Thump ATV110CC Owner'S Manual Download Page 4

Page: 4 / 78

Contents

Tires

................................................................................ 36

Drive Chain

.................................................................... 38

Front and Rear Wheel Removal

...................................... 40

Troubleshooting ................................................................................. 41

Cleaning Procedure ........................................................................... 46

Storage Procedure .............................................................................. 48

Circuit Diagram ................................................................................. 49

Preparing for a Ride ........................................................................... 50

Transporting your Thumpstar ........................................................... 51

You & the Environment ...................................................................... 52

Taking Care of the Unexpected .......................................................... 53

Technical Information ....................................................................... 57

Oxygenated Fuels ............................................................................... 58

Specification ....................................................................................... 59

Spare Part Catalogue ......................................................................... 60

Parts Finder ....................................................................................... 70

Warranty ............................................................................................ 71

Disclaimer ......................................................................................... 72

Service Manual .................................................................................. 73

Title Ownership ................................................................................ 74

Summary of Contents for ATV110CC

Page 1: ...MANUAL 3627...

Page 2: ...nd regulation in effect at the time of manufacture Thumpstar reserves the right to make changes at any time without notice and without incurring any obligation This publication includes the latest pro...

Page 3: ...Tank Cap 11 Remote Engine Stop Switch 12 Break In Running In 14 Inspection Before Riding 15 Starting the Engine 16 Braking 19 Turning 19 Skidding or Sliding 20 Operation on Hills 21 Stopping the Engin...

Page 4: ...ge Procedure 48 Circuit Diagram 49 Preparing for a Ride 50 Transporting your Thumpstar 51 You the Environment 52 Taking Care of the Unexpected 53 Technical Information 57 Oxygenated Fuels 58 Specifica...

Page 5: ...close attention to the warning and caution labels on the vehicle Never operate an atv without proper training or instruction IMPORTANT MANUAL INFORMATION Failure to follow the warnings contained in t...

Page 6: ...ection presents some of the most important information and recommendations to help you ride your motorcycle safely Please take a few moments to read these pages This section also includes a special me...

Page 7: ...3 Warning Labels...

Page 8: ...All Terrain Vehicle riding requires special efforts on your parts to ensure your safety Know these requirements below before you ride IMPORTANT NOTICE TO PARENTS Even though the ATV has four wheels i...

Page 9: ...nder the in uence of alcohol or drugs This can impair judgment and result in serious injury or even death 7 Keep safe distance between your vehicle and other off road vehicle s 8 Never ride this vehic...

Page 10: ...ll national and local equipment regulations LOADING The incorrect loading could hurt the performance and reliability Max load limit 75kG ACCESSORIES Genuine accessories by our company have been specif...

Page 11: ...d be graded 93 octane or higher An unleaded type of gasoline is recommended If engine pinging is experienced substitute for another brand Engine Oil Use good quality SAE 10W 40 rnulti grade motor oil...

Page 12: ...8 Location of Parts Bumper Headlight Indicator Parking Brake Stop Switch Throttle Lever Fuel Tank Cover Indicator Switch Electric Start Headlight Switch...

Page 13: ...squeezing the rear brake lever towards the grip Parking Brake Knob This knob is used to set the parking brake which is used to prevent the ATV from moving when it is parked being started or at idle S...

Page 14: ...ease it to decrease engine speed This lever is operated by the rider s thumb CHOKE LEVER When this lever is in the down position a rich mixture is supplied by the carburetor for starting the engine wh...

Page 15: ...urn it clockwise and tighten it securely Be sure that the end of the vent tube is reinstalled in the hole in the vehicle body and routed properly as shown Do not overfill the fuel tank Stop adding fue...

Page 16: ...ho trains the young rider should always use this lanyard until the rider develops suf cient skills for safe operation of the vehicle This switch consists of a rubber cap tted over a plastic body When...

Page 17: ...ration of the ATV without parental use of the lanyard should be permitted to operate ATV with the throttle limiter set to maximum power position In addition an adult trying to follow a moving ATV with...

Page 18: ...tial that some stress be placed on the engine components during break in you must be careful not to excessively load the engine AVOID CONSTANT LOW SPEED Operating the engine at constant low speed ligh...

Page 19: ...f the engine stop switch Make sure your child doesn t get too close when you check the fuel level and drive chain or he she might be injured WHAT TO CHECK CHECK FOR Steering No rattle or looseness Bra...

Page 20: ...on before starting the ATV or beginning riding instruc tion This riding Tips section contains important operating information you will need to know before you go to the Instructing the Young Rider sec...

