PENTORA Y35-100 Owner'S Manual Download

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Engine Oil

Oil Recommendations

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance

Chart beginning on page 78. PENTORA recommends the use of SF15W/40(in summer) SF15W/30(in winter).

Duty 4-Cycle engine oil for this vehicle. Oil may need to be changed more frequently if

oil is not used. Do not use automotive oil.

NOTICE:

Mixing brands or using a non-recommended oil may cause serious engine damage. Always

use the recommended oil. Never substitute or mix oil brands.

Summary of Contents for Y35-100

Page 1: ...OWNER S MANUAL OWNER S MANUAL READ THIS MANUAL CAREFULLY OWNER S MANUAL Y35 100 Y35 100 PENTORA 125L ...

Page 2: ...ual Never allow a child under the age of 16 to operate an ATV without adult supervision Children differ in skills physical abilities and judgment Some children may not be able to operate an ATV safely Permit continued use only if you determine that your child has the ability and maturity to operate the ATV safely For your child s safety be sure your child can reach and operate all ATV controls inc...

Page 3: ... read and understand the information in your owner s manual You must also take an ATV training course before you begin riding Ask your parents to explain anything you don t understand and pay close attention to the warnings and instructions you read Your safety and the safety of others is the most important thing to think about at all times Never drive your ATV alone Always make sure an adult is w...

Page 4: ...Table of Contents Introduction 5 Safety 7 Know Your ATV 31 Pre Ride Check 38 Riding Rules 41 Engine and Vehicle Identification Number Location 45 Features and Controls 46 Operation 55 4 ...

Page 5: ...and Symbols The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual CAUTION The safety alert symbol indicates a potential A CAUTION indicates a hazardous situation 5 ...

Page 6: ...ous situation which if not avoided could result in death or The Mandatory Action Sign indicates an action serious injury that NEEDS to be taken to avoid a hazard WARNING Failure to follow the warnings and safety precautions contained in this manual can result in severe injury or death AN PENTORA ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles s...

Page 7: ...can reach and operate all ATV controls including handlebars brake levers throttle lever and engine stop switch Always follow the age guidelines for your vehicle Y 35 models are designed for children not less than 16 years of age No child under the age of 16 should ride any ATV designed and sold for an adult Never permit a guest to operate the ATV unless the guest has read this manual and all produ...

Page 8: ...e it offers the best protection against head injuries Gloves A helmet should fit your head comfortably and securely An open face helmet offers some protection but a full face helmet is recommended Regardless of the style look for a Long Pants DOT Department of Transportation sticker in any helmet you buy Always wear a face shield or goggles to protect motorcycle boots your eyes and help your visio...

Page 9: ...otection Drive training Developing your driving skills is an on going process Even if you have driven another ATV take time to become familiar with this ATV in a safe area to build your skills Do not drive in rough terrain until you get familiar with this ATV controls and feel comfortable with its size and weight Safety Warnings Operating Without Instruction Operating this ATV without proper instr...

Page 10: ...he ATV unless the guest has read this manual and all product labels and has completed a certified safety training course WARNING Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death Be sure to read all of the following warnings about driving hazards and how to avoid them These warnings are provided for your c...

Page 11: ...hibited for anyone under age 16 Handling Gasoline Gasoline is highly flammable and explosive under certain conditions Never allow a child to refuel or handle gasoline Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed o...

Page 12: ...start the engine or let it run in an enclosed area Operate this vehicle only outdoors or in well ventilated areas Failure to Inspect Before Operating Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Always follow all inspection and mainten...

Page 13: ...e chance of a serious injury in the event of an accident Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Carrying a Passenger Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which may result in an accident or overturn Never carry a passenger on t...

Page 14: ...re or while operating an ATV Operating on Pavement Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the ATV and could result in loss of control and accident or overturn Avoid operating the ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops 14 ...

Page 15: ...et road or highway including dirt and gravel roads In many states it s unlawful to operate ATVs on public streets roads and highways Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions and your experience 15 ...

Page 16: ... from the ATV If the operator s foot is not firmly planted on the footrest it could also contact the rear wheels Never remove your hands from the handlebars while operating and always keep both feet on the footrests Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving 16 ...

