All Terrain Vehicle (ATV)
Contents
1. om O O LL Note I Inspect check for any leakage or damage clean adjust lubricate or replaced if necessary Clean L Lubricate D By a Dealer Replace 2004 10 16 B017 DN 00 A6A 33 Maintenance Schedule S S S S LV Note Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or stain week ae 30 operating days Vales 000000 Lube O o OO io 1 M 8 _ 78 7 Wheel Wheel bearings o or or R TorR 0 or R Pivot amp Steering Shaft Rear Pivot Pivot BD D OO BD 0 D e Frons amp ear suspens dT orsina DY Note I Inspect check for any leakage or damage clean adjust lubricate or replaced if necessary Clean L Lubricate D By a Dealer R Replace 2004 10 16 B017 DN 00 A6A 342. before operating this vehicle If the oil supply to the engine 1s insufficient the engine will stop operating until you replenish the oil Engine oil SAE 20W Gear oil SAE 90W 2004 10 16 B017 DN 00 A6A 14 Fuel Valve amp Fuel Tank Fuel Valve naf Fuel Tank Fuel tank capacity 15 4 liters 1 32 gallons including 0 8 liter 0 21 gallon in the reserve supply Use only unleaded automotive gasoline with an octane level from 87 89 or 91 The three way fuel valve is on the left side of the vehicle just below the seat With the fuel valve set on the OFF position gasoline cannot flow into the engine carburetor With the fuel valve set on the ON positing fuel will flow from the tank and go into engine After refueling be sure to tighten the tank cap firmly With the fuel valve set on the RES position fuel will flow from the reserve fuel supply to the engine At this setting the fuel tank should be refilled as soon as possible Do not overfill the fuel tank be careful not to spill fuel it can cause severe injury or fire Turn off cellular phones and do not smoke when refueling eer If overfill wipe off any spilled fuel immediately Make sure the fuel tank cap is closed securely 2004 10 16 B017 DN 00 A6A 15 Safety Switch amp Speed Limiter C Qos aa 3 Cx ND A SAFETY SWITCH E AD S Safety Switch The safety switch is locate
3. complete satisfaction Never remove any labels from your ATV If a label becomes difficult to read or comes off a replacement label 1s available from your dealer Never run the engine in close areas The exhaust gas contains poisonous carbon monoxide a Do not touch any part of the engine muffler or exhaust system while the is still hot Never attempt to operate over large obstacles such as large rocks or fallen trees Always check for obstacles before operating in a new area Never operate an in fast flowing water Remember that wet brakes may reduce stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings When transporting the machine in another vehicle be sure it is kept upright and that the fuel cock is in the OFF position Otherwise fuel may leak out of the carburetor or fuel tank Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control handles differently from other vehicles including motorcycles and cars A collision or rollover can happen quickly and even routine maneuvers turning driving on hills or down hills and over obstacles 1f you fail to take proper precautions it can resul
4. until you have regained proper braking ability Never operate this in fast flowing water or in water deeper than specified your manual book After riding in the water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case Wash the in fresh water if it has been operated in salt water or muddy conditions 2004 10 16 B017 DN 00 A6A 25 Maintenance Spark Plug Center el 0 7 0 8mm 4 Side Electrode Sealing Washer Spark Plug Inspect spark plugs every other month for maximum efficiency Replace when plugs are needed Standard spark plug BR8HSA 1 Disconnect the spark plug 2 Clean up dirt from around the spark plug base 3 Remove the spark plug 4 Inspect the plug electrodes for wear If the electrodes and insulator tip appear unusually fouled or burned replace with new one 5 The spark plug plug gap is 0 7 0 8mm If adjustment is necessary bend the side electrode carefully 6 When Installing the spark plug screw it in finger tight and then tighten with the plug wrench another 1 2 turn to compress the washer Do not over tighten 2004 10 16 B017 DN 00 A6A 26 Maintenance Air Filter AN p xx a Sh WARNING Air Filter The air filter will accumulate dust and must be cleaned periodically If riding in very dusty area the filter must be cleaned more frequently Remove dirty air filter from machin
