TNG 150cc Owner'S Manual Download

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Revised 11/07

Owner’s Manual

Baja 150cc (BJ150)

Summary of Contents for 150cc

Page 1: ...Revised 11 07 Owner s Manual Baja 150cc BJ150 ...

Page 2: ... LOCATING YOUR VIN The serial numbers of the frame and engine are used for vehicle registration The VIN and label are located in the glove box Then engine is located on the back of the engine VIN 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 22 H PROPER OPERATION Page 24 I SERVICE MAINTENANCE SCHEDULE Page 30 J WINTERIZING Page 40 K TROUBLESHOOTING Page 43 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: ...ost Economical Speed 30 mph Battery Type 12V 8Ah Noise 80dB A Headlight Hi Lo Beam 35W 35W Engine Type Air Cooled 4 Stroke Front Running Light 3W Cylinder Arrangement Single Cylinder Brake Tail Lights 21W 5W Displacement 150cc Turn Signal Light 10W Ignition Type CDI Turn Signal Indicators Dash 3W Transmission CVT Instrument Illumination 3W Front Brake Disc Fuses 15 Amps Rear Brake Drum Fuel Type 9...

Page 14: ... 5 Handle Bars 9 Air box Filter 13 Instrument Panel 2 Center Stand 6 Turn Signals 10 Kick Starter 14 Ignition Switch 3 Muffler 7 Headlight 11 Side Stand 15 Fuel Cap 4 Seat 8 Rearview Mirrors 12 Electrical Compartment 1 2 3 4 6 7 7 13 14 15 11 10 9 12 5 ...

Page 15: ...15 15 1 Horn Button 6 Front Brake Lever 2 Rear Brake 7 Throttle 3 Turn Signal Switch 8 Electric Starter Button 4 Hi Lo Beam Switch 9 Engine Stop Switch 5 Speedometer 1 3 2 4 5 6 7 9 8 ...

Page 16: ...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 17: ...or 2 Speedometer 3 Odometer Clock 4 Hi Beam Indicator 5 Gas Gauge 6 Volt Meter 7 Trip Meter Turn Signal Switch and Indicator To assign right turn push the switch to and the right turn indicator light flashes To assign left turn push the switch to and the left turn indicator light flashes To cancel turn signal push in the button on the switch White 1 3 4 2 5 6 7 ...

Page 18: ...tes accumulated distance in kilometers CLOCK See page 17 Toggle between the left and right buttons until the desired time date is achieved Gas Gauge see page 17 Indicates the fuel Level The needle moves towards E empty as the gas level is decreasing TRIP METER see page17 Indicates kms for a trip The trip meter is able to be reset Throttle Control see page 15 Control speed by rotating the throttle ...

Page 19: ...p Switch see page 15 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 15 To decrease speed and stop the scooter from moving To apply rear brake pull the left brake lever gradually To apply the front brake pull the right lever toward...

Page 20: ...e stuff when washing the scooter Luggage Rack WARNING Luggage rack can carry 11 lbs max Do not exceed maximum 17 5 lbs for cargo Fuel Tank Cap see page 14 for location To remove the gas tank cap slide the latch located on the back of the rear seat laterally to release the hinging seat Lift the rear seat to expose the fuel cap Turn the gas cap counter clockwise to remove Fill the tank up to the bot...

Page 21: ...t 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 Seat Latch Hinge Seat Forward to Access Gas Cap ...

Page 22: ...gher gasoline to refuel the scooter 2 Check the brake light Turn the ignition key to the ON position Grip the front brake lever or rear brake lever while watching the rear brake light to make sure that it illuminates 3 Check the Turn Signals Turn the ignition key 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...

Page 23: ...ront and rear wheels These tires must always be replaced with tires of the same type 5 Check the Brakes Front Brake Compress the front brake lever and measure the distance traveled before the brake begins to slow the front wheel The lever should travel between 10 to 20 mm before the wheel begins to drag Rear Brake Depress the rear brake lever and measure the distance travelled before the brake beg...

Page 24: ...llow the engine to cool down before attempting to replace the spark plug For replacement instructions see page 34 8 Check the Engine Oil See Page 34 9 Check the TRANSMISSION Oil See Page 35 H PROPER OPERATIONS TECHNIQUES WARNING Be sure you have read this owner manual completely and understand all operating features Do not start the engine or operate the scooter in closed areas as the exhaust fume...

