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Drive Chain

LUBRICATION

Lubricate every 300 miles (500 km) or sooner if chain appears dry. Turn

the rear wheel by hand. Saturate each chain link joint so that the lubricant

penetrates between the link plates, pins, bushings, and rollers. Lubricate

with quality chain oil.

CHAIN GUIDE REMOVAL

1. Remove bolt to remove the chain guide and release the chain.

2. Use 8mm spanner in removing the bolt.

Bolt

Summary of Contents for TSK50cc

Page 1: ...MANUAL 3627...

Page 2: ...is resold Thumpstar reserves the right to make changes at any time without notice and without incurring any obligation This publication includes the latest production information available before pri...

Page 3: ...bels 16 Operating Controls 17 Operation Component Locations 17 Fuel Valve 18 Choke Knob 19 Ignition Switch 20 Before Riding 21 Protective Gears 22 Is Your Motorcycle Ready 23 Pre Ride Inspection 24 Ba...

Page 4: ...n 62 Spark Plug 62 Suspension 65 Brakes 67 Wheels 70 Tires Tubes 74 Training Wheel 78 Drive Chain 79 Battery 84 Appearance Care 87 Preparing for a Ride 89 Transporting your Thumpstar 90 Storing your T...

Page 5: ...rch A7TC NGK C7HSA Tire Pressure 20 PSI Front 20 PSI Rear Tire Size 2 50 10 Valve Clearance TSK 50 003 intake 005 exhaust Air Filter TSK 50 Airbox Part Number 1 027 0360 Handle Bar 7 8 560 570mm Wheel...

Page 6: ...rect safety gear and safety procedures Warning Thumpstar is only recommend riding privately on closed course tracks by experienced riders and is not for general offroad recreational use before riding...

Page 7: ...bars and route cables and front brake hose before install ing fork Front brake hose 1 should be at front then throttle cable 2 last the kill switch wire 3 The longer front wheel 1 spacer will always b...

Page 8: ...ront mudguard and ensure step washer are installed correctly Fit foot pegs and use grease on foot peg pins Ensure the correct pressure in tires page 74 Loosen rear wheel adjust chain tension page 80 W...

Page 9: ...erformance Engine break in Run bike at no more than three quarter throttle do not allow engine to rev to a high speed Engine break in should be no less than one hour After one hours carry out the foll...

Page 10: ...s This section 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 sp...

Page 11: ...et that fits correctly Thumpstar strongly recommends the use of eye protection goggles and or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before...

Page 12: ...ibed in this manual Never operate a bike in fast flowing water Wet brakes may have reduced operating ability Test your brakes after contact with water If necessary apply them several times to let fric...

Page 13: ...pe of petrochemicals Gasoline can catch fire and is toxic to life and the environment Thumpstar motorbikes recommend the following safety tips to avoid accidents injury death Always turn off the engin...

Page 14: ...r bike the following list is an advisory guideline of the equipment that should be obtained before using your bike for the first time and to be used for every ride regardless of experience and skill l...

Page 15: ...vide protection from abrasions and help to keep your hands from getting sore tired or cold Note that gloves may become slippery when wet and are not advisable for use FOOTWEAR CLOTHING Sturdy footwear...

Page 16: ...e not the only factors Remember this model is designed for experienced riders only PHYSICAL ABILITY An important consideration that riders must be big enough to hold the motorcycle up get on and comfo...

Page 17: ...dy to ride this motorcycle If you decide that you re ready to safely operate this motorcycle make sure you carefully read and understand the owner s manual before riding Also be sure that you have a h...

Page 18: ...d load can seriously affect your motorcycle s handling braking and stability Adding accessories or making modifications that change this motorcycle s design and performance can also make it unsafe Als...

Page 19: ...Thumpstar accessories Check with your dealer for assistance and always follow this guideline Make sure the accessory does not reduce ground clearance and lean angle limit suspension travel or steering...

Page 20: ...16 Safety Labels WARNING Not wearing a helmet increases thechance of serious injury or death in acrash Be sure you always wear a helmet eye protection and other protective apparel when you ride...

Page 21: ...Engine Stop Switch Front Brake Lever Rear Brake Lever Lanyard START BUTTON The start button is used for starting the engine Pushing the button in starts the engine When the start button is pushed the...