5. 017 DN 00 A6A Engine On Stop Switches Engine Stop Switch The engine stop switch is on the left handle bar When the switch is in the ESS position the engine will be OFF When the switch is in the y position the engine will be ON This switch also can be used as a safety or emergency switch On 2 Off 2004 10 16 B017 DN 00 A6A 10 Starting Procedure KEY _ 5 REMOTE CONTROL ENGINE KILL Starting Procedure Parking the vehicle on a level surface and lock the parking brake Insert the ignition key into its switch and turn it to the ON position Remote control for engine kill MINI 50cc ONLY If you use the remote control by to kill engine while engine is on and operating you have to press O remote control first and then restart the by turning on the key to ON position Without pressing remote control first it s not possible to restart by Move the engine stop switch to ON only turning on the key Push the throttle level lightly Engine kill switch for parents to kill engine within 50m remote control Push the start button on the left handle bar Try not to kill engine while ATV is running unless Note under necessary condition If you don t use the remote control to kill engine you can start the mini ATV as per normal Starting Procedure 2004 10 16 B017 DN 00 A6A
6. 11 Throttle Lever THROTTLE LEVER Throttle Lever The throttle lever 15 beside the right handle bar grip and 16 activated by the right hand thumb To accelerate the vehicle simple press the lever forward and open the throttle to decelerate release the lever and the spring tension will close the throttle automatically Before starting the engine check the throttle to be sure it can operate smoothly Make sure it returns back to idle position as soon as the lever 15 released 2004 10 16 B017 DN 00 A6A 12 Front Brake amp Rear Brake REAR BRAKE Rear Brake The rear brake is the lever located on the left handlebar When braking squeeze this lever This brake also has a locking feature that allows it to act as a parking brake To use the parking brake pull the left brake lever back and lock it Make sure the vehicle is completely stopped before using the parking brake To release the parking brake firmly squeeze the left brake lever until the lock release Check your brakes at the start of every ride Do not ride the ATV if you find any problem with the brakes Please contact your local dealer to fix the problem 2004 10 16 B017 DN 00 A6A 13 Engine Oil 0 We recommended that the oil be changed every other month for heavy riding change once a month Check for leaks from wear and tear Engine Oil Two Stoke engine oil must be added to the oil tank periodically Check the oil level in the oil tank
7. All Terrain Vehicle ATV Welcome to the growing family This vehicle is delivered to you with the confidence and the reliability that have made us standout in these fields This vehicle is designed and manufactured for OFF ROAD use only please check your local riding laws and regulations before operating this machine Read this manual together with your children It 1s important that you take the time to get acquainted with how your ATV works The user manual provides detailed safety instructions operation and maintenance procedures An is not a toy and can be hazardous to operate without proper instructions we highly recommend that you take a training course from a certified instructor Please follow the age recommendation ATV Size Minimum Age 50cc 6 12 years old 90cc 12 years old and up Please pay close attention to the following labels ALWAYS USE APPROVED NEVER USE ON PUBLIC NEVER CARRY NEVER USE WITH HELMET AND ROADS PASSENGERS DRUGS OR PROTECTIVE GEAR ALCOHOL 2004 10 16 B017 DN 00 A6A 1 Specifications 50cc 90cc Engine Type Max Power Cylinder No Bore Stroke Displacement Max Torque Carburetor Starting Lubricate Lubricate Capability Suspension Front 2004 10 16 2 Stroke Horizontal 3 0ps 6000 rpm 40 x 39 2 3 8N m 5500 rpm A Suspension Rear Brake Front amp Back Rear Front amp Rear Tire Wheelbase Seat Height N A Drum Option amp Mechanica
8. ate an ATV on any public street road and highway Try to avoid on any paved surfaces including sidewalks driveways and parking lots Never operate at speeds faster than your skill or attempt any stunts This can result in severe injury Never modify an through improper installation or use of accessories Always use the size and type of tires specified in this manual Always maintain proper tire pressure as described in this manual Please inspect your ATV each time before use and make sure it 1s in safe operating condition Always follow the maintenance procedures Read the warranties thoroughly so you understand the coverage that protect your new and are aware of your rights and responsibilities Always turn off the engine when refueling Do not refuel when the engine is hot or running Do not spill gasoline on the engine or the exhaust pipe muffler Never refuel while smoking and do not use the cellular phone while riding you ATV An handles differently from other vehicles including motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers such as turning and driving on hills and over obstacles if you fail to take proper precautions 2004 10 16 B017 DN 00 A6A Are You Ready N Important Information AN If you have any questions or if you ever need special service or repairs remember that your source dealer knows your the best and 15 dedicated to your