Page 25: ...tarter when starting the scooter in the following situation DO NOT ADVANCE THE THROTTLE WHILE KICK STARTING Cold or wet weather If the fuel has run dry If the scooters has been stored for any length of time If electric start does not work If bike does not start please refer to trouble shooting section WARNING Do not change the position of the ignition switch while the vehicle is in motion only whe...

Page 26: ...left handle with your left hand and grasping the rear rack with your right hand push the scooter forward and move the stand back with your foot until the stand retracts under the scooter See Fig 1 Side Stand Grasp the handlebars with both hands and tip the scooter upright Move the stand back with your foot until the stand retracts under the scooter See Fig 2 3 RIDING POSITIONS See Fig 3 Place your...

Page 27: ...m 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 brake lever while putting pressure on the rear brake ...

Page 28: ... 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 stand of the scooter WARNING Do not touch the engine and the exhaust system as they can become very hot CAUTION If t...

Page 29: ...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 4 to maintain engine warranty CAUTION Have your TNG Scooter dealer check the vehicle if any engine trouble occurs during this period ...

Page 30: ...6 Months Fuel Line I Fuel Filter R Air Filter I I I Spark Plug R Valves I R R Engine Oil R I 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 31: ...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 32: ...able level See Fig 5 Turn it counterclockwise to soften brake HYDRAULIC BRAKE FLUID LEVEL Front Brake Check the fluid level by looking at the reservoir See Fig 6 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 visible If it isn t the p...

Page 33: ...ir 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 34: ...other to turns Reattach the spark plug cover 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 CHECKING ENGI...

Page 35: ...level up near 5 the hi mark CAUTION If the scooter is being used under more severe conditions such as gravel roads or lots of stop go traffic then the oil should be changed more frequently than every 4000 km CHECK THE TRANSMISSION OIL Inspect the transmission oil after the first 300 km and then after every 4000 km or six months which ever comes first NOTE Must use Opti 4 oil in transmission to mai...

Page 36: ...ON If the scooter is used in excessively wet areas or used in severe conditions replace the transmission oil more often than recommended Make sure that the fill and drain plugs are tight and not leaking Make sure that no foreign substances fall into the transmission box Transmission Oil Fill Plug Transmission Oil Drain Plug ...

Page 37: ...d 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 careful to fit all pieces into their correct place Failure to achieve proper fit will cause leaks in the air intake system that can cause engine damage Handle the air filter cartridge car...

Page 38: ... 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 replacing the battery 2 Observe correct polarit...

Page 39: ...d out 2 If the fuse is open then it needs replacement 3 NOTE Check fuse for good tight contact within fuse housing WARNING Always turn the ignition off before inspecting the 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 ...

Page 40: ... extensive damage to the electrical system and possibly a fire NOTE If the new fuse burns out immediately have a TNG dealer check scooters complete electrical system J WINTERIZING INSTRUCTIONS Proper preparation of your scooter for winter storage will make it more likely that you will be able to get out and enjoy that first spring ride There are five basic areas that should be considered when prep...

Page 41: ...ize any electrolyte that may be present Rinse with clean water and dry thoroughly You may return the battery to the battery compartment or you may store it separately If it is put back into the battery compartment for storage it is best that you do not hook up the battery cables until you are ready to take the scooter out of storage Charge the battery to 100 If the battery is stored at temperature...

Page 42: ...ening a window in the room is not generally required battery charging should always be done far away from any source of flame or electrical spark 2 FUEL SYSTEM Properly preparing the fuel system before putting your scooter into storage will reduce potential problems due to a plugged or corroded system There are two ways this can be accomplished A DRY FUEL SYSTEM This technique is suitable if you a...

Page 43: ...way through the entire fuel delivery system and into the carburetor Top off the tank with gasoline to vacate all of the air This will reduce or eliminate chances of condensation due to temperature fluctuations 3 TIRES It is best if the weight of the scooter can be kept off the tires so that a flat spot or cracked sidewall does not develop With nearly all TNG Scooters when the bike is on the center...

Page 44: ...e knocked over easily 4 ENGINE OPTIONAL If you are placing your scooter into storage in an unheated area temperature fluctuations may cause condensation inside the cylinder of the engine Condensation could cause 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 cy...

Page 45: ...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 46: ...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 47: ...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 48: ...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 49: ...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 50: ...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 51: ...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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ... 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 64: ...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 65: ...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 66: ... 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 67: ...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 68: ...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 69: ...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 ...

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TNG 150cc, Owner'S Manual

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Summary of Contents for 150cc

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