Page 21: ...on When the engine is warm Operation of the choke system should not be necessary Open the throttle slightly and start the engine by pulling up on the recoil starter rope forcefully Release the throttl...

Page 22: ...accident and injury While operating the ATV the rider should keep both feet on the footrest all all times or injuries resulting from accidents such as the rear wheels running over the rider s feet cou...

Page 23: ...lways turn at the same speed This means that if the rear wheels are getting equal traction the vehicle will move straight ahead because the rear wheels will travel the same distance For the vehicle to...

Page 24: ...ahead even though the front wheels are turned The rider should practice the above technique at low speeds in a wide open area until he she has mastered it SKIDDING OR SLIDING If the rider experlences...

Page 25: ...h even surfaces but extreme care should be taken When the ATV is operated on hills it can roll over more easily then when it is operated on level ground under certain conditions only children who are...

Page 26: ...t the parking brake and dismount to the right while still leaning uphill 4 Use one of the following procedures to turn the vehicle around 1 Ask the adult who is supervising to help drag the rear end o...

Page 27: ...of the stream is hard If you are unfamiliar with the area you wish to cross park the ATV and inspect the stream first to find a suitable spot for crossing When crossing operate the vehicle at a slow s...

Page 28: ...ring riding Please go through this manual with your child page by page and fully explain all of the instructions requirements and warnings it contains Be sure to put as much emphasis on safety precaut...

Page 29: ...ILIARIZATION WITH THE VEHICLE Your child should become completely familiar with the names and functions of all controls Let the young rider sit on the ATV with the engine off and ask him her to operat...

Page 30: ...e opposite direction Before permitting your child to operate the ATV under power be sure to adjust the throttle limiter to provide a low maximum speed capability Turning the limiter clockwise reduces...

Page 31: ...ce turning until he she can do it correctly and with confidence PUTTING IT ALL TOGETHER When your child has mastered the basic riding maneuvers in the previ ous steps he she should practice putting th...

Page 32: ...unmarked items by referring to the instructions in this section If you are not sure whether you can successful ly complete any of the unmarked maintenance jobs ask your authorized dealer to do the ma...

Page 33: ...INTENANCE CHART NOTE inspect and clean adjust lubricate or replace if necessary Item Interval After 1 Month Every 3 Month Every 6 Month Air Cleaner Elements Clean at least every month Spark Plug C R C...

Page 34: ...ust there will be greater intake resistance resulting in decreased power output and increased fuel con sumption 1 Do not operate the engine without the air cleaner element in place or severe damage ma...

Page 35: ...r your engine this may cause severe engine damage which may not be covered under warranty use one of the spark plugs listed below or equivalents Consult your dealer if you are not sure which spark plu...

Page 36: ...rm this adjustment To adjust the idle speed 1 Start the engine and warm it up 2 After engine warms up turn the throttle stop screw in or out so that the engine idles at Make sure that the engine is fu...

Page 37: ...e fuel hose every 4 years even if it appears to be in good condition Damage from aging may not be visible ENGINE OIL The transmission oil should always be changed when the engine is hot so that the oi...

Page 38: ...intenance Schedule Operating the ATV in harsh conditions can be hazardous if you do not inspect brake wear often Operating in mud water sand or other extreme conditions can cause accelerated brake wea...

Page 39: ...oensure that the brake oil never be leakage Repeat this procedure until the parking brake is properly adjusted 4 Measure the amount of free play needed to lick the brake lever Adjust the brake if nece...

Page 40: ...re that the recoil starter ratchet engages after the adjuster lock nut has been tightened TIRES Using tires of a different size or type than the tires originally equipped on your ATV can change the AT...

Page 41: ...pump to fill the tires TIRE REPLACEMENT Air in the low pressure tubeless tires of this vehicle is sealed by the con tact surfaces of the inner wheel rim and tire bead If either the inner wheel rim or...

Page 42: ...rive chain should be checked once a month Always follow the guidelines below for inspection and servicing the chain You should periodically inspect the drive chain for the following Loose pins Damaged...

Page 43: ...and pets Dispose of used kerosene properly Do not use gasoline Trichlene or other commercial cleaning solvents to clean the drive chain These fluids have a strong dissolving power that could damage t...

Page 44: ...ect the drive chain slack before each use FRONT AND REAR WHEEL REMOVAL 1 Place the vehicle on level ground and set the parking brake 2 Loosen the three wheel nuts on the wheel to be removed 3 Lift up...