9. d 2004 10 16 B017 DN 00 A6A 23 Crossing A Slope When you go across a slope rather than directly up or down it s called traversing Traversing a sloping surface on your requires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Lean your body uphill direction as you travel across a slope and keep both feet firmly on the footrests When riding on the loose surfaces you may need to turn your front wheel s gently uphill to keep straight line across the hill Make sure not to attempt any sharp turns either up or downhill If your ATV does begin to tip over turn the front wheel s downhill direction if there are no obstacles in your path or dismount the ATV immediately Avoid hills with excessively slippery or loose surfaces it could cause loss of control or cause the to over turn 2004 10 16 B017 DN 00 A6A 24 Crossing Through Shallow Water The be used to cross slow moving shallow water of up to maximum of 50cc 18cm and 90 100cc 20cm in depth Before entering the water choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or upset the ATV Drive slowly and carefully A Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water
10. d on handle bar To operate the vehicle the switch cap must be connected to the safety switch The switch cap is attached to a rope this rope should be controlled by the parents or the instructor They must pull out the safety switch cap to stop the engine 2004 10 16 B017 DN 00 A6A 16 Tires Pressure WARNING tS If the tire pressure is too high or too low steering will be affected and tire wear will be increased Operating tire pressure You should check the pressure before running the vehicle when the tires are cold Recommended for 50 Max pressure 10 1 Min Pressure 3psi NOTE Do not fill more than 10psi of pressure Seal damage may occur Never set tire pressure below minimum it could cause the tire to dislocate from the rim Loading Maximum vehicle load for the 50 179 lbs includes weight of operator cargo and accessories 2004 10 16 B017 DN 00 A6A 17 Under the seat Remove the seat Under the seat there is a safety knob Pull forward to remove the seat cover You will be able to find the battery and tool kit 2004 10 16 B017 DN 00 A6A 18 Vehicle Identification Number VIN amp Engine Number a 5 CO R Vin numbers VIN Numbers The frame VIN and engine serial numbers are required when you register your ATV They may also be required when ordering replacement parts Please record the frame and engine serial number for future refer
11. e Never try to wash a dirty filter on the machine Remove the filter from the air cleaner case Wash the filter element in a non flammable or high flash point solvent to help break down the old filter oil Do not twist the air filter element when squeezing it 1f damaged replace it Fill a bucket with one gallon or more of hot soapy water with strong detergent submerge filter into bucket of hot water and let soak for 10 15 minutes After filter has soaked thoroughly clean the filter out by hand be mindful not to tear or rip the filter It must be rinsed very thoroughly filter should be back to their original new color After rinsed dry in a none dust free places Make sure the filter is in a completely ventilated area for a minimum of 24 hours or more until is dry Apply all purpose oil to the air filter and reinstall it Never operate the engine with the air filter removed This will allow unfiltered air to enter causing rapid engine wear and possible engine carburetor jetting damage 2004 10 16 B017 DN 00 A6A 27 Maintenance Carburetor amp Drive Chain Drive Chain The drive chain will wear with use and requires periodic adjustment Remove the chain guard to check the chain Carburetor adjustment tension The amount of slack should be 10 20mm the chain slack can be adjusted by loosening the lock nuts and Keep this part free of dirt and particles If they i removing the chain tensioned plate enter t
