHITE YELLOW bi BLACK RED 6 K w BLUE YELLOW 2J GREEN b4 YELLOW lu Ë S WHITE BLACK 2b BROWN BLUE bb YELLOW 11 DEEP GREEN 26 81 RED WH...

Page 28: ...GREEN BLACK 32 RED ORANGE 4 BLUE 2 RED 17 R YELLOW WHITE 1 1 BLUE GREEN 49 g ORANGE 2 RED 1 fôr PINK M ORANGE WHITE b w YELLOW GREEN RED 1 M 1 BLUE RED 3b RED GRAY b1 BLACK RED 4 BROW 2 SM SKY BLUE PURPLE b2 SKYBLUE ORANGE b iift É GREEN WHITE A E w RED YELLOW 3 BLACK GREEN BROW YELLOW 6 w BLUE YELLOW 22 M YELLOW 3H w BLACK YELLOW 7 M H BLUE BLACK 23 t GREEN jy Ê M WHI TE BLUE H H w BLACK YELLOW 2...

Page 29: ...ings 2 Spark plug too loose 3 Broken cracked or otherwise failed piston Replace Clean dry Replace Replace Replace Replace Clean Clean or replace Clean or replace Replace Tighten Replace Noisy engine 1 Piston or cylinder worn down 2 Combustion chamber fouled with carbon 3 Piston pin bearing or piston pin worn 4 Worn or burnt crankshaft bearings Replace Clean Replace Replace Engine idles poorly 1 St...

Page 30: ...orque Values of Engine components Tightening Location Specification Torque Quantities kg cm Cylinder Head Bolt M6 80 100 4 Cylinder Stud Bolt M8x182 5 500 800 2 M8x195 5 2 Cylinder Intake Pipe Stud Bolt M6x50 500 800 2 Muffler and Exhaust Pipe Tightening Screw M6 100 120 2 Muffler Right Crankcase Upper Tightening Screw M8x42 300 400 1 Muffler Right Crankcase Lower Tightening Screw M8x38 300 400 1 ...

Page 31: ...x35 3 Gearbox Oil Fill Cover Screw M8 90 150 1 Gearbox Oil Drain Cover Screw M8x12 90 150 1 Clutch Side Cover Screw M6x40 50 80 6 M6x65 2 Starter Arm Tightening Screw M6x22 100 120 1 29 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 32: ...s Loosen the carburetor leakage screw to check for inlet of fuel Poor Fair Poor Recharge the battery and be sure the pin is properly secured In case of poor charging proceed with a new charging and check the charging system of the power plant for failure Check for fuel in the fuel tank J Check the engine inside piston bearing and others for failure No fuel I Wit h fuel Add in designated fuel Fair ...

Page 33: ...or replace with new ones Poor Fair Readjustment Check choke of the carburetor for troubles Fair Poor _L Check if the slop nozzle of the carburetor is obstructed or the threshold fails Fair Poor Test the compression Clean or replace the slow nozzle or correct replace with new threshold Fair Poor Check air filter gril for obstruction Check cylinder washer for leakage check cylinder piston piston rin...

Page 34: ...r O Carburetor choke O Obstructed carburetor slow nozzle O Ailing carburetor threshold O Obstructed air filter grill O Leakage in cylinderwasher O Seriously damaged cylinder piston O Dead batte ry O Poor contact of batte ry pin and conductors O Starting switch with poor or failure O Starting relay with broken wire or short circuit O Loose contact and wiring O Starting gear and speeding clutch gear...

Page 35: ...h sparks Check for loose C D I plugs terminal conduction and resistance values Replacement of poor spark plug Abnormal Normal Poor or abnormal C D I or plugs replacement of C D I and mount properly the plug Check high voltage coils main switches PICK UP distributor coil for normality Normal Abnormal Check for correct main wiring contacts and terminals if necessary correct them Poor high voltage co...

Page 36: ... D adapter Poor C D I Poor PICK UP Poor distributor high voltage wiring Poor main switch Main wiring broken or in short circuit Ignition coil broken or in short circuit Poor adapter contact Normal Abnormal Use C D I tester for checks of C D I a Poor PICK UP b Poor main switch c Poor contact of adapter d Broken main wiring of short circuit Normal Abnormal Check ignition coil for breaking or short c...

