Read Instructions Before Using Your New Badger 100
Contents
1. Call 877 441 6999 for Service Centers and parts Practice safe riding skills Always wear a helmet Ride on surfaces no greater than 15 degrees Practice safety first LOCATION OF LABELS REGULAR SERVICE PROCEDURES 1 Check oil before starting 2 Adjust chain as necessary 3 Clean clutch assembly every 5 hours as needed 4 Check tire pressure 5 Lubricate chain 6 For further help refer to trouble shooting chart Do not return to retailer Call 877 441 6999 Remember to check oil level in engine Read and understand owners manual Remember to wear a helmet and follow all safety precautions SILO z DO NOT RETURN THIS PRODUCT TO STORE FOR TECHNICAL SUPPORT C19 TO OUR WEBSITE www yukontrailinc com OR CALL TOLL FREE 877 441 6999 FORTHE LATEST PRODUCT INFO WEIGHT LIMIT DO NOT EXCEED 150 LBS SPECIFICATIONS Description Data Description Data 1295mm Overall length 51 inch Bore x Stroke 52 X 45 476 2mm PTO shaft i Overall width 18 75 inch rotation Counter clockwise 863 6mm Displacement Overall height 34 inch of cylinder 97 927 1 NGK 6RTF BM4A Wheelbase 36 5 inch Spark plug BMR4A 0 6mm 0 7mm Dead weight CTS Park plus 024 inch 028 96 7kg Ground P Payload 200 Ibs clearance 127 mm 5 inch 145 70 6 Es Ignition Non contact ace specified system transistor magneto pressure on tire 145 70 6 24 psi Max to sea2. 031 CHECK UP OF SPARK PLUG 1 Remove the cap of spark plug and screw off the spark plug using the plug wrench 2 Clean the spark plug all around or replace it if it is corroded or there is too much deposit on it 3 Regulate the gap of the spark plug to 7mm 79mm 028 031 3 The spark plug of the designated type should be used The applicable type of spark plug NGK 6RTF BM4A BMRAA CHECKING 8 CLEANING THE AIR Locate Air Filter Box at rear of engine Remove air filter cover by unscrewing Phillips head screw Remove foam Air filter element Tap Air filter element gently to remove most of the dust and dirt Wash foam element per instructions below then allow to dry thoroughly Reinstall foam air filter element Reinstall air filter cover IAWN Air Filter box Phillips head screw Foam Air filter element Wash with mild soap and water Rinse with fresh water then queeze out excess CAUTION The air filter element must be intact or the engine will suck in dust and dirt resulting in a shorter service life of the engine Water should be prevented from entering into the filter when washing the vehicle The filter element shall be cleaned gently without twisting to prevent it from cracking Never wash it with gasoline or any acid alkaline or organic volatile oil to avoid its aging which will result in reducing the effect of the air
3. OWINERKS MANUAL Read Instructions Before Using Your New Batlger 100 Table of Contents Lec 2 SAFETY 3 LOCATION OF 5 4 5 5 LOCATION OF 5 6 OPERATION emere oo aero nod eoo EEEE 7 LEFT AND RIGHT HAND 7 ENGINE ON OFF SWITCH AND PULL 7 FUEL FILL 55556 on bbe od era aid Gate anes 8 FUEL VALVE Wi scccscsescecccsictvecsssetesee sc eee ee nee be 608 INSPECTION BEFORE 9 ENGINE STARTING AND STOPPING 10 INSPECTION AND 11 CHECKING 11 CHANGING 2 CHECKING amp CLEANING AIR 13 ADJUSTING THROTTLE 14 ADJUSTMENT OF REAR 15 ADJUSTMENT OF 16 CLUTCH CLEANING AND
4. call Customer Service 877 441 6999 INSTRUCTIONS FOR STORAGE If the vehicle is not going to be used for a long period of time for example in winter time some steps should be taken to prevent malfunction of and damage to its components which might be caused by long storage Before storing the vehicle for a long period proper maintenance has to be carried in case maintenance is not completed when the vehicle is put back into use after storage 1 Change engine oil 2 Drain off fuel from the fuel tank and carburetor spray atomized anti rust oil onto the inside wall of the tank and then close the tank Dispose of any drained fuel properly so as not to adversely affect the environment n Carburetor Drain screw Attention If the storage will last for more than one month fuel in the carburetor must be fully drained This will help ensure that the carburetor maintains its normal performance after the storage 4 WARNING Gasoline is flammable and may cause fire and even an explosion under certain conditions Therefore do not smoke make a fire or have any fire around while draining off fuel 3 Take out the spark plug pour about 15 20 5 68 oz of clean engine oil into the cylinder step down on the kick lever repetitively several times so as to have machine oil distributed all over the engine and finally fit the spark plug back on 4 Wash the vehicle clean wipe it dry and apply an even coat of wax