Page 17: ...e owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Operating on Steep Hills Operating on excessively steep hills could cause an overturn Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 15 degrees 17 ...

Page 18: ...d in the owner s manual Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill Always check the terrain carefully before descending a hill 18 ...

Page 19: ...he vehicle to lean sharply to one side Travel straight down the hill when possible Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper 19 ...

Page 20: ...til you ve mastered the turning technique on level ground as described in the owner s manual See page 69 Stalling While Climbing a Hill Stalling rolling backwards or improperly dismounting while climbing a hill could cause an overturn Always maintain a steady speed when climbing a hill If all forward speed is lost 20 ...

Page 21: ...ply the front brake slowly When fully stopped apply rear brake as well and then lock the parking brake Dismount on uphill side or to either side if pointed straight uphill Turn the ATV around and remount following the procedure described in the Owner s Manual See page 72 Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could c...

Page 22: ...ing in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 22 ...

Page 23: ...verse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 65 Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly Improper Vehicle Modifications Improper installation of accessories or modification of the ATV may cause changes in handling which cou...

Page 24: ...ual Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding Operating Through Deep Water Operating the ATV through deep or fast flowing water could cause the tires to float causing loss of control or overturn Avoid operating th...

Page 25: ... Apply them lightly several times while driving The friction will help dry out the pads Improper Cargo Loading Overloading the ATV or carrying towing cargo may cause changes in handling which could cause loss of control or an accident Never haul cargo or tow a load with this ATV Never tow or pull an object behind the ATV A wagon sled or other towed object does not have brakes or steering The objec...

Page 26: ...fied service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems Unauthorized Use of the ATV Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use Physical Skills Safe operation of this rider active ve...

Page 27: ...s especially dry grass Always inspect the underside of the ATV after driving through tall grass weeds brush and other tall ground cover Promptly remove any grass or debris clinging to the vehicle Safety Labels Warning labels have been placed on the vehicle for your protection Read and follow the instructions on each label carefully If any of the labels shown in this manual differ from the labels o...

Page 28: ...cement Age Warning WARNING Operation of this ATV by children under age 16 increases the risk of severe injury or death NEVER permit children under age 16 to operate this ATV Operation Warning WARNING Improper ATV use can result in SEVERE INJURY OR DEATH Always use an approved helmet and protective gear Never use 28 ...

Page 29: ...gers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS Tire Pressure Warning WARNING Improper tire pressure or overloading can cause loss of co...

Page 30: ... 0kPa 3 5psi Rear 24 0kPa 3 5psi Minimum Front 20 7kPa 3 0psi Rear 20 7kPa 3 0psi Never set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING Maximum weight capaerty 82kg 181lbs Includes weight of operator cargo and accessories 30 ...

Page 31: ...DEATH Know Your ATV These units are not designed for adult use Serious damage to the vehicle may occur if the maximum rider weight capacity is exceeded See the specifications section beginning on page 125 for your ATV s capacity CHILDREN Before you ride your new PENTORA ATV there are some important things that you need to 31 ...

Page 32: ...e this symbol on your ATV or in this manual it means PAY ATTENTION because you could die or be seriously injured if you don t follow the instructions Before you have an adult start the engine for you for the first time let s learn about the controls on your new ATV 1 Engine Stop Switch When the engine is running push this button down to shut the engine off quickly The button must be up before you ...

Page 33: ... the throttle lever with your thumb when you want the ATV to go forward Always make sure the throttle control does not stick before you drive your ATV 1 3 2 4 Shift Lever The shift lever is on the right side of the ATV 4 33 3 ...

Page 34: ...Cap The gas cap has to be taken off when an adult puts gas in your ATV Never take the gas cap off Always make sure it s tightly closed Always have an adult put gas in your ATV Never try to do it yourself 34 5 ...

Page 35: ... locked in place before riding 7 Brake Levers Squeeze the brake levers toward the handlebar to slow down or stop the ATV The left lever controls the rear brake The right lever controls the front brake Always squeeze both brake levers at the same time Always squeeze both brake levers at the same time or you could lose control of the ATV And be seriously injured Always take your thumb off the thrott...

