Royal Alloy TG300 ABS Owner'S Manual Download | Manualshive

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Summary of Contents for TG300 ABS

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Page 3: ...uestions about the operation and maintenance please contact your dealer The scooter is designed to fully meet the exhaust emissions standards prevailing on the date of manufacture To keep the compliance to the exhaust emissions standards please carry out the maintenance schedule and instructions in this manual in cooperation with your dealer The following important information will appear in this ...

Page 4: ...mpany is working hard towards improvement of product design and quality This manual contains the latest product information at the time of print However it is possible that the manual may have slight differences with your scooter If you have any question please contact your dealer Warning Read this manual carefully before riding the scooter ...

Page 5: ... 17 Engine Oil 17 Transmission Oil 17 Running in of New Scooter 18 Inspection before Riding 19 Inspection of Braking effect and free play 20 Inspection the Front Brake and Anti Dive Linkage20 Inspection of the Tyres 20 Inspecting the Quantity of Fuel 21 Inspecting the Quantity of Engine Oil 21 Inspecting the Transmission Oil Level 22 Inspection of the Ignition Unit and the Lights 22 Riding Tips 23...

Page 6: ...Contents 5 Fuel Hose 30 Air Filter 30 Tyres 32 Fuses 33 Troubleshooting 34 Storage Procedures 35 Specifications 36 ...

Page 7: ... high speed should be avoided and special care should be taken when turning Bear this in mind the braking distance on rainy days can be twice as much as on dry days Correct Wearing of Safety Helmet Wear a safety helmet whenever you ride and make sure you fasten the strap securely whenever you wear the helmet Safety clothing Recommendation Bright coloured and well fitting garments are recommended M...

Page 8: ...fore using the motorcycle 1 Exhaust Muffler pipe 4 Seat 7 Front turning lamps 2 Rear light Brake light number plate light 5 Acceleration grip right switch 8 Side reflector 3 Rear rack 6 Head lamp 9 Front right shock absorber Warning Rear rack has a maximum payload of 5 kgs 5 2 1 3 4 6 7 9 8 ...

Page 9: ...ke lever 5 Rear indicator lamps 9 Main stand 2 Rear view mirrors 6 Rear shock absorber 10 Side stand 3 Left grip switch 7 Rear disc brake 11 Front disc brake 4 Glove box 8 Air filter 12 Front left shock absorber 1 7 2 6 4 5 3 8 9 10 11 12 ...

Page 10: ...Note Remember your engine number in mind for convenience in purchasing correct spare parts from your distributor Chassis number Chassis number is stamped on the frame right side frame rail Engine number Chassis number Please write down the serial numbers below for future reference Chassis Serial No Engine Serial No ...

Page 11: ... the fuel level is low and refilling is necessary 3 TRIP The trip registers the single distance that the scooter has been ridden 4 DATE TIME Dispaly the date time 5 13 LH Direction Indicator RH Direction Indicator When the turning switch lever is set to left the LH Direction Indicator will flash When the turning switch lever is set to right the RH Direction Indicator will flash 6 12 LEFT Right set...

Page 12: ...his warning light appears during running please consult your dealer 11 Oil indicator STOP ENGINE if this warning light appears during running check oil level if found to OK Then please consult your dealer 14 Odometer The odometer registers the total distance that the scooter has been ridden 15 Water temperature gauge 16 Speedometer The speedometer shows the speed at which you are riding in MPH or ...

Page 13: ... the key in and turn it anti clockwise to LOCK position 3 Pull out the key To unlocking the handlebars insert the key from LOCK position and turn it without pressing clockwise to OFF position Switches on the Handlebars Left 1 Beam Switch This switch is used to change the headlamp beam When you turn the switch to Note Rotate the handlebars to ensure that they are unlocked Tip you may turn the handl...

Page 14: ... Centre Push in the switch at the centre position to cancel the turn signal operation Please turn off the lamps when they are no longer necessary otherwise you may cause problems to drivers in front of or behind you Switches on the Handlebars Right 4 Starter Button This button is used to start the engine Turn the ignition key to ON squeeze the rear brake lever 6 and press the button 4 5 Throttle G...