5. and protective clothing could be hazardous Operating without an approved DOT motorcycle helmet or eye protection increases your chances of a severe head injury or death in an accident Operating without protective clothing also increases your chances of severe injury in an accident Always wear an approved DOT motorcycle helmet which fits properly Always wear eye protection goggles or face shield You should also wear gloves boots long sleeve shirt or jacket and long pants You should wear eye protection when you ride If arockora branch hits your eyes you could be severely injured Wear goggles or a face shield Wear proper clothing when you ride The proper clothes can protect you from injury Wear a good pair of gloves strong boots that are over the ankle long pants and a long sleeve shirt CAUTION Never perform any unauthorized modifications to this vehicle Only use original replacement part which can be obtained through YUKON TRAIL INC 877 441 6999 DO NOT RETURN STORE For questions regarding assembly and use call Customer Service 877 441 6999 THIS VEHICLE BE HAZARDOUS OPERATER IF DRIVEN CARELESSLY SERIOUS INJURIES OR DEATH RESULT IF YOU DO NOT FOLLOW THESE INSTRUCTIONS Read and familiarize yourself with owners manual and all labels before operating this vehicle Always wear an approved motorcycle helmet eye gear and protective clothing Long hair loose clothing or it
6. oil will damage the engine ENGINE STARTING AND STOPPING A WARNING Never start the engine in a closed place as the exhausted gas from the vehicle contains toxic carbon monoxide Ensure there is fuel in fuel tank and oil in crank case Set fuel valve lever to ON position Place choke lever in ON position Start engine with pull start cord Allow engine to idle until engine is warm Move carburetor choke lever toward OFF position when engine has sufficiently warmed up Note Engine may run ideally with OuhWN Choke Leve OFF ON Fuel valve lever CAUTION Unnecessarily increasing RP M s to a high level while the Mini Bike is warming up is harmful to the engine Procedures for stopping engine 1 Release throttle twist grip to slow down engine 2 Depress stop button located on right hand grip Depress button until engine comes to a complete stop 3 Set fuel valve lever the fuel tank valve handle to OFF position INSPECTION AND MAINTENANCE CHECKING THE OIL Check engine oil each time prior to operating mini bike The oil level should be between upper and lower lines of oil gauge 1 Set the Mini Bike on level ground screw off the oil gage plug wipe the oil gage rod clean and then insert the gage plug into the crankcase again to check the oil level There is no need to screw the oil gage plug completely in the hole to check the oil 2 Add lubricating o
7. 17 VEHICLE 18 INSTRUCTIONS FOR STORAGE 19 RESUMPTION OF SERVICE AFTER STORAGE 20 MAINTENANCE 5 21 TROUBLE 5 2 2 22 ELECTRICAL 5 22 DO RETURN STORE For questions regarding assembly and use call Customer Service 877 441 6999 NOTICE Failure to follow these instructions nullifies any warranty whether stated or implied Before operating your Badger 100 Mini Bike V Warning R A pre operation check must be conducted before starting the engine insure safety prevent mishaps and damage to components It is strongly suggested that all operators take a certified motorcycle rider s course prior to operating the vehicle Full attention is required during driving paying close attention to the following points to avoid any injury to you by other motorized vehicles Do not drive too close to other vehicles Never carry a passenger This mini bike is for one operator only Never operate this mini bike at night Night is defined as the period of time 30 minutes before sunset to 30 minutes after sunrise Driving at high speeds is the cause of many accidents do not drive ata speed that the actual situation does not permit This user s manual con