12. e the battery should be Loosen the lock nut and turn the adjuster replaced every three years maintain free play of 5 10mm 2004 10 16 B017 DN 00 A6A 30 Maintenance Tire Thread Tire Thread e Replace tire when groove becomes less than 3 mm 0 12 in or has side wall cracks or cuts Worn tires can blow and cause loss of control Tire depth limit 3mm Never apply grease oil or gasoline to the tire bead it will diminish the tire 2004 10 16 B017 DN 00 A6A 3l Wiring Diagram TWIN LIGHT 12 TWIN LIGHT 12 10 OILLAMP 12V 065 9 9 EMERGENCY SWITCH HD Caw EWR CH B 2004 10 16 RESISTOR A6A CIRCUIT DIAGRAM r pw BBL RR STOP SW CDIUNIT AC GEN BATTERY 12V4A BIBLACK BLU E BLACK B W BLACK WHITE STARTSW KILL SW G Y GREEN YE O O BLUE LLbLIGHTBLUE O L HANDLE SWITCH B017 DN 00 A6A START RELAY 32 Maintenance Schedule The maintenance intervals table below are based average riding conditions Riding in unusually dusty areas requires more frequent servicing an week 5 30 operating days LI Month Fuel Line 0000000 Line D E LLL meer rate speet aajne fDi Cmaeememesum DwaeseWa o manam 241 E
13. ence Frame No Engine No 2004 10 16 B017 DN 00 A6A 19 Posture 2004 10 16 Head and eyes up looking well ahead Shoulder relaxed elbows bent slightly out away from your body Keep hand on the handlebars and wrists should always be straight Knees toward the gas tank Feet on the footboards during operation Otherwise your feet may contact the rear wheels Always keep your hands on the handlebars and foot on the footrest at all time B017 DN 00 A6A 20 Turning eee The rider must learn to move his weight and control the throttle to allow the rear tires to turn properly When turning the wheels on the outside of the turn must travel a wider radius and thus a greater distance than the wheels on inside of the turn Since the rear wheel axle does not permit a differing rate of wheel rotation 1t is enough to merely steer this vehicle into a turn To turn properly steer in the direction of the turn and lean your body to the inside of the turn while supporting your weight on the outer foot Use the throttle to maintain power throughout the turn Incorrect turning may cause the front wheels to slide straight ahead If this should occur close the throttle and stop Avoid braking or accelerating until you have regained directional and speed control in order to avoid skids or while traveling on slippery terrain 2004 10 16 B017 DN 00 A6A 21 Riding Uphill r 24 a 532222 Uphill Practice ridi
14. he engine it may Cassese sewer damage of engine Don t forget to tighten the lock nuts well Lubricating the chain 15 sometimes needed The SAE 80 or 90 gear oil 1s The carburetor is a vital part of the engine and recommended requires very sophisticated adjustment Most adjusting should be left to a authorized dealer Check for who has the professional knowledge and experience to do so Rusted Links damaged rollers Twisted or binding Links Parts found defective must be replaced 2004 10 16 B017 DN 00 A6A 28 Maintenance Disc Brakes Disc Brakes Disc Brakes Check the brake cable for rust or signs of wear that could cause sticking or failure Lubricate the brake cable with a available cable lubricant to prevent premature wear or corrosion Make sure the brake arm spring rod and fasteners are in good condition 2004 10 16 B017 DN 00 A6A 29 Maintenance Throttle Cable amp Battery THROTTLE CABLE Throttle Cable Inspect the throttle cable s condition and Battery operation Replace the cable if it has become worn or kinked When reinstalling the battery be sure to connect the cable to the positive lead and Keep cable smooth with lubricant to prevent the black cable to negative lead premature wear or corrosion Adjustments can be made with the adjuster beside the throttle lever Replace the battery immediately when it looses power and does not hold a charge On normal servic
15. l Disk 145 70 6 Automatic C V T Unleaded Gasoline 48 8 x 28 5 x 30 1 1240mm x725mm x 765mm 33 9 860mm 23 6 600mm Ground Clearance 4 3 110mm Double Wishbone Overall Dimension Dry Weight Max Load B017 DN 00 A6A 165 Ibs 75kg 165 Ibs 75kg Understand your and specifications Tm 2 pud CCS SEL S S xL PLUG CAP SN S By B017 DN 00 A6A 2004 10 16 ATV Parts locations and specifications OIL LIGHT Ce A VES p IGNITION EATUR al F 7 c Ti 7 7 C D I UNIT 2004 10 16 B017 DN 00 A6A Are You Ready important Information N Before you ride your ATV we urge you to read and do the followings Always follow the age recommendation for the ATV Do not allow your child to ride without adult supervision This vehicle is not designed for carrying a passenger Carrying passengers can cause loss of control resulting in severe injury or death This vehicle is properly balanced to carry only the operator Never operate without wearing an approved motorcycle helmet that fits properly We urge you to wear eye goggles face shield gloves boots long sleeved shirt or jacket and long pants Never use with drugs or alcohol before or while operating this vehicle Never oper