Page 37: ...yant needle valve Poor carburetor choke valve Poor engagement of carburetor and inlet tube Obstructed carburetor slow injection Poor engagement of cylinder head washer Severe wear of cylinder piston piston ring Poor Fair Correction Check of for air between the carburetor and the air inlet Poor Fair Add tightening force or replacement of the washer Check for obstruction in the carburetor slow injec...

Page 38: ...in spark plugs Incorrect adjustment of carburetor adjustment screw Poor choke valve in carburetor Dirty or obstructed carburetor injection nozzle Poor carburetor buoyant needle valve Dirty fuel filter Obstructed fuel circuitry Poor engagement of cylinder washer Serious damage of cylinder piston piston ring Poor skip T Intense sparks See 2 8 2 poor skip of spark plug for checking methods Check carb...

Page 39: ...t Check the compression I Poor Adjustment or replacement Fair Check fuel pipe and carburetor for obstruction Check for leakage in cylinder washer check cylinder piston piston ring for wear Correct adjustment or replacement when necessary Cleaning or replacement 37 PDF created with pdfFactory Pro trial version www pdffactory com a a ...

Page 40: ...c 3 1 3 Lubrication System 3 1 4 Cooling System 3 1 5 Spark Plug 3 2 ELECTRIC SYSTEM 3 2 1 Ignition Charging Device 3 2 2 Lamps 3 3 BODY 3 3 1 Frame Cover 3 3 2 Compartment and Seat 3 3 3 Front Rear Suspension System 3 3 4 Brake System 3 3 5 Tire Tire pressure 38 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 41: ...3 1 ENGINE 3 1 1 Fuel system For 125c c 39 PDF created with pdfFactory Pro trial version www pdffactory com ...

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Page 128: ...ch Please do not over twist the spark plug Note Torque of spark plug 100 120 kg cm 3 2 ELECTRIC SYSTEM 3 2 1 Ignition Charging Device 1 Ignition Device CDI Unit of two ignitions per revolution is adopted The ignition Lead is 18 374 000rpm OLD 15 374 000rpm NEW 2 Charging Device Power is given by flywheel magneto The voltage is controlled by voltage regulator Power is charged to battery A Flywheel ...

Page 129: ...ery sealing bolt 3 Insert the filling hole of electrolyte container into the filling hole of battery Try not to spillage it 4 There are three pipes on each side Tap the bottom of container lightly when the electrolyte bubbles Pulling it out will be unnecessary 5 Remove the container from the battery after all electrolyte is filled into battery 6 Insert the fixing plug in the filling hole of batter...

Page 130: ...cessary to 3 months 6 months 10 months 40 hours 60 hours time charge 10 hours 20 hours 30 hours Pour electrolyte into battery Lay 30 minutes then begin to use 6 Connect the black lead to the pole of battery and red to pole put the battery to the location and clamp the rubber band 7 For the connected plastics long tube to the air vent hole of battery the other end of the tube must be setted through...

Page 131: ...pole of the charger and with CAUTION 1 Keep the battery away from flames sparks and cigarettes 2 If the temperature of the electrolyte is higher than 45 C it must to change to half of the current intensity or stop to charge until decrease to get under 35 C 3 After charging the battery adjusting the electrolyte to upper level and recharge 1 2 hours again then put into the fixing plugs washing and p...

Page 132: ...ll fully discharged by itself above three months 3 2 2 Lamps 130 PDF created with pdfFactory Pro trial version www pdffactory com Head lamp Remove the bolts of the cover Cover Remove the head lamp couples Rear lamp Remove the bolts of the cover Cover Remove the rear lamp couples Inspection Check if the lamps is damage please replace with new one Installation Install in reverse order of removal pro...

Page 133: ...ANDLE BAR 9 COVER HANDLE BAR UPPER UNDER 10 WIND SHIELD 11 FRONT SPEEDOMETER COVER 12 SPEEDOMETER COVER 13 SPEEDOMETER COVER 14 COVER LEG SHIELD FRONT 15 LEG SHIELD FRONT 16 COVER SET LEG SHIELD 17 FRONT LUGGAGE BOX 18 LEG SHIELD REAR 19 COVER RIB LH RH 20 LEG SHIELD SIDE LH RH 21 CUSHION LEG SHIELD LH RH 22 FRONT FENDER INNER 23 LEG SHIELD LOWER 24 FENDER REAR TANK FUEL 25 FRONT FENDER FOR CUB 26...