8. G Starting engine with clutch cover removed could be hazardous Starting engine with clutch cover removed increases the chance of getting your person caught in moving components which could result in severe injury Never start Mini Bike with clutch cover removed Blow out clutch with compressed air through large holes Clutch Cover Oil Clutch here ONLY VEHICLE WASHING Cleaning the vehicle regularly can slow down the color fading of its body and make it easier to check if there is any damage and any oil leakage CAUTION Washing the Mini Bike with over pressurized water may cause damage to some of its components Therefore do use a pressure washer to clean the vehicle The following parts should be cleaned using low pressure water Wheel hub Exhaust pipe Fuel tank and lower portion of cushion Carburetor Head lock and ignition switch Meters 1 After pre wiping the vehicle should be washed with clean water to remove dirty residues so as to prevent corrosion Plastic subassemblies should be cleaned by wiping with a cloth or foam soaked in neutral detergent solution followed by washing with clean water 2 After the cleaned vehicle is air dried grease the chain and run the engine at idling speed for a few minutes 3 Prior to driving carefully check the braking system repeatedly and repair or adjust it if necessary DO NOT RETURN STORE For questions regarding assembly and use
9. cap closed securely Engine stop switch Proper operation Engine oil Proper level Check oil by inspecting Engine Oil Dip Stick The engine oil should be between the Minimum and Maximum lines Throttle Proper free play of throttle lever smooth response quick return to idle position General condition Bolts and nuts are tight no rattle from parts of the engine when running no visible evidence of Damage Failing to inspect the Mini Bike before operating could be hazardous Failing to perform proper maintenance could also be hazardous Failing to inspect and maintain your Mini Bike could increases the chances of an accident or equipment damage Always inspect your Mini Bike each time before riding and make sure it is in a safe operating condition Refer to the INSPECTION AND MAINTENANCE section in this manual Operating this Mini Bike with improper tires or improper tire air pressure could be hazardous If you use improper tires or improper air pressure you may lose control of the Mini Bike This will cause an accident Always use the tires with size and type tires specified in this user s manual Always maintain proper tire air pressure as described in the INSPECTION AND MAINTENANCE section DO NOT RETURN STORE For questions regarding assembly and use call Customer Service 877 441 6999 CAUTION Verify oil level prior to starting see page 11 Starting the engine with low or no
10. eck Brakes Check Throttle Check Throttle cable Check means This item of maintenance should be carried out at a service center It may be also done by the user with reference to this manual provided special tools and authorized spare parts are used The user must also be capable of completing the procedure means This item can only be carried out by an authorized service center in order to ensure safety Notes 1 Maintenance should be conducted more frequently when Mini Bike is driven in dusty areas 2 When Mini bike has exceeded the maximum figures specified in the table maintenance should be still cycled according to the intervals of time or hours stated herein DO NOT RETURN STORE For questions regarding assembly and use call Customer Service 877 441 6999 TROUBLESHOOTING Engine will not Start 1 Fuel valve OFF Move Fuel valve lever to ON 2 Choke OPEN Move Chock Lever to CLOSED 3 Out of fuel Refuel 4 Bad fuel engine stored without treating or draining gasoline or refueled with bad gasoline Drain fuel and carburetor Refuel with fresh gasoline 5 Spark plug faulty fouled or Remove and inspect spark plug improperly gapped Clean gap or replace 6 Spark plug wet with fuel Remove and inspect spark plug flooded engine Dry and reinstall spark plug 7 Fuel filter clogged carburetor Take the engine to a qualified malfunction ignition mechanic Replace