Page 36: ...ront Brakes 8 Start Button Use this button to start the engine when you re ready to drive 9 Ignition Switch The ignition switch key must be turned on before pushing the start button You can also use this key to turn off the engine 36 8 ...

Page 37: ...Let s review the three ways to stop the engine of your ATV 37 9 ...

Page 38: ...almost ready to have an adult start your ATV But before the ATV is started for the first time you must do a Pre Ride Check In fact every time you want to ride you must have an adult help you check some things on your ATV before starting it Let s learn about these things now 38 ...

Page 39: ...e You could be seriously hurt if you ride with a sticky throttle Have an adult or your dealer fix the throttle before you ride 2 Make sure the brakes don t stick Check the brake levers by squeezing them toward the handlebar and then letting go They should come right back to where they were before you squeezed If they go back slowly or stay close to the handlebar your ATV has sticky brakes They mus...

Page 40: ...ked in place 5 Have an adult check the engine oil level when the engine is cold The engine is very hot after it has been running and it can burn your skin if you touch it Children must never check the oil on their own An adult should always be in charge of keeping the gas and oil levels at the full marks 6 This last check is done with the engine running You must check to make sure that all two way...

Page 41: ...ready to learn about riding your ATV There are some things you can do and there are some things you must never do Rules are very important when you re driving an ATV Adults have riding rules too The rules help keep us safe when we ride The adult with you is your teacher Always pay attention to what your teacher says so you can learn how to always drive safely 41 ...

Page 42: ... rules Always wear the right kind of clothing and safety gear when riding your ATV Helmet Your helmet is very important for safe riding A helmet can prevent a severe head injury Eye Protection Always wear shatterproof goggles or a helmet face shield and always keep them clean so you can see where you re driving Gloves Wear gloves to protect your hands from sun and 42 ...

Page 43: ...uld keep you from moving easily when you shift your weight If it s too big it could hang down and get caught in a moving part Wear long sleeves and long pants to protect your arms and legs Make sure you know where you re going to drive before your ATV is started Make sure the area is safe all around your ATV Your ATV is made for one person Never carry a passenger A passenger will make the ATV hard...

Page 44: ...lways drive within the sight of an adult Never ride on public trails Don t ride your ATV on roads or over railroad tracks Your ATV makes noise that will keep you from hearing cars trucks or trains that may be coming towards you Learn where there are lakes rivers ponds and ditches in your driving area Stay away from them Never ride on frozen water You could get hurt or you could even die All ice ca...

Page 45: ...Engine and Vehicle Identification Number Location 45 ...

Page 46: ...Features and Controls Main Key Switch Turn the key clockwise to the ON position before starting the engine To avoid draining the battery always turn the key to the OFF position when the engine is not running Always remove the ignition key when the vehicle is not in use 46 2 EIN 1 ...

Page 47: ...e engine will not start or run when the stop Engine stop switch switch is down in the OFF position Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency 47 ...

Page 48: ... Button The start button is located on the left handlebar control Follow the Starting the Engine procedure beginning on page 61 Throttle Controls WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer or other...

Page 49: ... result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle mechanism Always ensure that the throttle cable is installed and properly routed to the throttle control Throttle Lever Press the throttle lever toward the handlebar to increase engine speed and vehicle movement Engine speed r...

Page 50: ...hange gears stop the ATV With the engine idling move the lever to the desired gear Do not try to shift gears with engine speed above idle or while the ATV is moving Maintaining shift linkage adjustment is important 50 ...

Page 51: ... the vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at idle Brakes Squeeze both brake levers toward the handlebar at the same time to apply the brakes The left lever controls the rear brakes The right lever controls the front brakes WARNING Applying only one brake could cause loss of control and result in serious injury or...

Page 52: ...Rear Brakes Front Brakes Parking Brake Parking brake lock 1 Squeeze the left brake lever 2 Push the parking brake lock back to lock the brake lever in place 3 Release the brake lever 52 ...

Page 53: ...is engaged could cause an accident resulting in serious injury or death It could also result in drive line or engine damage Always be sure to disengage the parking brake before operating the ATV Lights PENTORA Youth ATV have two headlights equipped with high and low beam that are designed for driving in the dark reduced speeds in conditions of reduced visibility This ATV is designed for off road u...