16. ng at first on gentle slopes Try more difficult hills only after developing and being comfortable with your basic skills Avoid excessive steep hills or slopes this could cause loss of control or the ATV to overturn Keep both feet on the footrest at all times When climbing a hill shift your body weight forward at all times proceed at a Steady rate of speed and throttle opening Never ride past the limit of your visibility Slow down or stop Proceed slowly only when you have a clear view If you are unable to continue uphill dismount the vehicle on the uphill side turn the vehicle around and then descend the hill If you cannot complete the hill due to steepness do not engage the rear brake to stop from rolling backwards This can easily tip the ATV backwards Engage front brake and dismount the ATV Only remount after turning the ATV around 2004 10 16 B017 DN 00 A6A 22 Riding Downhill Downhill go downhill shift your body weight back choose a low gear which will allow the engine compression to do most of the braking for you improper braking may cause a loss of traction Be cautious when going downhill with loose or slippery surfaces Choose a straight down hill path and avoid obstacles Avoid going down a hill at an angle Use the brake s to slow you down as you going downhill and always use low gear Never go down a hill at high speeds Always maintain control of spee
17. rs Check all fittings and fasteners Brakes Check operation of cable or fluid level on rear brakes Parking Brakes Check for smooth condition and operation xb xe e Drive Chain Check the tension of the chain and make sure there no damaged or rusted links and check on sprocket condition 9 Always warm up the engine for at least 5 minutes before take off never accelerate hard with a cold engine it does damage to your engine life Apply chain lubricant to lubricate the drive chain 2004 10 16 B017 DN 00 A6A Break In your ATV Make sure all fluids have been filled coolant trans oil etc Before starting a freshly rebuilt or new engine it is strongly recommended that you make sure that the carburetor has been thoroughly cleaned and fuel tank has been flushed clean Fresh fuel oil mixture has been used air box has been cleaned and a new or freshly serviced air filter has been installed Once the above steps have been completed start your engine and follow the break in procedure Break In your ATV During the first two weeks of riding operate your new vehicle tenderly Don t run it very fast and don t approach the maximum rpm Following these guidelines will greatly enhance the long term power and life of the engine To get maximum engine life always warm up the engine for at least 5 minutes before take off never accelerate hard with a cold engine it does damage to your engine life 2004 10 16 B
18. t in serious injury or death Be cautious when riding and check your ATV each time before taking off always have emergency first aid kit tools with your ride 2004 10 16 B017 DN 00 A6A 6 Are You Ready Protective Apparel n Never operate without wearing an approved motorcycle helmet that fits properly You should also wear eye goggles face shield chest protector gloves boots long sleeved shirt or jacket and long pants Your helmet is the most important piece of protective gear can help prevent a serious head injury Your helmet should fit snugly and fasten securely Select a helmet that meets or exceeds state s safety standards Full face helmets help protect your face as well as your head Open face helmet are lighter and may be cooler but should be used with eye and mouth protection Good padded gloves can help keep your hands from getting sore cold or bruised Over the ankle boots with low heels can prevent your feet from slipping off the footrest and protect your feet ankles and lower legs 2004 10 16 B017 DN 00 A6A Is Your ATV Ready Always inspect your before you ride please follow the checklist it decreases the possibility of an accident or equipment damage 1 Fuel Check the level fill fuel if needed Engine Oil Check oil level fill oil 1f needed Wheels and Tires Check tire pressure wear or damage Switches Check to make sure they are working properly Fittings and fastene
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