11. ems warn by the operator must be covered to prevent them from getting caught in moving parts of the vehicle or surroundings whi ling All fenders and guards must be in place at all times while the vehicle is use or serious injury may Hands Feet and loose articles must be kept away from the engine chain and drive components Check that the throttle and brake contrals work freely before starting t e engine Before starting the engine operator must be seated with kickstand up NO PASSENGERS This vehicle is not made for use on public streets roads or ighways and is not intended to be used in such places Do not speed on this vehicle your risk of loosing control increases if you ride at speeds too fast for specific terrains No persons younger than 16 years of age should ride this vehicle Do not jump pop wheelies or try to perform any other stunts as they can result in serious injury or death Improper tire pressure can cause loss of control resulting in serious injury or death Check pressures on all tires only when tires are cold 4 psi 27 6 kpa Remove air from tires before demounting Only use replacement tires specified by manufacture Riding on slope greater than 15 Degrees amp theriskofan accident Retur Mini Bike to store Attempt wheelies Ride on rough rocky terrain Attempt stunts Attempt steep hills Operate without first reading owners manual Do
12. filter oil to catch particles before they enter the engine Replace the filter element with a new one if it is broken or cracked ADJUSTING THE THROTTLE CABLE Make sure the throttle cable is adjusted properly To adjust throttle cable rotate adjustment nut located at the hand throttle Check if the throttle twist grip has the required free operating movement The required free operating movement 2 6mm 078 24in If the grip cannot be moved freely turn the adjusting nut to ensure proper operating movement After adjustment start the engine and check for the operating movement again Repeat the adjustment if necessary until the desired operating movement is obtained Throttle cable adjust nut ADJUSTMENT OF REAR BRAKE 1 The front brake hand grip should have free operating movement of 5 7mm 2 3in Adjust with free play adjustment bolt 5 7mm free play 2 To make rear brake pad adjustment turn rear adjusting bolt clockwise to loosen and counter clockwise to tighten brake tension 3 Brake pads should be replaced by a qualified service technician once brake shoes are worn Free play adjustment 4 Brakes are adjusted by turning in or out bolt the rear brake adjusting bolt Rear brake adjusting bolt ADJUSTMENT OF CHAIN 1 When chain adjustment is needed loosen 4 bolts under engine 2 Move engine forward to tighten chain or backward to loosen chain 3 Tighten bolts
13. il up to the edge of the fuel plug 3 Screw oil gage plug tightly CAUTION Never start the engine when there is insufficient lubricating oil Otherwise it will cause harm to the engine Oil dip stick Lubricating Oil Recommended The lubricating oil is an important factor affecting the performance and service life of the engine Please refer to the chart for the correct grade of engine oil based on the environmental conditions in your area Do not use any other type of oil other than what is recommended in the chart DO NOT MIX OIL WITH THE GASOLINE 45L 40qt Oil Lubricating oils of Eh different viscosity shall be employed in different regions and at different eC 30 20 0 0 10 20 30 40 temperatures TEMP 22 4 14 32 50 68 86 104 INSPECTION AND MAINTENANCE Changing the Oil 1 Remove the Screw Plug located at the bottom of the engine and let the oil drain into an approved collection container DO NOT PERFORM THIS PROCEDURE WHILE THE ENGINE IS HOT SERIOUS BURNS COULD RESULT FROM CONTACT WITH HOT OIL 2 Dispose of the used oil properly For proper disposal procedures contact your local oil recycling center 3 Clean and replace the Screw Plug tightly 4 Refill the engine with the proper amount of oil and recheck the amount of oil in the engine by using the oil gauge plug Screw plug for oil draining 7mm 79mm 028
14. ld or used for any other purpose A COPY OF THE SALES RECEIPT AND UPC BAR CODE MUST BE INCLUDED WITH THIS REGISTRATION CARD Thank you for purchasing an Yukon Trail Inc Badger 100 Mini Bike If there are parts missing or if your Badger 100 Mini Bike does not run properly do not return your Badger 100 Mini Bike to the place of purchase Please call Yukon Trail Customer Service at 877 441 6999 PLEASE DO NOT RETURN PRODUCT TO RETAILER FOR WARRANTY OR REPLACEMENT PARTS or register online at www yukontrailinc com using the warranty link or fax to 877 443 9284 Yukon Trail Inc LIMITED WARRANTY Your Badger 100 Mini Bike is warranted to be free of manufacturing defects in material or workmanship for a period of 90 days During the warranty period Yukon Trail Inc will at its option repair provide replacement parts or replace your Badger 100 Mini Bike at no charge This warranty does not cover normal wear and tear or damage caused by neglect or misuse of the product Should you experience a problem or need to return your Badger 100 Mini Bike for repair please call the Yukon Trail customer service department TOLL FREE AT 877 441 6999 between the hours of 9AM and 4PM PST Monday thru Friday You will be instructed how to proceed A copy of receipt is required You may also contact Yukon Trail Inc by writing Yukon Trail Inc Ontario CA 91761 Or www yukontrailinc com Made in China E QE 5