Page 45: ...e engine stoop switch cap is installed on the remote engine stop switch 4 Make sure there is enough fuel reaching the carburetor from the fuel tank a Loosen the drain screw which is located under the...

Page 46: ...ug hole There may some fuel inside the cylinder which could be ignited Due the possibility of electrical shock anyone with a heart condition or pacemaker should avoid this check PROBLEM Engine stalls...

Page 47: ...le using this Manual are followed by the page number reference in parenthesis The items that require use of the Thumpstar Manual are followed by an asterisk POOR PERFORMANCE AT LOW AND UNSTABLE IDLE S...

Page 48: ...44 POOR PERFORMANCE AT LOW AND UNSTABLE IDLE SPEED CHECK POSSIBLE CAUSES Troubleshooting...

Page 49: ...45 Troubleshooting BLOCKED NOT BLOCKED...

Page 50: ...important to remove all debris during cleaning PREPARATION FOR CLEARING Wash the ATV before any mud dries on the ATV Block or seal the end of the exhaust pipe using a piece of plastic wrap cloth rag o...

Page 51: ...ful with brushes as they may scratch plastic or painted surfaces Rinse the ATV thoroughly with clean water Dry all areas using a chamois or soft absorbent cloth INSPECTION AFTER CLEANING Remove the ra...

Page 52: ...siphon Drain the fuel from the carburetor using the carburetor drain screw Do not allow the fuel to spill catch the fuel in a suitable container Do not allow fuel to come in contact with the hot engin...

Page 53: ...49 Circuit Diagram...

Page 54: ...ces Canada only riding clubs and off road magazines are good sources of information WHAT TO TAKE TO THE RIDING AREA Along with your ATV and riding gear you should take along some tools and supplies in...

Page 55: ...tach the lower ends of two straps to the tie down hooks on your vehicle Attach the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork WHAT TO TAKE...

Page 56: ...ormance and may be illegal Choose Sensible Cleaners Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluoro carbons CFCs which damage the atmosphere...

Page 57: ...ecide what to do If a problem is relatively minor and you have the tools supplies and skills to make a permanent repair you may be able to fix it on the trail and con tinue riding Or you may be able t...

Page 58: ...Mechanic sooty exhaust rich fuel mixture See or talk to your Thumpstar Certified Motorcycle Mechanic detonates or pings under load If applicable switch to the recommended octane gasoline or change you...

Page 59: ...r doesn t hold the tube must be replaced The tire will also need to be replaced if it is damaged Replacing a tube or tire involves removing and re installing the wheel If you are unable to repair a fl...

Page 60: ...n you get home thoroughly check your ATV and correct any problems you find Also be sure to have your Certified Motorcycle Mechanic check the frame and suspension after any serious crash IF A COMPONENT...

Page 61: ...Engine size of your Thumpstar Version No To identify which version your model is Thumpstar models are categorized by version number rather than by model year so to find the correct OEM parts you will...

Page 62: ...er the name Gasohol MTBE Methyl Tertiary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by Volume You may use gasoline containing me...

Page 63: ...0mm Suspension Rear Mono shock 270mm Brakes Front Drum Brakes Rear Disc Single Piston Dual Park Brake Wheel Tyre Front Steel Rim Tubeless 19x7 00 8 Wheel Tyre Rear Steel Rim Tubeless 18x9 50 8 Wheelba...

Page 64: ...60 Spare Part Catalogue...

Page 65: ...61 Spare Part Catalogue...

Page 66: ...62 Spare Part Catalogue...

Page 67: ...63 Spare Part Catalogue...

Page 68: ...64 Spare Part Catalogue...

Page 69: ...65 Spare Part Catalogue...

Page 70: ...66 Spare Part Catalogue...

Page 71: ...67 Spare Part Catalogue...

Page 72: ...68 Spare Part Catalogue...

Page 73: ...69 Spare Part Catalogue...

Page 74: ...www thumpstar com au https www thumpstar co nz Go to our website then copy the part number or ERP CODE in our Spare Part Catalogue and paste it in the search bar then press enter or click the search...

Page 75: ...ry Purchasing a motorcycle in the crate without setup by a Thumpstar Autho rized Dealer void the limited warranty Limited Warranty is not transferable and if valid for original purchaser only USA Comp...

Page 76: ...y of this bike for any specific purpose or user The products in this manual are designed for competition use for a single rider with proper safety equipment Thumpstar also recommends that any minors o...

Page 77: ...fore riding check your local states cities motorcycle codes for more information regarding laws This product is for use on closed private tracks only By purchasing you acknowledge that you have read a...

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