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Thumpstar ATV 125CC, Owner'S Manual

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Thumpstar ATV 125CC Owner'S Manual Download Page 146

139

Taking care of the Unexpected

IF YOU  CRASH

Personal safety is your first priority after a crash. If you or anyone else has 

been injured, take time to assess the severity of the injuries and whether it 

is safe to continue riding. If you cannot ride safely, send someone for help. 

Do not ride if you will risk further injury.

If you decide that you are capable of riding safely, first evaluate the condi-

tion of your ATV. If the engine is still running, turn it off and look it over 

carefully; inspect it for fluid leaks, check the tightness of critical nuts and 

bolts, and secure such parts as the handlebar, control levers, brakes, and 

wheels.

If there is minor damage, or you are unsure about possible damage but 

decide to try riding the ATV back to your base, ride slowly Personal safety 

is your first priority after a and cautiously.

Sometimes, crash damage is hidden or not immediately apparent. When 

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 FAILS

The drive chain, master link, brake lever or pedal, control cables, and 

other components can be damaged as you ride in dense brush or over 

rocky terrain. Making a trailside repair depends on how serious the 

damage is and what tools and supplies you have with you.

•  If the drive chain comes off because the master link clip gets knocked 

off, you may be able to put the chain back on with a new master link. 

However, if the chain brakes or does other damage when it comes off, 

you may not be able to make a trailside repair.

•  If any component of the front brake system is damaged, you may be 

able to ride carefully back to your base using the rear brake for slowing 

or stopping.

•  If you damage a throttle cable or other critical component, your ATV 

may be unsafe to ride. Carefully assess the damage and make any re-

pairs that you can. But if there is any doubt, it’s best to be conservative 

and safe.

Summary of Contents for ATV 125CC

Page 1: ...MANUAL 3627...

Page 2: ...and 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 pr...

Page 3: ...Fasteners 17 Instrument Lights And Switches 17 Operation ATV 70 18 To Start Out And Accelerate 18 To Decelerate 18 Engine Break In 19 Operation ATV 125 20 Remote Engine Stop Switch 20 Break In 22 Ins...

Page 4: ...er Adjustment 43 Rear Shock Absorber Adjustment 43 ATV 70 Periodic Service 44 ATV 70 Component Inspection 46 Engine 46 Engine Oil 46 Idle Speed Adjustment 47 Throttle Speed Adjustment 48 Brake Lever L...

Page 5: ...Speed Adjustment 63 Throttle Cable Adjustment 64 Fuel Hose 64 Engine Oil 64 Brake 65 Brake Adjustment 65 Brake Oil 66 Brake Friction 66 Tires 67 Tire Pressure 68 Tire Replacement 68 Tubeless Tire Repa...

Page 6: ...id Level 100 Checking The Front Brake Level Free Play 103 Checking The Brake Pedal Height 103 Checking The Clutch Lever Free Play 104 To Check The Drive Chain Slack 105 Lubricating The Drive Chain 107...

Page 7: ...ting your Thumpstar 134 You the Environment 135 Taking Care of the Unexpected 136 Technical Information 140 Specification 141 ATV 70 141 ATV 125 142 ATV 250 143 Spare Part Catalogue 144 ATV 70 144 ATV...

Page 8: ...rating your vehicle Make sure you understand all instructions Pay close attention to the warning and caution labels on the vehicle Never operate an ATV without proper training or instruction IMPORTANT...

Page 9: ...s 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 message for pare...

Page 10: ...le operating this ATV Never operate at speeds too fast for your skills or the conditions Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in...

Page 11: ...d death while operating quads Adult sized quad bikes should not be operated by children Even the smaller youth quads have been involved in fatal incidents in Australia Quad bike accidents are common a...

Page 12: ...tand all of the labels on your quad They contain information for safe proper operation of your quad Never remove any labels from your quad If a label becomes difficult to read or comes off a replaceme...

Page 13: ...6 Safety Labels Rear Brake Lever Parking Brake Main Switch Handle Bar Throttle Lever Speed Limiter Front Brake Lever LOCATION OF PARTS Rear Bumper Seat Lock Battery...

Page 14: ...7 Safety Labels ATV 125...

Page 15: ...8 LOCATION OF PARTS Bumper Headlight Rear Shock Parking Brake Stop Switch Thumb Throttle Lever Fuel Tank Cover Indicator Switch Electric Start Headlight Switch Safety Labels...

Page 16: ...tand all of the labels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label become difficult to read or comes off reque...

Page 17: ...10 Safety Labels 6...

Page 18: ...11 LOCATION OF PARTS 1 Front Shock Absorber 2 Fuel Tap 3 Rear Shock Absorber 4 Owner s Tool Kit 5 Air Filter 2 3 4 5 Safety Labels...