15. or repair malfunction valves stuck etc faulty components as necessary Engine Lacks Power 1 Filter element s clogged Check air filter Clean or replace 2 Choke lever may be not fully Check choke lever open 3 Bad fuel engine stored without treating or draining gasoline or refueled with bad gasoline Drain fuel tank and carburetor Refuel with fresh gasoline 4 Fuel filter clogged carburetor Take engine to a qualified malfunction ignition malfunction mechanic Replace or repair valves stuck etc faulty components as necessary ELECTRICAL SCHEMATIC Engine Switch B1 B1 Transistor Magnito Spark Plug Ignition Coil DO NOT RETURN STORE For questions regarding assembly and use call Customer Service 877 441 6999 WARRANTY REGISTRATION RETURN THE BADGER 100 MINI BIKE PRODUCT REGISTRATION WITH A COPY OF YOUR SALES RECEIPT TO Yukon Trail Inc 4142 Pacific Privado Ontario CA 91761 Name Address City State Zip Phone E mail Date Purchased Model Store Where Purchased Store Address Receipt or Transaction The registration must be returned to Yukon Trail Inc within 10days of purchase It is the only information Yukon Trail will have for notification to you of any information regarding this product This information is for the sole purpose of product registration and will not be so
16. t Rear wheel See specified Tire pressure bead 4 psi Operating pressure on tire pressure Brake Type Disc Drive Capacity of Capacity of gasoline tank 1 4L 36 gal oil tank 45L 40 qt DO NOT RETURN STORE For questions regarding assembly and use call Customer Service 877 441 6999 LOCATION OF PARTS Hand Brake Seat Cushion Side Panel Spark Plug Rear Shock Rear Wheel Clutch Cover Oil Fuel Plug Drive Chain Front Shock Front Wheel Throttle Handle Front Fender Gas Tank Air Filter Rear Fende Rear Shock Brake Caliber Pull Start Cord Footrest Kickstand LEFT AND RIGHT HAND GRIP OPERATION Brake Lever Throttle control grip Right Hand Grip OFF button Pulling in brake lever located on left hand grip will stop mini bike Applying the hand throttle moving throttle counter clockwise will cause engine rpms to increase causing mini bike to move forward Depressing OFF Button will turn off engine ENGINE PULL CORD OPERATION Pull Cord Pulling the pull cord will start the engine FUEL AND FUEL VALVE OPERATION Fuel filling The capacity of the fuel tank is 4 2L 95 gal Unscrew the gas cap by turning it counter clockwise and carefully fill the tank with unleaded gasoline through the opening DO NOT MIX GAS AND OIL TOGETHER THIS IS A 4 STROKE ENGINE Replace the gas cap by carefully aligning the threads on
17. tains important safety and maintenance information Read it carefully before riding Failing to follow the warnings contained in this manual could result in INJURY or DEATH It is important that this manual remain with the vehicle when you transfer it to another user or owner All information illustrations photographs and specifications contained in this manual are based on the latest product information available at the time of publication Due to improvements or other changes there will be some discrepancies in this manual We reserve the right to make product changes at any time without notice and without incurring any obligation to make the same or similar changes to the vehicle previously built or sold Always avoid operating this mini bike on paved surfaces including sidewalks paths parking lots driveways streets roads and highways Never operated this or any Off Road vehicle on a public street road or highway where motor vehicles are in operation DO NOT RETURN STORE For questions regarding assembly and use call Customer Service 877 441 6999 SAFETY GEAR A DOT approved motorcycle helmet is the most important part of you safety gear A DOT approved motorcycle helmet can help prevent a serious head injury Choose a helmet that fits snugly Motorcycle dealers can help in selecting a good quality helmet which fits properly Operating this Mini Bike without wearing an approved DOT motorcycle helmet eye protection
