Rokon Trail-Breaker Illustrated Owners And Parts Manual Download Page 34 | Manualshive

Page: 34 / 57

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Kohler Air Box

Section 10

Continued

ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A

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Copyright 2002-7

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Item Part

Number

Name

Description

Qty

1

KOH6304120-S

Air Box Gasket

1

2

KOH6309404-S

Air Box Base

1

3

KOH6309609-S

Air Box Cover

1

4

KOH6314605-S

Air Box Plate

1

5

KOH6308306-S

Kohler Air Filter

1

6

KOH6308651-S

Air Box Screw

2

7

109202

Air Box Plug

1

8

KOHAIRBOXASSY

Kohler Air Box Assembly

Includes all of the above

1

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Summary of Contents for Trail-Breaker

Page 1: ...rnational Inc 50 Railroad Avenue Rochester NH 03839 Tel 603 335 3200 Fax 603 335 4400 e mail parts rokon com web site www rokon com Made In The USA 2002 7 Rokon International Inc Printed in U S A ROKO...

Page 2: ...cle Registration Card must be signed and returned to ROKON within 10 days of the date of purchase We congratulate you on your decision to purchase a ROKON Utility Vehicle By following the procedures a...

Page 3: ...lustrated Parts Manual 25 56 BEFORE YOU OPERATE YOUR NEW ROKON THE FOLLOWING IMPORTANT POINTS MUST BE OBSERVED 1 Children under 16 should not operate a ROKON 2 Carefully read and follow the instructio...

Page 4: ...r operate on hills too steep for the ROKON or for your abilities Never exceed a 60 grade or 31 degrees Practice on smaller hills before attempting larger hills Always follow proper procedures for clim...

Page 5: ...porting the machine in another vehicle be sure that it is kept upright and that the fuel cock is in the OFF position see page 6 of manual Otherwise fuel may leak out of the carburetor and flood the en...

Page 6: ...he vehicle is stolen VIN Engine Number Section 2 Description and Machine identification The Vehicle Identification Number is on the center frame tube beneath the driver seat The Engine Number is on th...

Page 7: ...right hand side of the handlebar counterclockwise The throttle grip is spring loaded and will automatically close the throttle and slow the engine when released Brakes The ROKON Utility Vehicle is equ...

Page 8: ...P THE VEHICLE BEFORE SHIFTING Shift only at low idle or when the engine is off Feel the gears into engagement rocking the bike if necessary to synchronize the gears The shift pattern is from inside ou...

Page 9: ...has a fill to plug near the bottom of the transmission shown on page 46 There is no fill level for the miter box Over filling of either the miter box or transmission will result in leakage Throttle Ch...

Page 10: ...Go slow and be extra careful on unfamiliar terrain You can come upon hidden rocks bumps or holes without enough time to react Always be alert to changing terrain conditions when operating a ROKON Tra...

Page 11: ...e ROKON or lead to an upset or an accident Avoid jumping the ROKON as loss of control and damage may result The real secret to riding perfection is throttle control Remember that gradual acceleration...

Page 12: ...nd will penetrate to the inner parts of the rollers 3 Clean the air filter based on use See Engine Manual 4 Use normal repair procedures for tires and tubes Re seat the tire beads with 40 PSI then def...

Page 13: ...in wheel 4 Chain scoring tire sidewall Improper chain alignment Improper axle spacer thickness Defective wheel bearings Section 6 Continued Periodic Maintenance and Adjustment Storing your ROKON 1 Clo...

Page 14: ...Improper gear mesh 7 Rear wheel won t drive Wheel chain off sprocket Sheared roll pin on drive sprocket 8 Front wheel won t drive Wheel chain off sprockets Sheared roll pin in sprocket Broken overrid...

Page 15: ...uled 3 Engine starts but will Insufficient fuel supply not continue to run Fuel line clogged Vent on filler cap plugged Dirty carburetor Air leak in fuel system Defective or fouled spark plug Idle scr...

Page 16: ...flywheel Worn bearings Broken or loose parts inside engine Lack of oil in crankcase 8 Engine stalls under load Fuel line restricted or tank vent closed Engine overloaded 9 Poor acceleration Air cleane...