Page 22: ...he closed position engine idle when you remove your hand FUEL VALVE The two way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor ON Turning the fuel valve ON before...

Page 23: ...The choke increases the percentage of fuel in the fuel air mixture delivered to the engine ON Used to start a cold engine with air temperature below 35 C 95 F OFF Used for normal operation for restart...

Page 24: ...torcycle Before riding insert the key and turn it to the right for the ON position Key Position Function Key Removal OFF The engine cannot be operated The key can be removed ON With the engine stop sw...

Page 25: ...perate all the necessary controls Before each ride we also suggest that you make sure you are in good mental physical condition are free of alcohol and drugs are wearing an approved motorcycle helmet...

Page 26: ...any helmet you buy Always wear a face shield or goggles to protect your eyes and help your vision ADDITIONAL PROTECTIVE GEAR In Addition to a helmet and eye protection we also recommend the following...

Page 27: ...kdown far from help NOTE TO PARENTS If a youngster will be performing any of the following pre ride inspection procedures it s your responsibility to provide careful supervision and make sure they are...

Page 28: ...41 67 Engine Oil Check the level and add oil if needed page 44 Fuel Check the level and add fuel if needed Also make sure the fuel fill cap is securely fas tened page 41 Drive Chain Check the conditio...

Page 29: ...s shut automatically when it is released in all steering positions page 56 Brakes Squeeze the front brake lever and step on the rear brake pedal to check that the controls operate normally Adjust free...

Page 30: ...le Safety Even if you have ridden other motorcycles take time to become familiar with how this motorcycle works and handles Practice in a safe area until you build up your skills and get accustomed to...

Page 31: ...E To restart a warm engine follow the procedure for High Air Temperature on page 27 Normal Air Temperature 10 35 C 50 95 F 1 Push the choke knob up all the way to fully ON 2 Press the start button and...

Page 32: ...e 1 Do not use the choke 2 Start the engine See step 2 under Normal Air Temperature Low Air Temperature 10 C 50 F or below 1 Follow steps 1 2 under Normal Air Temperature 2 Warm up the engine by openi...

Page 33: ...ase the brake controls steer straight ahead until you regain control then reapply the brakes more gently Generally reduce your speed or complete braking before beginning a turn Avoid braking or closin...

Page 34: ...ge Servicing Your Thumpstar Keeping your motorcycle well maintained is absolutely essential to your safety It s also a good way to protect your investment get maximum performance avoid breakdowns and...

Page 35: ...rage riding conditions More frequent service is needed if you subject your motorcycle to s evere use or ride in unusually wet or dusty areas Frequent servicing of the air cleaner is especially importa...

Page 36: ...a youngster to perform or assist in any maintenance task such as f illing the tank with gasoline you should provide close supervision to make sure that it is performed safely MAINTENANCE SAFETY The m...

Page 37: ...rom moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and engine unless instructed to do so make sure you have the tools and skills required To help...

Page 38: ...is schedule are provided in a service manual available for purchase from your dealer Because your motorcycle does not have an odometer service intervals in the maintenance schedules are expressed in t...

Page 39: ...ir Filter 1 C Crankcase Breather X Spark Plug X Valve Clearance 4 X Engine Oil 3 X Engine Idle Speed X Drive Chain X L R Drive Chain Slider X Drive Chain Roller X Drive Sprocket X Driven Sprocket X Br...

Page 40: ...l skill 3 Replace after the first break in ride 4 Inspect after the first break in ride Perform the pre ride inspection at each scheduled maintenance period Each item on the maintenance schedule requi...

Page 41: ...nd there are no leaks Check the braking mechanism works manually before riding Some brakes are adjustable for performance reasons brake adjustments are sensitive and in the interest of safety should o...

Page 42: ...to your Bike SPARK PLUG Remove the coil lead from the spark plug Remove the spark plug with the correct tool Ensure the Gap at the contactors is 0 6 0 7mm Clean around the contactors where the spark...

Page 43: ...st the engine id off and test each adjustment afterwards To adjust the Carburetor Support the motorcycle by means of the side stand Adjust the idling speed using the adjustment screw recommended r min...

