Target Audience:
Owners seeking to perform their own maintenance and repairs, independent repair shops, and technical training institutions.
Value Proposition:
Provides dealership-level repair information, enabling cost savings on maintenance and repairs compared to professional service.
Specificity:
Vehicle and model specific, not generic, ensuring accuracy and relevance for TGB Hornet 50/90 models.
Technical Accuracy:
Utilizes the same information as official dealership technicians, guaranteeing accuracy of procedures, specifications, and diagnostic data.
Systems Covered:
All mechanical and electrical systems, including engine, transmission, drivetrain, suspension, steering, braking, fuel system, exhaust system, electrical system, chassis, bodywork, and maintenance procedures.
Estimated Page Count:
Comprehensive, typically 300-600+ pages for a full service manual, depending on model year and variations. (Actual count not specified, but implied to be extensive by 'A-Z' coverage).
Type:
Service Repair Workshop Manual
Language:
English (assumed based on product description)
Format:
Digital (likely PDF, implied by common sales of such manuals)
Engine Overhaul:
Complete disassembly, inspection, repair, and reassembly of all engine components, including cylinder, piston, rings, crankshaft, connecting rod, valves, camshaft, and lubrication system.
Transmission Repair:
Detailed procedures for clutch inspection and adjustment, gear selection mechanism, and potential gearbox overhaul (if applicable to the specific model variant).
Drivetrain Service:
Front and rear axle inspection, lubrication, and repair; driveshaft and universal joint maintenance (if equipped).
Suspension Maintenance:
Front and rear shock absorber/strut inspection, replacement, and adjustment; spring inspection; control arm and bushing checks.
Steering System Repair:
Handlebar and steering column inspection, linkage checks, and potential steering mechanism adjustments or repairs.
Braking System Service:
Brake lever, cable, caliper, and drum/disc brake inspection, adjustment, fluid replacement, and pad/shoe replacement procedures.
Fuel System Maintenance:
Carburetor inspection, cleaning, adjustment, and jetting; fuel filter replacement; fuel line checks.
Exhaust System Service:
Muffler and pipe inspection for leaks or damage; mounting hardware checks.
Electrical System Diagnostics:
Wiring diagrams, battery testing and replacement, lighting system checks, ignition system troubleshooting (coil, CDI, spark plug), starter motor operation, and charging system analysis.
Chassis And Bodywork:
Frame inspection, plastic body panel removal and installation, seat maintenance, and basic hardware tightening.
Routine Maintenance:
Oil changes, air filter cleaning/replacement, spark plug replacement, chain adjustment, brake adjustments, and general lubrication.
Troubleshooting Guides:
Step-by-step diagnostic procedures for common and uncommon problems, symptom-based troubleshooting.
Component Disassembly Assembly:
Detailed instructions for removing, servicing, and reinstalling individual parts and assemblies.
Torque Specifications:
Critical torque values for all fasteners to ensure proper assembly and prevent damage.
Wiring Diagrams:
Comprehensive electrical schematics for accurate troubleshooting and repair of the electrical system.
Special Tool Requirements:
Identification of any specific tools required for certain repair or maintenance procedures.
Depth:
Complete A-Z repair coverage, suitable for dealership technicians, indicating a high level of detail from basic maintenance to complex overhauls and diagnostics.
Engine Type:
Air-cooled, 2-stroke, single-cylinder (typical for TGB Hornet 50/90).
Displacement 50Cc:
Approximately 49.4 cc (for 50cc variant).
Displacement 90Cc:
Approximately 85 cc (for 90cc variant).
Bore X Stroke 50Cc:
Typically around 39mm x 41.4mm (example, specific values in manual).
Bore X Stroke 90Cc:
Typically around 47mm x 49.5mm (example, specific values in manual).
Compression Ratio:
Typically around 7.5:1 to 8.5:1 (example, specific values in manual).
Horsepower 50Cc:
Approximately 4.0 - 5.0 HP at specific RPM (estimate, exact figures in manual).
Horsepower 90Cc:
Approximately 6.0 - 7.5 HP at specific RPM (estimate, exact figures in manual).
Torque:
Specific torque figures for engine RPM will be detailed in the manual.
Carburetor Type:
CVK (Constant Velocity Kit) or similar, specific model designation provided in manual.
Fuel Type:
Unleaded gasoline (Octane rating specified in manual).
Carburetor Size:
Typically 16mm to 19mm (example, exact specifications in manual).
Oil System:
Premix or automatic oil injection system (details of oil type and ratio specified).
Length:
Specific dimensions provided in the manual, typically around 1400-1500mm.
Width:
Specific dimensions provided in the manual, typically around 800-900mm.
Height:
Specific dimensions provided in the manual, typically around 900-1000mm.
Dry Weight:
Typically between 80-100 kg (exact figures in manual).
Payload Capacity:
Specific payload capacity detailed in manual.
Front Rack Capacity:
Specified in manual, typically around 5-10 kg.
Rear Rack Capacity:
Specified in manual, typically around 10-15 kg.
Atv Safety Standards:
Adheres to relevant ATV safety standards; specific certifications detailed if applicable.
Braking System:
Hydraulic disc front brakes and drum or disc rear brake (details specific to model variant).
Throttle Limiter:
Often includes a throttle limiter screw for controlled speed operation (adjustment covered).
Roll Over Protection:
Standard ATV design with handlebars for rider control.
Lighting System:
Headlights, taillight, and brake light for visibility (electrical system diagnostics cover these).
Engine Oil Change:
Typically every 1000 km or 6 months (specific interval provided in manual).
Air Filter Cleaning:
Every 500 km or as needed, depending on operating conditions (detailed in manual).
Spark Plug Replacement:
Typically every 3000 km or annually (specific interval and plug type in manual).
Brake Fluid Change:
Every 2 years or as recommended by visual inspection (specifics in manual).
Engine Oil Type:
Specific API service classification and viscosity grade (e.g., SAE 10W-40) for 2-stroke oil will be listed.
Transmission Oil:
Not applicable for CVT models with enclosed drive units; maintenance focuses on belt and clutch components.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (specific type and capacity in manual).
Gear Oil:
If applicable for final drive unit, specific GL-4 or GL-5 gear oil type and capacity will be stated.
Carburetor Fouling:
Common issue on small 2-stroke engines; manual provides cleaning and adjustment procedures.
Cvt Belt Wear:
Normal wear and tear; manual details inspection and replacement intervals.
Electrical Connections:
Corrosion or loose connections can cause intermittent electrical faults; manual covers troubleshooting these.