Page 17: ...ual for help with part names and assembly sequence Maintenance The brakes operate with little or no maintenance but work more smoothly and last longer if kept clean and lubricated The floating brake d...

Page 18: ...applied to the caliper during puck replacement 2 Hydraulic lines do not need to be removed 3 Remove the two SAE grade 8 hex bolts 18 This will dismount and disassemble the caliper exposing the Pucks...

Page 19: ...f necessary Check air pressure and balance and X X X X correct if necessary 8 Wheel Bearings Check for looseness and damage and X X X X replace if necessary 9 Drive Chain Lubricate X X X X X Check Cha...

Page 20: ...are to be taken out as one unit leave roll pin attached for ease of disassembly This is done by inserting a pin punch into the roll pin access hole located under the front seat which was removed and...

Page 21: ...e the two carrier bearing bolts which are located under the fuel tank 4 Remove front chain guard cover front drive chain and headlight Note Ground wire for the headlight must be routed behind front mi...

Page 22: ...universal joint gears or seals 6 After repairs are made and with the universal joint in place slide miter box gently into place You will feel it hit the drive shaft Slide your index and middle fingers...

Page 23: ...ching the drive shaft to the slip clutch is sheared If slip clutch is not spinning check to see if roll pin attaching slip clutch to the transmission is sheared If roll pin is not sheared then an inte...

Page 24: ...Lock Washer 25 2 1 4 84 7 5 16 Transmission Loctite 242 Lock Washer 180 15 Brake Mounting Self Locking Nuts Wheel Bearings Loctite 242 Foot Rest Self Locking Nuts 3 8 Engine Mounting 360 30 1 2 720 6...

Page 25: ...r inspection at a place to be determined by ROKON Have warranty service performed by an authorized ROKON agent as directed by ROKON Warranty will not cover Parts replaced as a result of normal wear ie...

Page 26: ...Muffler 40 41 Handlebar Assembly 42 Pullstarter 43 Front Seat 44 Rear Seat 45 Torque Converter Drive Pulley 46 Torque Converter Driven Pulley 47 Tow Bar 48 Transmission Complete 49 Transmission with...

Page 27: ...1006 Screw Flat Head Slotted 2 10 0701 1005 Puck 1 12 0701 1003 O Ring Buna N 1 13 0708 1001 Housing Pneumatic Retractable 1 14 0701 1007 Washer 4 15 0701 1008 Nut Flexloc 2 18 3030 1007 Hex Bolt 2 2...

Page 28: ...Link as needed 3 100354 Full Link as needed 4 108984 Chain Length as needed 5 101568 Front Chain 107P not shown 1 6 101570 Rear Chain 117P not shown 1 Chain Section 10 Continued 1 4 2 3 ROKON INTERNAT...

Page 29: ...108043 Decal SCOUT in Red 2 6 108990 Decal ROKON Oval in Red 2 7 108991 Decal ROKON Oval in Brown 2 8 101626 Decal Shift Instructions 1 9 108057 Decal Made in USA 2 10 108988 Decal Oil Warning 1 11 1...

Page 30: ...tor 1 6 100190 Kill Switch Assembly 1 7 101135 Brake Light Mounting Plate 1 8 100170 Bolt HH Bolt 1 4 28 x 1 1 2 2 9 100169 Nut Lock Nut 1 4 28 2 10 100448 Cable Tie Long As Necessary 2 11 100449 Cabl...

Page 31: ...Plug 1 3 HON5247408 Air Filter 1 4 101548H Crank Key 1 5 108253 E Clip 1 6 108254 Screw M4 Size 6 mm length 7mm pitch 1 7 108256 Cable Holder 1 Honda Engine Section 10 Continued 1 4 2 6 7 5 3 ROKON I...

Page 32: ...Kohler Engine Section 10 Continued 1 19 18 3 16 17 14 15 13 4 7 6 9 5 10 12 11 8 23 ROKON INTERNATIONAL 50 Railroad Ave Rochester New Hampshire 03839 U S A Copyright 2002 7 31...