Page 44: ...hanic page 74 GENERAL CLEANLINESS The cleaning of your motorcycle can prolong the life of many component parts such as plastics brakes and frame etc Jet washing can cause damage to certain components...

Page 45: ...ine speed under normal load change brands of gasoline If pinging or spark knock persists consult your Certified Motorcycle Mechanic Use only unleaded fuel in your Thumpstar If you ride your Thumpstar...

Page 46: ...counterclockwise and remove it 2 Add fuel until the level reaches the bottom of the filler neck Avoid overfilling the tank There should be no fuel in the filler neck Breather Tube Fuel Cap Filler Nec...

Page 47: ...il it is secure 4 Insert the breather tube in the steering stem nut If you replace the fuel fill cap use only a Thumpstar Genuine replacement part Fuel Electric Start Wiring Diagram C A M H M S STARTE...

Page 48: ...ng on the circular API service label viscosity weight SAE 10W 30 10W 40 JASO T 903 standard MA suggested oil 4 stroke oil or an equivalent motorcycle oil For normal air temperatures See next page for...

Page 49: ...is within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard is...

Page 50: ...5 minutes Stop the engine Wait 2 3 minutes 4 Unscrew and remove the oil fill cap dipstick Wipe it clean 5 Hold the motorcycle upright 6 Insert the oil fill cap dipstick until it seats but do not screw...

Page 51: ...ur the drained oil into a suitable container and dispose of it in an approved manner 8 Remove the old sealing washer and install a new sealing washer on the drain bolt 9 Install the oil drain bolt and...

Page 52: ...s High altitude performance can be improved by specific modifications to the carburetor If you always operate your engine at altitudes above 6 500 feet 2 000 meters have your servicing dealer perform...

Page 53: ...e over a given portion of throttle valve opening These circuits overlap as show below MAIN JET The main jet affects fuel air ratio from half 1 2 to full throttle 4 4 The size should be reduced at high...

Page 54: ...jet and pilot screw affects fuel air ratio over fully closed to 1 4 throttle Adjust the pilot screw tot obtain the best off idle performance If the engine blubbers rich exiting a corner turn the pilo...

Page 55: ...Screw Opening Slow Pilot Jet Needle Clip Position Main jet ADJUSTMENTS FOR ALTITUDE TEMPERATURE All jetting recommendations are based on standard jetting with an unmodified engine The following condit...

Page 56: ...should not be necessary to go more than one jet size richer or leaner to fine tune your Thumpstar If larger jetting changes are necessary check for air leaks blocked or restricted exhaust or fuel syst...

Page 57: ...he correct service interval for your riding conditions Your motorcycle s air cleaner has very specific performance requirements Use a new Thumpstar Genuine air cleaner specified for your model or an a...

Page 58: ...for tears or cracks in the foam orseams of the air cleaner Re place the aircleaner if it is damaged 5 Allow the air cleaner to dry thoroughly before applying oil A wet air cleaner will not fully abso...

Page 59: ...e clutch adjuster clockwise one turn do not turn excessively 3 Slowly turn the adjuster counterclockwise until a slight resistance is felt 4 From this position turn the adjuster clockwise 1 8 turn and...

Page 60: ...2 Loosen the upper lock nut on the throttle cable mechanism 3 Turn the upper adjuster 4 Tighten the lock nut Return the dust coverto its normal position 5 After adjustment check for smooth rotationof...

Page 61: ...ride The more the adjuster is screwed in the less the children to be able to turn the throttle For full throttle when throttle limiter is not being used we recommend installing a smaller screw 1 Loose...

Page 62: ...steering positions If there is a problem see your Certified Motorcycle Mechanic 3 Inspect the condition of the throttle cables from the throttle grip down to the carburetor If the cable is kinked or c...

Page 63: ...Rotate the generator flywheel counterclockwise until the T mark on the flywheel lines up with the index mark on the left crankcase cover In this position the piston may either be on the compression o...

Page 64: ...lock nut while holding the adjusting screw to prevent it from turning Finally recheck the clearance to make sure that the adjustment has not been disturbed 7 Check that the mount rubbers in good condi...

