2007 TGB Target 525 ATV Factory Service Manual

The 2007 TGB Target 525 service manual details maintenance and repair procedures for the single-cylinder, water-cooled engine, BSR33 carburetor, CVT, and shaft-drive system.

Text search and wiring detail: Service text is searchable, with 13 embedded bookmarks linking to grouped sections under technical file names. Labels in the overall wiring diagram are not text-searchable; its small wire codes and connector labels are readable when enlarged.

• Engine repair: Engine removal, cylinder head and valve service, piston and ring inspection, valve timing, and crankshaft/crankcase reassembly.

• CVT and shaft drive: Belt replacement, drive-face and driven-pulley service, starting-clutch inspection, and output-shaft and universal-joint procedures.

• Fuel and lubrication: BSR33 carburetor disassembly, fuel-level and idle adjustment, throttle-cable adjustment, oil-pump inspection, and maintenance schedules.

• Cooling system: Radiator pressure testing, thermostat inspection, water-pump service, coolant replacement, and air bleeding.

• Brakes and chassis: Caliper and master-cylinder service, brake bleeding, rear-axle bearing inspection, steering tie-rod service, and toe-in adjustment.

• Electrical diagnosis: Charging, CDI ignition, starter-relay, fuel-gauge, and temperature-sensor testing, supported by circuit diagrams and the overall wiring diagram.

TGB prepared this manual for technicians carrying out component inspection, service, and repair.

Cylinder Head, Crankcase, and CVT Repair

Engine sections cover valve-guide replacement, valve-seat inspection and resurfacing, rocker-arm checks, and piston-ring installation. Crankcase coverage extends to the balancer shaft, gearshift assembly, bearings, and oil seals.

Illustrated V-belt assembly views accompany roller, pulley, and clutch inspection limits. The CVT procedures warn that holding the drivetrain through the rear wheel or brake during pulley-nut work can damage the reduction gears.

BSR33 Carburetor and Oil Pump

The fuel-system chapter covers the air cut-off valve, throttle valve, jets, and float valve. Idle and exhaust-emissions adjustment procedures use a tachometer and exhaust analyzer.

Oil-pump disassembly and rotor-clearance checks sit alongside strainer and filter service. The carburetor section also warns that forcing the air adjustment screw can damage its seat.

Shaft Drive, Brakes, and Suspension

Final-drive procedures cover front and rear output shafts, bevel gears, and universal joints, with gear-tooth contact and backlash checks during reassembly. Front-differential and final-gear oil service are covered separately.

Brake sections distinguish the rear hand-operated and foot-operated master cylinders. Chassis work extends to wheel hubs, rear-axle bearings and seals, steering-shaft bushings, and front and rear shock removal and installation.

Body-cover removal sequences and exhaust-pipe and muffler removal support access for engine work.

Cooling and Electrical Fault Diagnosis

The cooling-system troubleshooting chart links overheating symptoms to circulation, thermostat, fan, and temperature-indication checks. This helps distinguish a cooling fault from an indication fault before parts are selected for replacement.

Charging, ignition, and starting circuit diagrams accompany charging-coil resistance checks, pulse-generator testing, brake-start interlock checks, and starter-relay diagnosis. Switch-continuity tables, fuel-unit resistance checks, and fan thermo-switch testing supplement the overall electrical diagram.

Electric starter-motor coverage addresses removal and installation; the recoil starter has separate disassembly and reassembly instructions.

Workshop Specifications and Special Tools

Component-specific torque tables, wear limits, clearances, and fluid-capacity data accompany the repair sections. Some overview and component tables contain conflicting specifications, including cylinder dimensions; applicable limits require confirmation against the actual engine before machining or parts selection.

Special-tool listings identify the ACG flywheel puller 440659, valve-and-spring installer/remover 440667, and universal-joint installer 440668, tying the procedures to specific workshop equipment.

Work in a well-ventilated area and support the ATV securely before disassembly.

Printable PDF and Included Pages

The ZIP contains one printable, English-language PDF with 233 pages total. This count includes five opening pages (cover, foreword, reading guide, contents, and serial-number identification), seven notes pages, and six otherwise blank pages.