Page 33: ...ut Self Lock 10 32 1 12 100165 Washer Washer 10 flat 1 13 100884 Rear Driven Pulley 1 14 100885 Torque Converter Drive Pulley 1 15 108137 Drive Belt 1 16 108123 Clutch Bolt 1 17 108983 Locking Clip 1...

Page 34: ...3 4 5 6 7 6 Item Part Number Name Description Qty 1 KOH6304120 S Air Box Gasket 1 2 KOH6309404 S Air Box Base 1 3 KOH6309609 S Air Box Cover 1 4 KOH6314605 S Air Box Plate 1 5 KOH6308306 S Kohler Air...

Page 35: ...Frame Section 10 Continued 2 4 1 10 23 24 11 26 14 15 3 9 8 12 6 13 19 18 17 16 21 22 5 25 7 21 22 ROKON INTERNATIONAL 50 Railroad Ave Rochester New Hampshire 03839 U S A Copyright 2002 7 34...

Page 36: ...er Chain Guard 1 14 101629 Stud for Fairing 6 15 101630 Receptacle for Fairing 6 16 100126 Bolt 1 4 20 x 5 8 HH Bolt 2 17 100255 Washer 2 18 100573 Wheel Adjuster Bolt 2 19 100036 Nut 3 8 24 Jam 2 20...

Page 37: ...24 x 1 3 4 Fully Threaded 2 9 100036 Nut Hex Nut Jam 3 8 24 2 10 100427 Front Mud Flap 1 11 108106 Front Chain Guard 1 12 101629 Stud 1 13 101630 Receptacle 1 14 100035 Screw Pan Head Screw 10 32 x 1...

Page 38: ...Washer 1 4 Lock Washer 2 4 100170 Screw HH 1 4 28 x 1 1 2 2 5 100255 Washer 2 6 100169 Nut 1 4 x 28 Locking 2 7 100892 Front Cargo Rack Kit Includes all items above Front Cargo Rack Section 10 Contin...

Page 39: ...18 1 8 102590 Fuel Tank Fitting 1 9 101969 Rubber Fuel Tank Washer 1 10 101970 Bolt HH 1 2 20 x 3 4 1 11 102589 Flat Washer 1 12 103120 RED Fuel Tank Red not shown 13 103120 OD Fuel Tank Olive Drab n...

Page 40: ...fler Honda not shown 1 3 108998 Sandwich Mount 2 4 108997 Nut 1 4 20 Jam Nut Nylock 4 5 100255 Washer 2 6 KOH6331402 S Muffler Guard not shown Section 10 Continued Muffler 1 1 4 5 3 4 ROKON INTERNATIO...

Page 41: ...2 4 3 17 18 17 18 5 8 19 20 15 15 11 12 11 21 22 1 16 2 19 7 9 8 6 13 Section 10 Continued Handle Bar ROKON INTERNATIONAL 50 Railroad Ave Rochester New Hampshire 03839 U S A Copyright 2002 7 40...

Page 42: ...Honda Only not shown 1 11 100610 Brake Disc 2 12 100599 Throttle Spring 1 13 100043 Woodruff Key 9 2 14 104309 Brake Switch 2 15 107033 Boot 2 16 103113 Twist Grip 1 17 108985 Handlebar Clamp Bolt Sh...

Page 43: ...bly 1 4 KOH6316601 S Starter handle 1 5 KOH6308921 S Recoil Spring 1 6 15585 Pull Rope 1 7 KOH6309302 S Pulley 1 8 KOH6375706 S Kit pawl repair includes 9 1 9 KOH6308652 S Screw 1 10 KOH6310902 S Star...

Page 44: ...2 7 101970 Bolt HH Bolt 1 2 20 x 3 4 2 8 108999 Bolt 1 9 101181 Bolt HH Bolt 3 8 24 x 1 3 4 1 10 100212 Nut Lock Nut 3 8 24 1 11 100168 Bolt Not Pictured for Lower Shock Mount 2 11 100169 Nut Not Pic...