Page 65: ...for faults in other systems by adjusting idle speed See your Certified Motorcycle Mechanic for regularly scheduled carburetor adjustments 1 Warm up the engine shift to neutral and place the motorcycle...

Page 66: ...e recommended heat range NOTICE Using spark plugs with an improper heat range can cause engine damage 1 Clean any dirt from around the spark plug base 2 Disconnect the spark plug cap 3 Remove the spar...

Page 67: ...1 6 turn after it seats If installing a new plug tighten it twice to prevent loosening a First tighten the plug NGK 1 4 turn after it seats b Then loosen the plug c Next tighten the plug again 1 6 tur...

Page 68: ...ir leaks in the inlet tract or exhaust system the passage of too much air because of the use of the wrong air cleaner use of a less restrictive aftermarket exhaust system or a hole or holes deliberate...

Page 69: ...etermine whether or not replacement parts or repairs are needed FRONT SUSPENSION INSPECTION 1 Check fork operation Pull the front brake lever in to lock the brake Then pump up and down on the fork leg...

Page 70: ...ent points are secure 3 Check for oil leaks in the shock absorber If any rear suspension com ponents appear worn or damaged see your Certified Motorcycle Mechanic for further inspection REAR SUSPENSIO...

Page 71: ...not feel within the normal range while riding check the brake pads If they are not worn beyond the recommended limit there is probably air in the brake system See your Certified Motorcycle Mechanic d...

Page 72: ...ads at each regular maintenance interval Check the cutout in each pad If either pad is worn to the cutout replace both pads as a set See your Certified Motorcycle Mechanic for this ser vice Check that...

Page 73: ...69 Brakes FRONT AND REAR BRAKE LEVER FREEPLAY Adjust the freeplay of the brake lever with the front wheel pointed straight ahead Front Brake Lever Rear Brake Lever...

Page 74: ...ot covered by warranty It s also important that the rim locks are secure to prevent tire slippage It is not necessary to remove the wheels to perform the recommended ser vice in the Maintenance Schedu...

Page 75: ...ear of the motorcycle with tie down straps 2 Remove the front axle nut 19mm and front axle shaft 3 Remove the wheel 4 Pull the brake assembly out carefully Take care to prevent getting grease oil or d...

Page 76: ...as soon as possible to verify proper assembly Im proper assembly may lead to loss of braking capacity REAR WHEEL REMOVAL 1 Raise the rear wheel off the ground by placing a maintenance stand or support...

Page 77: ...s can cause poor brake performance or rapid brake shoe wear after reassembly REAR WHEEL INSTALLATION 1 Reverse the removal procedure Install the side collar into the wheel 2 Adjust the drive chain 3 T...

Page 78: ...ing tread life and riding comfort Generally underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Underinflated tires can also cause wheel damag...

Page 79: ...to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are Front 20 psi 138 kPa 1 4 kgf cm Rear 20 psi 138 kPa 1 4 kgf cm If you decide to adjust tire...

Page 80: ...heck the position of both valve stems A tilted valve stem indicates the tube is slipping inside the tire or the tire is slipping on the rim See your Certified Motorcycle Mechanic TUBE REPLACEMENT If a...

Page 81: ...to the original Replace the tube any time you replace a tire The old tube will probably be stretched and if installed in a new tire could fail Have the wheel balanced after a new tire is installed We...

Page 82: ...he motorcycle they are available for learners until they have developed a utilizable sense of balanceon the motorcycle The training wheel can be installed by inserting it in the 4 slot located on the...

Page 83: ...e rear wheel by hand Saturate each chain link joint so that the lubricant penetrates between the link plates pins bushings and rollers Lubricate with quality chain oil CHAIN GUIDE REMOVAL 1 Remove bol...

Page 84: ...r transmission is in neutral It is not necessary to remove or replace the drive chain to perform the rec ommended service in the Maintenance Schedule INSPECTION 1 Check slack in the lower drive chain...

Page 85: ...cycle Mechanic replace the chain slider 5 Replace the drive chain if chain slack is excessive when the rear axle is moved to the farthest limit of adjustment Excessive slack indicates the chain is wor...