Page 15: ...foot and lift the rear of the scooter backwards using the rear rack until the stand is securely in place with the rear wheel off the ground Fuel Tank Cap To access the fuel cap open up the seat To open the fuel cap insert the ignition key into the cap and turn the fuel cap tab clockwise Please note Don t use the key to rotate the cap as this make cause the key to break shuold the key and lock cove...

Page 16: ...is in the left of vehicle Note When the key is inserted the oil fillingport can be opened or closed unless the key and lock coverwere rotated at the same time Warning Never open coolant tank cap when the scooter is hot Hot coolant can cause burns and may cause injury ...

Page 17: ...nd to the rear of the seat push the button in and the seat will open 2 To close the seat gently lower the seat down onto the locking pin Front Luggage Box Caution Do not keep breakables in the luggage box Do not keep valuable item in the luggage box Do not place fuel and oil in the luggage box Only store water proof items in luggage box ...

Page 18: ...sing the highest octane pump fuel available Engine Oil Use of high quality 4 stroke engine oil will extend the longevity of the engine Grade SE or SD engine oil in API method are recommended with a viscosity of SAE10W 40 If this oil is not available please purchase appropriate substitutes according to the data listed below Transmission Oil Use good quality SAE 75W 80 synthetic motor oil Specificat...

Page 19: ...e maximum recommended throttle operation during the break in period Change below to miles Initial 100 miles 160 km Less than 1 2 throttle Initial 250 miles 400 km Less than 3 4 throttle Vary the engine Speed The engine speed should be varied and not held at a constant speed This allows the parts to be loaded with pressure and then unloaded allowing the parts to cool This aids the bedding together ...

Page 20: ...e riding the scooter be sure to check the following items Never underestimate the importance of these checks Perform all of them before riding the machine Warning Ensure that the battery is fully charged and that the battery is secure and the battery terminals connectors are secure A battery with loose connections will damage electrical components including the ECU WHAT TO CHECK CHECK FOR Steering...

Page 21: ...e Linkage Check the anti dive link bar has free movement by twisting from side to side If any excessive play is found in the up and downward movement remove and inspect replace as required Inspection of the Tyres 1 Tyre Pressures Observe the wear condition of the tyre and determine the tyre pressure If the tyre pressure is abnormal check it with a tyre pressure gauge and adjust it to the correct v...

Page 22: ... engine damage 1 Keep the vehicle in an upright and level position 2 Start the engine let it idle during a few minutes and then switch it off 3 Wait at least five minutes to let the oil that is inside the engine to run back down into the crankcase 4 Loosen the refilling oil cap dipstick and remove 5 Clean the dipstick of oil residues insert the oil filler cap but don t screw in otherwise there wil...

Page 23: ...d the Lights Start the engine and check if the headlight and the rear lights are on Operate the front and rear brake separately and check if the brake light is activated Operate turning indicator switch and check if the turn signal indicator lights are working normally Inspecting the Rear View Mirrors Check to see if objects to the rear and both sides can be seen clearly from the rear view mirrors...

Page 24: ...Otherwise damage may result to and starter motor and gear wheels If the engine remains un started after several attempts turn the throttle grip by 1 8 1 4 and try again The grip should be released soon after the engine is started Setting off Release the main stand and mount the scooter While holding the handlebars with both hands remove the scooter from the main stand With both brakes applied moun...

Page 25: ...ockwise Gradual rotation is recommended Rotate it back clockwise it to slow down clockwise Apply Brakes Combined application of both brakes is recommended Quickly release the throttle grip or rotate backwards clockwise to the minimum position and squeeze the brake levers simultaneously It is advisable to reduce the speed by gradual application of the brakes Caution Single braking of the front or r...

Page 26: ... indicates the intervals between periodic services in miles and months At the end of each interval be sure to inspect check lubricate and service as instructed If your scooter is used under heavy load conditions such as continuous full throttle operation or is operated in a dusty climate certain services should be performed more often to ensure reliability of the machine as explained in the mainte...

Page 27: ... km 7400 miles 12000 km 11200 miles 18000 km 14800 miles 24000 km 18600 miles 30000 km 22300 miles 36000 km 26000 miles 42000 km 29800 miles 48000 km 33500 miles 54000 km 37300 miles 60000 km Torque driver pins L L L L L Safety fasteners I I I I I I Plastic sliders in variator cover R R R R R Clutch bell C C C C C C C C C C Spark plug R R R R R Driving belt R R R R R Throttle control A A A A A A A...