Page 54: ...ocated directly below the Gas Cap handlebars Use unleaded gasoline with a minimum pump octane number of 90 R M 2 octane Non ethanol fuel is recommended Do not use fuel with ethanol content greater than 10 Indicator Description Neutral Transmission is in neutral Reverse Transmission is in reverse 54 ...

Page 55: ... the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Break in Period The break in period for your new PENTORA ATV is defined as the first ten hours of operation or the time it 55 ...

Page 56: ...st three hours of use Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 1 Fill the fuel tank with gasoline Always exercise extreme caution whenever handling gasoline See page 11 2 Check the oil level See page 84 Add the recommended oil as needed to maintain the oil level in the safe operating range 3 Drive...

Page 57: ...ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Pre Ride Checklist Item Remarks Page Front suspension Inspect lubricate if necessary 81 57 ...

Page 58: ...astener tightness check that axle nuts are secured by cotter pins 108 Fuel and oil Check and fill as needed 11 54 Pre Ride Checklist Item Remarks Page Throttle Check for proper operation 38 48 49 Engine stop switch Check for proper function 47 Far and near light Check for proper operation Brakelight Check for proper operation 110 Air filter pre filter Inspect clean or replace 104 58 ...

Page 59: ...otective clothing 7 Safe Operation Practices 1 Complete the recommended safety training before operating this vehicle 2 Do not allow anyone under age 16 to operate this vehicle 3 Never carry a passenger on this ATV 4 Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area 5 Operate this vehicle off road only Never operate the vehicle on pavement or on any public...

Page 60: ...s from the handlebars while operating and always keep both feet on the footrests 8 Never consume alcohol or drugs before or while operating an ATV 9 Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure 10 Never operate a damaged ATV After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage 11 Never...

Page 61: ...ely after starting could cause engine damage Allow the engine to warm up for several minutes before operating 1 Shift the transmission to neutral 2 Lock the parking brake 3 Push the engine stop switch up to the ON position 4 Turn the ignition key to ON 61 ...

Page 62: ...nds releasing the button when the engine starts If it doesn t start release the starter wait five seconds then activate for another five seconds Repeat until the engine starts Stopping the Engine 1 Release the throttle completely 2 Apply the brakes until the vehicle stops moving 3 Shift the transmission to neutral 4 Stop the engine There are two ways to stop the engine Turn the key off Push the en...

Page 63: ...hen the engine is not running Driving Procedure 1 Sit upright with both feet on the footrests and both hands on the handlebars 2 Shift the transmission to neutral 3 Start the engine and allow it to warm up 4 Check your surroundings and determine your path of travel 5 Squeeze the left brake lever 63 ...

Page 64: ...ing and using the throttle and brakes on level surfaces Making Turns Your ATV is equipped with a solid rear axle which drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning 64 ...

Page 65: ...ctice making turns at slow speeds WARNING Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds Driving in Reverse Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at sharp angl...

Page 66: ...weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid 66 ...

Page 67: ... Turn in direction of skid Driving Uphill Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn Whenever traveling uphill follow these precautions 1 Drive straight uphill 67 ...

Page 68: ...se surfaces 5 Keep both feet on the footrests 6 Shift body weight uphill 7 Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 8 Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 68 ...

Page 69: ...unting of the vehicle Driving on a hillside Driving on a hillside is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable follow these precautions 1 Slow down 69 ...

Page 70: ... 3 If the vehicle begins to slide or tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately Driving Downhill When driving downhill follow these precautions 1 Avoid steep hills 15 maximum 2 Shift body weight uphill Transfer your weight to the rear of the vehicle 70 ...

Page 71: ... in slowing Turning Around on a Hill If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 1 Stop the vehicle and lock the parking brake while keeping body weight uphill 2 Shift the transmission to neutral 3 Shut off the engine 4 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 71 ...

Page 72: ...d slowly release the brake allowing the ATV to roll around to your right until it s pointing across the hill or slightly downward 7 Lock the parking brake and remount the ATV from the uphill side keeping body weight uphill 8 Restart the engine 9 Squeeze the rear brake lever 10 Shift the transmission to forward gear 72 ...