Page 86: ...th the adjuster block on both sides of the swingarm 5 Torque the rear axle nut to 47 lbf ft 64 N m 6 5 kgf m 6 Recheck drive chain slack 7 Check rear brake pedal freeplay and adjust as necessary Freep...

Page 87: ...wise appears unserviceable Replacement chain 428 Chain and heavy duty brackets 3 Inspect the sprocket teeth for wear or damage We recommend replacing the sprocket whenever a new chain is installed 5 L...

Page 88: ...nt from the battery even when the ignition is OFF Limited operation also allows the battery to discharge If you have electrical accessories on your motorcycle or do not ride frequently we recommend th...

Page 89: ...it every 30 days Before you remove the battery be sure to read all the information that follows as well as the information on the battery label The battery is located in the battery compartment behin...

Page 90: ...area 9 Slow charge the battery see following section once every 30 days INSTALLATION 1 Reinstall in the reverse order of removal Be sure to connect the posi tive terminal first then the negative termi...

Page 91: ...degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your motorcycle If your motorcycle is still warm from recent oper...

Page 92: ...s 6 Lubricate the drive chain to prevent rusting 7 Start the engine and let it idle for several minutes The engine heat will help dry moist areas 8 As a precaution ride at a slow speed and apply the b...

Page 93: ...Canada only riding clubs and off road magazines are good sources of information WHAT TO TAKE TO THE RIDING AREA Along with your motorcycle and riding gear you should take along some tools and supplies...

Page 94: ...or trailer rail Attach 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...

Page 95: ...ard STORING YOUR THUMPSTAR MOTORCYCLE If you won t be riding for an extended period such as during the winter thoroughly inspect your motorcycle and correct any problem before stor ing it That way nee...

Page 96: ...ature variation 10 Cover your motorcycle with a porous material Avoid using plastic or similar nonbreathing coated materials that restrict air flow and allow heat and moisture to accumulate REMOVAL FR...

Page 97: ...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 98: ...94 POOR PERFORMANCE AT LOW AND UNSTABLE IDLE SPEED CHECK POSSIBLE CAUSES Troubleshooting...

Page 99: ...95 Troubleshooting BLOCKED NOT BLOCKED...

Page 100: ...ne performance and may be illegal Choose Sensible Cleaners Use a biodegradable detergent when you wash your motorcycle Avoid aerosol spray cleaners that contain chlorofluoro carbons CFCs which damage...

Page 101: ...cide 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 to...

Page 102: ...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 103: ...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 flat tire on...

Page 104: ...n you get home thoroughly check your motorcycle 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 CO...

Page 105: ...ment 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...

Page 106: ...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 107: ...s 550mm 41 45mm Tube Suspension Rear Mono shock Length 240mm Brakes Front Disc Single Piston Brakes Rear Disc Single Piston Wheel Tyre Front Steel Rim 2 50 10 Wheel Tyre Rear Steel Rim 2 50 10 Wheelba...

Page 108: ...104 Spare Part Catalogue Model Version VR 2...

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Page 122: ...118 Spare Part Catalogue...

Page 123: ...119 Torque Settings USE BLUE MEDIUM STRENGTH THREAD LOCK GLUE NOTE Put glue on tip of the bolt for glue to work correctly Places to use Thread Lock Glue...

Page 124: ...120 Torque Settings 1 2 3 4 5 14 6 7 8 9 15 16 10 17 11 12 12 13...

Page 125: ...88 9 0 7 Front axle pinch bolts 15 20 2 0 8 Rear axle nut 94 128 13 1 9 Chain adjuster lock nuts 20 27 2 8 10 Mid engine hanger bracket nut 47 64 6 5 11 Upper engine hanger plate nuts engine side 40...

Page 126: ...122 18 22 23 35 24 27 28 29 30 31 20 21 19 32 33 34 25 26 Torque Settings...

Page 127: ...bolt 51 69 7 0 28 Fork protector bolts 5 2 7 0 7 29 Muffler mounting bolts right 19 26 2 7 left 19 26 2 7 30 Exhaust joint pipe mounting bolt 19 26 2 7 31 Exhaust joint pipe clamp bolt 15 21 2 1 32 D...

Page 128: ...s 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 129: ...ery 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 Com...

Page 130: ...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 131: ...efore 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...

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