Page 28: ... 3 Steering stem lock nut 30 3 0 4 Handlebar locating bolt 25 2 5 5 Front fork mounting bolt 45 4 5 6 Master cylinder mounting bolt 10 1 0 7 Brake hose union bolt 23 2 3 8 Brake calipers mounting bolt 26 2 6 9 Bleeding valve 7 5 0 75 10 Front panel bolt 23 2 3 No Item Nm Kg m Reference 11 Rear axle nut 100 10 0 12 Rear shock bolt 40 4 0 13 Rear brake lever nut 11 1 1 14 Engine bracke t mounting bo...

Page 29: ... type and requires no maintenance such as fluid level and gravity Spark Plug Removal and Cleaning Unscrew and remove the three screws then remove left hand side panel which will gives access for removal of spark plug Caution BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID RISKS OF BURNS LEAVE ENGINE AND SILENCER TO COOL TO AMBIENT TEMPERATURE ...

Page 30: ...itable spark plug cleaners a wire and or metal brush Blow with a strong air blast to avoid re moved dirt getting into the engine Re place the spark plug if there are any cracks on the spark plug insulating material corroded electrodes or several deposits Check the electrode gap with a feeler gauge This gap should be 0 7 0 8 mm adjust it if necessary by carefully bending the ground electrode Make s...

Page 31: ... four years Air Filter The air filter element used in this scooter is a polyurethane foam element If the filter element has become clogged with dust intake resistance will increase with a resultant decrease in power output and increase in fuel consumption due to the richer fuel air mixture Check and clean the air filter element according to the following procedure Remove the screws Remove the two ...

Page 32: ...absolutely sure that the filter element is securely in position and is sealing properly Caution Before and during the cleaning operation carefully examine the air filter element for any tears in the material A torn filter element must be replaced with a new one If driving under dusty conditions the filter element must be cleaned more frequently NEVER OPERATE ENGINE WITHOUT THE FILTER ELEMENT Opera...

Page 33: ...n t mix it with silicon based or oil based fluid otherwise the hydraulic brake system will be damaged Don t use residual fluid in the container opened during last maintenance because it can absorb moisture from the atmosphere Do not over fill or spill the brake liquid onto the surface of paint or any surface Tyres Check the tyre inflation pressure and tyre tread condition For maximum safety and go...

Page 34: ...ecommended that a tyre be replaced when the remaining depth of tyre tread becomes 1 6mm or less Caution The standard tyres on your scooter are 110 70 12 front and 120 70 12 rear The use of a larger tyre other than standard may result in clearance issues Fuses The fuses are located under the left hand side panel If there is any electrical system failure first check the fuse In case the fuse is blow...

Page 35: ...e spark plug gap If there is no spark consult the dealer for repairs Caution Do not hold the spark plug close to the open spark plug hole in the cylinder head as gasoline vapour inside the cylinder could be ignited creating a fire hazard To reduce the chance of electrical shock hold the outer steel shell of the spark plug against an unpainted metal portion of the engine Due to the possibility of e...

Page 36: ...nals and wiring harness connections Store the battery in a room above freezing and connect a suitable battery trickle charger conditioner Tyres Inflate the tyres to the normal specifications See page 22 37 External Spray all vinyl and rubber parts with rubber preservative Spray the unpainted surfaces with rust preventative such as WD40 Coat the painted surfaces with a good high quality vehicle wax...

Page 37: ...art mode Engine oil 950ml Lubrication type Transmission oil 170ml Fuel type 1P75MN 1700 100 rpm 1 cylinder 4 Valve Liquid cooling 75 63 278 11 1 16 0 7250 23 0 6000 Electric SAE 10W 40 Pressure splash 75W 80 Octane rating of 95 or higher Tyre type Front tyre size Rear tyre size Inflation Front Rear Front brake Rear brake Spark plug Head lamp Turning lamp Taillamp Brake lamp Instrument indicator Ba...

Page 38: ...37 MEMO ...

Page 39: ...38 Owner s Manual RA Engineering Co Ltd ...

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