Page 73: ...ly controlling speed with the rear brake until the ATV is on more level ground Parking on a Hill or Incline Avoid parking on a hill or incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Lock the parking brake 73 ...

Page 74: ...on the downhill side as shown in the illustration Driving Over Obstacles Follow these precautions when operating over obstacles 1 Always check for obstacles before operating in a new area 2 Look ahead and learn to read the terrain 74 ...

Page 75: ...bstacles are immediately visible 4 Never attempt to operate over large obstacles such as rocks or fallen trees Driving Through Water Your ATV can safely operate through shallow water The recommended maximum depth for your ATV is below the bottom of the footrests Follow these precautions when operating through water 1 Determine water depth and current before 75 ...

Page 76: ...g until braking action is normal If you do not perform this procedure your brakes may be ineffective NOTICE Serious engine damage can result if the vehicle is not thoroughly inspected after operating in water deeper than the footrest level As soon as possible perform the inspections and maintenance services outlined in the periodic maintenance chart beginning on page 78 Engine oil gearcase oil and...

Page 77: ...ce outlined on page 90 and take the vehicle in for service at the first opportunity Emission Control Systems Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with local noise level requirements Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion ...

Page 78: ...ould be checked and maintained at certain interval The meanings of capital in following table are I Inspection including check clean lubricate refuel repair or replacing if necessary A Inspection adjusting if necessary C Cleaning R Replacing T Tightening 78 ...

Page 79: ...od Items Odometer km 3 0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 Everyday check before riding Crankcase lube R R R R I Oil pre filter screen C C C C Air filter C C C C Spark plug C R C Valve gap A A A A 79 ...

Page 80: ...I I I Brake fluid I I I Driving chain I I I I I Fasteners Excluding Engine Bolt T T T T I Engine Bolt I I I I When the mileage is over the highest on the table please perform according to the period set on the table Driving on dust place it is recommended to clean it frequently 80 ...

Page 81: ...ee page 83 Gearcase Transmission Oil Level GL 4 85W 90 Lubricant Transmission Fluid See page 84 Drive Chain PENTORA Chain Lube or SAE 80 90 See page 102 Front Suspension A Arm All Season Grease or grease conforming to NLGI No 2 Inspect tighten fasteners grease also after washing ATV 81 ...

Page 82: ...or driving in water Perform these procedures more often for vehicles subjected to severe use 82 ...

Page 83: ...8 PENTORA recommends the use of SF15W 40 in summer SF15W 30 in winter Duty 4 Cycle engine oil for this vehicle Oil may need to be changed more frequently if oil is not used Do not use automotive oil NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 83 ...

Page 84: ...n the dipstick Do not overfill 1 Position the vehicle on a level surface 2 Remove the dipstick Wipe it dry with a clean cloth 3 Reinstall the dipstick completely 4 Remove the dipstick and check the oil level Tip A rising oil level between checks in cool weather 84 ...

Page 85: ...stall the dipstick Engine Oil Change 1 Position the vehicle on a level surface 2 Clean the area around the pre filter plug 3 Start the engine Allow it to idle for two to three minutes 4 Stop the engine CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 5 Place a drain pan under the engine crankcase 6 Remove the pre filter plug Allow the oil to drain completely 85 Dipstick...

Page 86: ...burrs nicks or scratches 9 Reassemble the pre filter screen and spring to the pre filter plug 10 Reinstall the pre filter drain plug Torque to 11 ft lbs 15 Nm 11 Remove the dipstick Add 25 3oz 750 ml of the recommended oil Do not overfill See the specifications section beginning on page 125 for capacities 12 Reinstall the dipstick 13 Start the engine Allow it to idle for one to two minutes 14 Stop...

Page 87: ...ition the vehicle on a level surface 2 Remove the fill plug 3 Place a drain pan under the gearcase 4 Remove the drain plug Allow the oil to drain completely 5 Clean and reinstall the drain plug Torque to 14 ft lbs 19 Nm 6 Add the recommended oil Maintain the oil level at the bottom of the fill plug hole threads 7 Reinstall the fill plug Check for leaks 87 ...