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Page 135: ...ver Handle Bar Under Leg Shield Side Lower Leg Shield Rear Leg Shield Lower Cautions 1 Do not damage cover of body panels while dismounting 2 Handle with care regarding lugs of to avoid damage dismounting 3 When remounting do not scratch or crash wiring 4 While assembling every lug shall be fixated effectively 5 While assembling make matching panels and their slots 133 PDF created with pdfFactory ...

Page 136: ... during riding it will affect the safety and even cause injury E Please pay attention not to let fuel or oil drop into the compartment F The cover of the compartment can be cleaned with vacuum cleaner It can also be washed and put back after dried Please do not wash with volatile fluid such as gasoline G The seat is controlled by the seat lock on the side 2 Helmet Holder There is a Helmet Holder a...

Page 137: ...ar Suspension A Suspension Mechanism is composed of single telescopic absorber between the crank case and scooter body B Rear Axle Movable by telescopic shock absorber 3 3 5 Tire Tire pressure Inspection Check if tire has been cracked damage worn inclusions stone nail glass etc If tire is in poor condition please replace with new one Note Tire specifications See specification table Tire pressure W...

Page 138: ...OPERATING CAUTIOS TROUBLESHOOTING 4 3 2 BATTERY 4 3 3 SHORT CIRCUIT TEST 4 3 4 STARTER MOTOR 4 3 5 RESISTOR 4 3 6 CDI 4 4 REMOVAL AND INSPECTION OF BODY PARTS 4 4 1 Removal and Inspection of Front Fork and Steering 4 4 2 Removal and Assembly of Wheel and Shock Absorber 4 5 BRAKING SYSTEM 136 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 139: ...ified grease should also be applied on specified positions 6 Dust dirt and unusual articles should be avoided while reassembling 7 While assembling the main lip of oil seal should face inwards oil chamber and the antidust sub lip should face outwards Apply an even layer of specified grease onto the lip before it is pressed to its location with balanced force by specified jigs 8 While pressing the ...

Page 140: ...EMOVAL AND INSTALLATION OF ENGINE Removal of Engine Remove Seat and Cover Remove Exhaust Muffler Remove Clamp of Air Filter and Air Filter 138 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 141: ...ound Lead Remove the Throttle Cable on Carburetor Piston Remove Oil Hose Remove Negative Pressure Hose and Remove rear belt cooling duct Remove Fuel Hose Remove Water Hose Remove the engine mounting bolts and nuts 139 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 142: ... Remove the rear axle shaft bolts and remove rear wheel Installation Install in reverse order of removal procedures 140 PDF created with pdfFactory Pro trial version www pdffactory com ...

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Page 193: ...SE Gênerai information Crankshaft Trouble diaqnosis Assembly of crankcase Disassemblv of crankcase PDF created with pdfFactory Pro trial version www pdffactorv com 1 2 1 6 kgf m 1 0 1 5 kgf m 1 5 3 0 kgf m O B 1 2 kgf m ...

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Page 201: ...igniting if the voltage will rise again after an abrupt falling it is normal 5 If a battery is unused during a long time its energy storage will decrease by its auto discharge Therefore a recharging is necessary around every 3 months 6 To charge a battery it shall be removed from the car and its filler plugs removed To put the charging current ON or OFF you must operate at the charger s switch You...

Page 202: ... a suitable heat value and gap are to be used Otherwise engine will not work smoothly or break Troubleshooting Battery Recharging System No voltage 1 Battery cable fallen or disconnected 2 Fuse fused 3 Defective of flywheel magneto 4 Excessive battery discharging a Electrolyte leaked b Chemical reaction in battery c Short circuit in battery d Defective rectifier Low voltage 1 Insufficient rechargi...

Page 203: ...r bad contact at connections Ignition System Dysfunctioning of spark plugs 1 Defective of flywheel magneto 2 Defective high tension coil 3 Defective C D I 4 Defective spark plugs 5 Defective conductor contact breaking or short circuit for example a Conduction between flywheel magneto and C D I b Conduction between C D I and the main switch c Conduction between C D I and the high tension coil Engin...

Page 204: ...ections 3 Fuse fused 4 Defective main switch 5 Defective front and rear brake switches 6 Defective starter motor switch 7 Defective starter motor relay 8 Defective starter motor 9 Circuitry conductor defective or broken 10 Starter motor drive pinion locked with the over speed clutch gear Weak drive of starter motor 1 Insufficient recharging of battery 2 Bad contact on circuit conductors 3 Strange ...

