User manual TGB TARGET 525 SERVICE MANUAL

[. . . ] TARGET 525 SERVICE MANUAL TAIWAN GOLDEN BEE CO. , LTD. PDF created with pdfFactory Pro trial version www. pdffactory. com Homepage Contents FORWARD This service manual contains the technical data of each component inspection and repair for the 525 ATV. The manual is shown with illustrations and focused on "Service Procedures", "Operation Key Points", and "Inspection Adjustment" so that provides technician with service guidelines. If the style and construction of the ATV 525, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to change without notice. Service Department TAIWAN GOLDEN BEE CO. , LTD. PDF created with pdfFactory Pro trial version www. pdffactory. com Homepage Contents HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for 525 ATV. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment. [. . . ] Install the parts as show. Insert the bearing to the joint and turning the joint. If excessive play is noted, must be replace the new bearing. Reassemble the driven output rear shaft and front shaft. After The tooth contact and backlash have been adjusted and checked. 9-5 PDF created with pdfFactory Pro trial version www. pdffactory. com 9. FINAL DRIVING MECHANISM Reassembly driven output rear shaft Before reassembly thoroughly clean all parts with solvent. Using a vise hold the bevel gear. Torque: 100N-m (10kgf-m, 73lb-ft) Stake the nut with a punch. Apply grease to the bearing and seal lip. 9-6 PDF created with pdfFactory Pro trial version www. pdffactory. com 9. (The oil seal lip should be positioned joint yoke side. ) Using a vise hold the driven output rear shaft. After The tooth contact and backlash have been adjusted and checked. Put the bearing rings and shaft in the crankcase. (Tooth face contact 80% up) Remove the driven output Rear/Front shaft. Tighten the bevel gear nut and output rear shaft to the specified torque. Torque: 100N-m(10kgf-m, 73lb-ft) Stake the nut with a punch The bearing knock-pin should be outside. 9-7 PDF created with pdfFactory Pro trial version www. pdffactory. com 9. FINAL DRIVING MECHANISM Tooth contact: face contact 80% up Using the tool to install the bearings and joint. When the tooth contact and backlash have been adjusted or checked. Tool: 440668 Install the new c-ring by tapping and hammer. ( copper ) Using the new c-ring for reassembly. After reassembling the universal joint assy. Tapping the bearing with the plastic mallet lightly. 9-8 PDF created with pdfFactory Pro trial version www. pdffactory. com 9. FINAL DRIVING MECHANISM FINAL ASSEMBLY l After adjusting tooth contact correctly, remove the Front and rear output shafts and drive bevel gear. l Clean off any dye or paste from the gear teeth, and lubricate the teeth with engine oil. l Tighten the drive bevel gear nut and rear out put Shaft nut to the specified torque. Rear output shaft nut:100 NM(10. 0 kgf- m, 73 lb-ft) Drive bevel gear nut:100 NM(10. 0 kgf- m, 73 lb-ft) l Stake the collar of the nut into the notch in the shaft. NOTE: After the tooth contact have been checked and adjusted reassemble the joint. 9-9 PDF created with pdfFactory Pro trial version www. pdffactory. com 9. FINAL DRIVING MECHANISM ENGINE REASSEMBLY NOTE: When reassembly the engine pay attention, apply engine oil to sliding parts and running parts before re-assembling. CAUTION Be sure keep the drive belt, drive face and driven face away from any greasy matter. l Install the output shaft assembly with a plastic mallet. l Install the shim drive bevel gear and washer. l Tighten the bevel gear nut to the specified torque. Bevel gear nut torque:100 NM(10. 0 kgf- m, 73 lb-ft) l Use a center punch stake the nut. 9-10 PDF created with pdfFactory Pro trial version www. pdffactory. com 9. FINAL DRIVING MECHANISM DRIVE TRAIN l Install the rear and front out put shaft. l Install the C-ring. NOTE: Must fit the pins on the bearing into the groove of the crankcase. TRANSFER/GEARSHIFT l Install the transfer related parts. l Install the spacer spring, shaft and reverse idle gear. [. . . ] ELECTRICAL SYSTEM Headlight Switch Pin Position Headlight switch BAT3 LO HI PL Wire color Red Red Red Blue /Green /Yellow /Brown Winker switch Pin Position L WR R N PUSH OFF Wire color Brown Brown / White Green Winker switch Winker switch Horn switch Pin Position FREE BAT3 HO Wire Color Brown/ White Pink Horn switch Hazard switch Pin Position HD E Hazard switch Wire Color Brown / White Black 17-17 PDF created with pdfFactory Pro trial version www. pdffactory. com To this chapter contents 17. ELECTRICAL SYSTEM Front Brake Switch While grasp the brake lever firmly, the terminals of brown/blue and green/yellow of the brake should have continuity. Replace the switch if damaged. Brake light switch Rear Brake Switch While grasp the brake lever firmly, the terminals of white/black and Brown/White of the brake should have continuity. Replace the switch if damaged. Brake light switch Horn Remove the horn from front fender. 1 bolt Apply 12 V power source to two terminals of the horn, the horn should sound. [. . . ]