Page 88: ...ine damage Always use PENTORA recommended spark plugs or their equivalent Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when ...

Page 89: ...ealer or other qualified person check the ATV cylinder head for proper torque at the first service or after 25 hours Vehicle Immersion If the vehicle tips or overturns in water deeper than the footrest level or if the engine stops during or after operating in water restarting WILL result in serious engine damage Take the vehicle in for service before starting the engine Your PENTORA dealer can pro...

Page 90: ... is present 3 Remove the spark plug 4 Turn the engine over several times using the electric start 5 Dry the spark plug and reinstall it or replace it with a new plug 6 Attempt to start the engine If necessary repeat the drying procedure 7 Take the vehicle in for service as soon as possible whether you succeed in starting it or not Your PENTORA dealer can provide the required service 8 If water has...

Page 91: ...Spark Arrester WARNING To remove accumulated carbon clean the spark arrester at the intervals recommended in the 91 ...

Page 92: ...o not perform service on the spark arrester while the system is hot Allow components to cool sufficiently before proceeding Wear eye protection and gloves Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas 1 Remove the three bolts and remove the arrester from the end of the muffler 92 ...

Page 93: ... screen with compressed air 3 Inspect the screen for wear and damage Replace the arrester if damage is found 4 Reinstall the arrester 5 Torque the bolts to 5 Nm Arrester Screen Speed control system The dealer CANNOT under any circumstances either prior to the sale or later even at the consumer s request remove or adjust any speed limiting devices 93 ...

Page 94: ... top speed of this vehicle is restricted to 26 MPH 42 km h at manufacture it is limited by ECU Throttle Cable Adjustment Always check the throttle for smooth operation 94 Adjustment nut 1 16 1 8 1 5 3 2mm ...

Page 95: ... 3 2 mm If adjustment is required turn the adjustment nut until the freeplay falls in to the acceptable limit Front Brake Brake Fluid Reservoir Level Verification With vehicle on a level surface check brake fluid in reservoir for proper level Brake fluid level should be between MIN and MAX marks 95 ...

Page 96: ...eting the specification DOT 4 only WARNING To avoid serious damage to the braking system do not use fluids other than the recommended one nor mix different fluids for topping up WARNING The brake fluid replacement or brake system maintenance and repairs should be performed by an authorized PENTORA dealer Rear Brake Brake Fluid Reservoir Level Verification With vehicle on a level surface check brak...

Page 97: ...ing the specification DOT 4 only WARNING To avoid serious damage to the braking system do not use fluids other than the recommended one nor mix different fluids for topping up WARNING The brake fluid replacement or brake system maintenance and repairs should be performed by an authorized PENTORA dealer Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommen...

Page 98: ...ration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straightedge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measurement on each side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out...

Page 99: ...ing Inspection Check the steering assembly periodically for loose nuts and bolts If loose nuts and bolts are found see your PENTORA dealer or other qualified service facility before operating the vehicle 99 ...

Page 100: ... spring tension Rotate the adjuster either clockwise or counter clockwise to make adjustments Drive Chain Lubricate the drive chain with chain spray lube or an approved chain lube at the general lubrication interval specified in the Periodic Maintenance Chart beginning on page 78 Lubricate more often under severe use such as in dirty or wet conditions 100 adjuster ...

Page 101: ...e to clean the drive chain Adjusting or operating the ATV with improper rear drive chain slack can result in severe damage to the transmission and drive components Always make sure the slack is within the stated specifications Drive Chain Slack 1 Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the chain 101 ...

Page 102: ...be adjusted by rotating the rear axle 3 Measure chain slack It should have 1 4 1 2 6 12 mm deflection Air Filter 1 Remove the seat See page 34 2 Release the air box cover spring clips and remove the cover 3 Remove the foam air filter Wash the foam filter in warm soapy water then rinse and let 102 ...

Page 103: ...bricant to the foam filter 5 Clean away any oil or sediments in the air box 6 Reinstall the filter and air box cover Secure the clips 7 Reinstall the seat NOTICE Never operate the ATV with the filter element removed Dirt will enter the engine causing rapid wear 103 Support screen clips cover Foam Filter ...