Page 205: ...ous to do so in concealed location Please put battery in good ventilation location during charging and forbid fire Note 1 Standard charging current 0 6 A for 5 10 hours 2 Quick charging current 6 0 A for 30 minutes 3 Please do not use quick charge except for emergency 4 Measure the battery voltage 30 minutes after battery is charged The battery voltage should be higher than 12 8 V C Battery manufa...

Page 206: ...ion 1 Check continuity between segments Note A If continuity is good then it is normal B If no continuity then it is broken 2 Check continuity between segments and armature shaft Note A If no continuity then it is normal B If continuity is good then it is broken 3 Clean the commutators if there is metal powder between segments 4 Check the removed parts for damaging burning discoloration and wearin...

Page 207: ...ing Coil Inspection Disassembly The exciting coil connector Measure A Use megga meter s positive terminal to connec t exciting coil s black red terminal B Connect the megga meter s negative terminal with frame ground and measure the resistance B Pulse Coil Inspection Disassembly The pulse coil connector Measure A Use megga meter s positive terminal to connect pulse coil s blue yellow terminal B Co...

Page 208: ...case Helmet case Note There is a coupler under the helmet case And remove it Additions of side cover Remove the handles Remove the bolts on the side cover Leg shield Remove the bolts on the leg shield each side leg shield Installation Install in reverse order of removal procedures 206 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 209: ...edures 207 PDF created with pdfFactory Pro trial version www pdffactory com Front fender Remove the bolts on the front fender each side Mud guard Remove the bolts on the mud guard each side Raer leg shield Remove the bolts on the rearleg shield each side ...

Page 210: ...hield cover Fronnt leg shield Remove the bolts on the fronnt leg shield each side Fronnt leg shield Leg shield cover set Remove the bolts on the leg shield cover set Installation Install in reverse order of removal procedures 208 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 211: ... speedometer cover Remove the screws on the Front speedometer cover each side Speedometer cover Remove the screws on the speedometer cover each side Installation Install in reverse order of removal procedures 209 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 212: ...UB 1 FORK COMP FRONT 2 SHOCK ABSORBER ASSY 3 SUSPENSION ARM LH RH 4 FIXED PLATE LH RH CU8 B CUB B 1 FORK COMP FRONT 2 FORK COMP FRONT LH RH Z1U 1 HANDLE BAR ASSY 2 GRIP 3 CABLE 4 CABLE THRORRLE PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 213: ...ply brake when removing caliper from brake disk Otherwise the lining can contact Front wheel Inspection Check eccentricity and wear condition Note If eccentricity is higher than 0 2mm please replace with new one to ensure driving safety Speed meter gear assembly Inspection of Wheel Rim Put wheel rim on rotation stand Rotate the wheel slowly and use dial gauge to measure eccentricity Note 1 The tra...

Page 214: ...lease replace with new one Installation Install in reverse order of removal procedures Shock absorber Front Watch Please place main stand to park the motorcycle for maintenance Removal Remove upper and lower attaching bolts on front shock absorber each side 2 bolts Shock absorber Inspection Check if the shock absorber is worn scratched leaking or bent If its condition is poor please replace with n...

Page 215: ... or bent If its condition is poor please replace with new one Note Torque of shock absorber upper and lower attaching bolts 200 300 kg cm Installation Install in reverse order of removal procedures 213 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 216: ...4 5 Brake system CU8 CUB 1 MASTER CYLINDER 2 HOSE ASSY 3 CALIPER 4 PAD ASSY 5 DISC BRAKE 6 REAR FORK ASSY 214 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 217: ...CU8 B CUB B 1 MASTER CYLINDER 2 HOSE ASSY 3 CALIPER 4 PAD ASSY 5 DISC BRAKE 6 REAR FORK ASSY 215 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 218: ...id to plastic parts wipe it off with a rag for aestheticism B Checking and adjustment of free braking gaps Note front brake free gap of 10 20 mm Adjustment of braking gap Remove Front windshield Turn lose the securing nuts tighten the screws Remark 1 Turn it clockwise to enlarge the gap 2 Turn it counterclockwise to reduce the gap 3 Keep the free gap at between 10 20 mm and tighten the nut C Inspe...

Page 219: ...ween the ends of front brake lever Gap of Front Brake Lever 10 20 mm ___________ b Add brake oil c Check the brake lining F Inspection of Rear Brake a Check the gap between the ends of rear brake lever b Move the adjusting nut of brake cable clockwise to proper gap Gap of Rear Brake Lever 10 20 mm 217 PDF created with pdfFactory Pro trial version www pdffactory com ...