18. the cap and the tank and turning the cap clock wise Wipe any spilled fuel from the dirt bike using a cloth and dispose of the cloth properly DO NOT SMOKE OR REFUEL THE VEHICLE NEAR OPEN FLAMES OR NEAR HEATING UNITS ONLY REFUEL THE VEHICLE IN OPEN AREAS TO REDUCE THE LIKELIHOOD OF THE BUILD UP OF GASOLINE FUMES Fuel level Fill r neck A WARNING Overfilling the fuel tank could be hazardous If you overfill the fuel tank fuel may overflow when it expands Expanding is due to heat from engine or sun Overheated fuel could easily catch fire Stop adding fuel when the fuel level reaches the bottom of the filler neck Fuel Valve operation ON With the handle of the fuel valve to ON position the fuel supply will flow to the carburetor In this position the engine is able to start and run OFF With the handle of the fuel valve to OFF position the fuel supply is cut off to the carburetor In this position the mini bike will not start and will not run Fuel Valve Handle INSPECTION BEFORE RIDING ITEM TO CHECK CONTENT Steering Smoothness No restriction of movement No play or looseness Brakes Proper brake lever free play enough brake force Tires Proper air pressure Enough tread depth No cracks rips or other damages Note Check tire pressure spec is located on side of tire Fuel Enough fuel for the intended trip Fuel hose connected securely No damage to fuel tank or cap Fuel tank
19. to the painted surface and a coat of anti rust oil on the chrome plated surfaces 5 Inflate the tires as required and put the vehicle up on wooden blocks with the two wheels clearing the ground 6 Put the vehicle in a shady and cool place free from humidity and direct sunlight and cover it properly not with plastic or other painted materials If there is a garage store it within RESUMPTION OF SERVICE AFTER STORAGE 1 Remove the covering and remove the wooden blocks used in storing the vehicle Change the engine oil if the vehicle has been out of service for over 4 months 2 Drain off the remaining atomized anti rust oil from the fuel tank followed by filling it with fresh gasoline therein 3 Prior to driving all the required check ups must be made It is better to drive it at a low speed in an open area to test its performance before normal operation MAINTENANCE SCHEDULE VENE MAINTENANCE SCHEDULE EACH USE 1ST MO 20 EVERY 3 MO 50 EVERY 6 MO 100 EVERY YR 300 MAINTENANCE HRS ins ins Engine oil Check X Engine oil Change Air filter Check Air filter Clean Air filter Change Carburetor sediment X cup Clean Spark plug Check Adjust Spark plug Replace Idle speed Check Adjust valve clearance Check Adjust Fuel tank and filter Clean Fuel tube Check Centrifugal Clutch Every 5 hours Clean and Lube operation All nuts and X bolts Check for tightness Chain tension Ch
20. under engine Torque bolts to 25 ft Ibs 4 Repetitively check tension of chain Tighten Chain yp T MINOR CHAIN ADJUSTMENT Engine adjusting bolts Loosen 1 When minor chain adjustment is Chain needed turn Nut clockwise to tighten chain or counterclockwise to loosen chain 2 When adjustment is accomplished tighten Nut 2 GREASING PROCEDURES TO THE DRIVEN CHAIN 1 Shut off the engine 2 Add light amounts of machine oil or chain grease to the driving chain Too much machine oil or chain grease may cause splattering to occur Attention The chain should be replaced when the adjusting limit has reached it s maximum CLUTCH CLEANING AND MAINTENANCE After every 5 hour of use your clutch will need cleaning and lubrication If clutch becomes too dirty or has lack of lubrication the clutch will have a tendency to stick This will cause the Mini Bike to want to take off before throttle is applied To clean and lubricate clutch follow the instructions below 1 Make sure engine is turned off and engine is cool before removing clutch cover 2 Remove Clutch Cover 3 With compressed air blow through holes to remove any dust and or particles 4 Oil Clutch bearing with a few drops of 30W motor oil Note Make sure oil does not get inside clutch itself 5 Push Mini bike forward without starting allowing oil to flow through bearing surface 6 Re install clutch cover A WARNIN
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