Page 104: ... the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Follow the adjustment procedures exactly or see your dealer or 104 ...

Page 105: ...e handlebar bolts Loosen the four bolts 2 Adjust the handlebar to the desired height Be sure the handlebars do not hit the gas tank or any other part of the vehicle when turned fully to the left or right 3 Lightly tighten each bolt equally to prevent uneven gaps in the block Torque the bolts to 24 Nm Tires WARNING 105 bolts ...

Page 106: ...handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less 106 ...

Page 107: ...le by placing a suitable stand under the footrest frame 4 Remove the wheel nuts and remove the wheel Wheel Installation 1 Lock the parking brake 2 Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 107 Wheel nuts ...

Page 108: ...to 45 Nm Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by your authorized PENTORA dealer or other qualified service facility Taillight Replacement If the Taillight doesn t work the lamp may need to be replaced 108 Lamp ...

Page 109: ...ion 4 Reinstall the nuts Note Taillight with arc side up Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When 109 Lamp Nuts ...

Page 110: ...leaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly to reduce oxidation and excessive power consumption Battery Removal 1 Remove the battery hold down strap 2 Disconnect the black negative batter...

Page 111: ...and Connections Always install a fully charged battery Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance If recharging is necessary use a 5 amp battery charger 111 ...

Page 112: ...ve cable last 5 Attach the hold down strap 6 Verify that cables are properly routed Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge 112 ...

Page 113: ...hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle Washing the ATV The best and safest way to clean your PENTORA vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower...

Page 114: ...vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Cleaning Washing the ATV If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and decals Avoid...

Page 115: ...act your PENTORA dealer Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing PENTORA recommends the use of common household aerosol furniture polish for polishing the finish on your PENTORA vehicle Follow the instructions on the container Polishing Tips 115 ...

Page 116: ...sh of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Storage Exterior Make necessary repairs and clean the vehicle as recommended See page 114 Battery Storage 116 ...

Page 117: ... the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge Engine Oil Change the oil See page 85 Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box Drain the sediment tube 117 ...

Page 118: ...commended in the Periodic Maintenance Chart beginning on page 78 Transmission Oil Engine Oil Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 78 Storage Area Covers 118 ...

Page 119: ...ed materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Warranty This All Terrain Vehicle ATV emissions limited warranty is in addition to the manufacturer standard limited warranty for All Terrain Vehicles manufacturer warrants that this vehicle are 1 designed built and equipped to conform at the time of initial sale with the requirements ...

Page 120: ... the exclusive option of Local dealer repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY MANUFACTURER SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY...

Page 121: ...damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions to other similar causes beyond the control of manufacturer If you have any questio...

Page 122: ...cle Weight 120kg Loading capacity of dump bed N A Length Width Height 1540 980 1050mm Wheel Base 870mm 770mm Front Tires 18 7 8 Rear Tires 18 9 8 Fuel Capacity 6 5L Ground Clearance 105mm 15mm Engine type 4 Stroke Displacement 125cc 122 ...

Page 123: ...Starting System Electric Fuel System Carburetor Intake Exhaust valve clearance 0 05 0 07 0 06 0 08 Ignition System CDI Spark Plug Gap A7RTC 0 6 0 8 mm Drive System Mechanical transmission Final Drive Chain Front Brakes Disc Rear Brakes Disc Parking Brake Mechanical Lock Brake Light LED Far and near light 2 12V 18W 123 ...

Page 124: ...ged fuel filter Replace the filter Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Your PENTORA dealer can assist Low battery voltage Recharge the battery to 12 8 VDC...

Page 125: ...eck all connections and tighten Loose solenoid connections Check all connections and tighten Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing Your PENTORA dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plugs 125 ...

Page 126: ... Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Throttle release switch malfunction Your PENTORA dealer can assist Other mechanical failure Your PENTORA dealer can assist Low or contaminated fuel Add or ...

Page 127: ...tive spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires Your PENTORA dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or...

Page 128: ...Overheated engine Clean engine exterior Your PENTORA dealer can assist 128 ...

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PENTORA Y35-100, Owner'S Manual

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