Page 45: ...100343 Passenger Foot Peg Set 1 3 100281 Locking Washer Lock Washer 1 4 Spring 4 4 105037 Hex Head Bolt HH Bolt 1 4 20 x 1 3 8 4 Rear Seat Section 10 Continued 2 1 3 3 4 ROKON INTERNATIONAL 50 Railroa...

Page 46: ...16 Bearing Idler Bearing 1 7 703127 Washer 1 8 703129 Retractor 1 9 703151 Plate 1 10 703211 Washer Ramp Plate Retaining 1 11 108123 Clutch Bolt 1 12 108983 Locking Clip 1 13 100885 Torque Converter D...

Page 47: ...3111 Spring 1 5 703305 Button Shoe Ramp 3 6 601406 Torque Bracket Includes Items 5 7 1 7 901709 Set Screw 3 8 100884 Driven Pulley Rear Includes 1 7 1 Torque Converter Driven Pulley Section 10 Continu...

Page 48: ...0169 Nut Lock Nut 1 4 28 2 7 100848 Bolt HHCS 5 16 24 x 3 4 2 8 100208 Washer Flat Washer 3 8 2 9 100551 Nut Locknut 5 16 24 Hex 2 10 100893 Tow Bar Kit Includes all except 3 11 100170 Bolt HH 1 4 28...

Page 49: ...Fill Level Transmission Complete Section 10 Continued Fill Plug Drain Plug ROKON INTERNATIONAL 50 Railroad Ave Rochester New Hampshire 03839 U S A Copyright 2002 7 48...

Page 50: ...884 Rear Driven Clutch 1 3 100610 Brake Disc 1 4 100040 11 Tooth Sprocket 1 5 100270 Roll Pin 1 6 100043 Woodruff Key 3 Transmission with Attachments Section 10 Continued 1 4 5 6 3 6 2 ROKON INTERNATI...

Page 51: ...3 6 41 38 37 37 38 37 2 13 11 23 2 5 11 20 21 12 10 7 8 7 8 9 4 2 14 17 5 15 16 18 19 24 25 26 22 27 2 6 5 10 28 31 5 40 30 32 33 29 34 35 4 5 5 5 6 6 6 42 43 ROKON INTERNATIONAL 50 Railroad Ave Roche...

Page 52: ...ector Shaft 1 20 101528 Spring 1 21 101527 Ball 1 22 101530 Spacer 1 23 101541 Shift Knob 1 24 101631 3 Gear 40T 1 25 101631 2 Gear 51T 1 26 101631 1 Gear 60T 1 27 101516 Gear 32T 1 28 107039 Shaft In...

Page 53: ...n 1 10 100045 Roll Pin 2 11 103136 Snap Ring 4 12 101615 Shim ID 3 4 OD 1 1 8 005 more as needed 1 13 101616 Shim ID 3 4 OD 1 1 8 010 more as needed 1 14 100043 Woodruff Key Connects to Brake Disc 1 1...

Page 54: ...al Joint 1 11 100046 Roll Pin 3 16 x 1 1 2 3 12 100100 Miter Box Assembly Front All Models 1 13 100312 Bearing Retainer Drive Line Support 1 14 100047 Roll Pin 3 16 x 1 1 15 101655 Drive Line Boss 2 1...

Page 55: ...ly not shown 1 9 100772 Bearing 4 10 100522 Axle Spacer 4 11 100208 Washer 4 12 100756 Spacer Dead Side 2 13 100758 Spacer Sprocket Side 2 14 101181 Bolt 3 8 24 x 1 3 4 4 15 100288 Lockwasher 3 8 Lock...

Page 56: ...00117 Wheel 15 Steel 2 7 100405 Axle 2 8 105030 Valve Stem Kit 15 only not shown 1 9 100772 Bearing 2 10 100522 Axle Spacer 2 11 100208 Washer 2 12 101181 Bolt 3 8 24 x 1 3 4 2 13 100853 Shim 2 14 100...

Page 57: ...Wiring Diagram Section 10 Continued ROKON INTERNATIONAL 50 Railroad Ave Rochester New Hampshire 03839 U S A Copyright 2002 7 56...

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