Page 19: ...12 Safety Labels 1 Spark Plug 2 Fuse 3 Battery 1 Clutch Lever 2 Handlebar Switches 3 Main Switch 4 Front Brake Fluid Reservoir 4 Fuel Tank Cap 5 Brake Pedal 5 Throttle Lever 6 Brake Lever 2 3 1 5 4...

Page 20: ...ngine Oil Check oil level in engine and add recommended oil to specified level if necessary Check ATV for oil leakage Correct if necessary Radiator Check colling liquid in radiator and add colling liq...

Page 21: ...y Check chain condition Lubricate if necessary Wheels and Tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if nec essary Check air pressure Correct if Sh...

Page 22: ...system Check for correct brake pedal height If the pedal height is incor rect have a dealer adjust it Check the operation of the lever and pedal They should move smoothly and there should be a firm fe...

Page 23: ...use severe injury or death from loss of control or rollover Tire pressure below the minimum specified could also cause the tire to dislodge from the rim un der severe riding conditions Set tire pressu...

Page 24: ...n approved for this model FRONT Size AT20 7 0 10 Type Tubeless REAR Size AT19 10 9 Type Tubeless AFTERMARKET TIRES AND RIMS The tires and rims that came with your ATV were designed to match the perfor...

Page 25: ...rous Make sure everything is working smoothly before starting TO START OUT AND ACCELERATE 1 Release the parking brake 2 Open the throttle gradually 3 Once the vehicle has attained adequate speed relea...

Page 26: ...position 10 20 HOURS Avoid prolonged operation above 3 4 throttle Rev the vehicle freely but do not use full throttle at any time AFTER BREAK IN Avoid prolonged full throttle operation Vary speeds occ...

Page 27: ...ains the young rider should always use this lanyard until the rider develops sufficient skills for safe operation of the vehicle This switch consists of a rubber cap tted over a plastic body When the...

Page 28: ...n 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 the...

Page 29: ...ome 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 light load can...

Page 30: ...e 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 Brakes...

Page 31: ...Instructing and Young Rider section 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 th...

Page 32: ...ack to its disengaged position 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 fo...

Page 33: ...ent 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 could oc...

Page 34: ...s 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 tur...

Page 35: ...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 experiences inadve...

Page 36: ...ven 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 cap...

Page 37: ...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 of the...

Page 38: ...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 steady...

Page 39: ...key to ON and the engine stop 3 Shift the transmission into neutral The neutral Indicator light should come on If the indicator lights does not come on have a dealer check the electrical circuit NOTE...

Page 40: ...4 speed forward transmission The transmission allows you to control the amount of power you have available at a given speed or for starting accelerating climbing hills etc To shift into neutral relea...

Page 41: ...time release the clutch lever slowly WARNING Opening the throttle abruptly or releasing the clutch lever too quickly could make the ATV wheelie which would increase the change of an acci dent includi...

Page 42: ...smission is properly lubricated only when the engine is running Inadequate lubrication may damage the transmis sion Always use the clutch when changing gears The engine transmission and drive train ar...

Page 43: ...d to assist you in the performance of pre ventive maintenance and minor repairs However additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly NOTE Mak...

Page 44: ...37 ATV 70 atv 70CC...

Page 45: ...n THROTTLE Once the engine is running movement of the throttle lever will increase the engine speed Regulate the speed of the engine by varying the throttle position Because the throttle is spring loa...

Page 46: ...on and can be used at all times to stop the engine especially in an emergency The engine will not start or run when the engine stop switch is turned to START SWITCH The starter motor cranks the engine...

Page 47: ...operate properly If this should happen remove the battery and recharge it replace if necessary REAR BRAKE LEVER The brake lever is located on the left side of the handle bar Pull down on the lever to...

Page 48: ...the maximum speed of the ATV For children s safety the ATV has been adjusted to a speed under 15km h 9 3 mph SEAT To remove the seat pull the seat lock lever upward and pull up the seat at the rear Do...

Page 49: ...rning it counterclockwise Automotive gasoline with octane number of 91 or higher may be used After refueling be sure to tighten the tank cap firmly FRONT BRAKE LEVER The brake lever is located on the...

Page 50: ...he spring preload turn the adjuster in direction a To decrease the spring preload turn the adjuster in direction b REAR SHOCK ABSORBER ADJUSTMENT The spring preload can be adjusted to suit the vehicle...

Page 51: ...ours more often if wet or dusty areas Carburetor Check idle speed starter operation Adjust if necessary O O O O Cylinder Head Cover Breather System Check breather hose for cracks or damage Replace if...

Page 52: ...eck pressure and wear Replaced if damaged O O O O O Wheel Bearings Check bearing assembly for looseness or damage Replace if damage O O O O Steering System Check operation replace if damaged Check toe...

Page 53: ...the vehicle on a level surface b Warm up the engine for several minutes and stop it c Wait a few minutes until the oil level settles before checking d Remove the dipstick and wipe it off with a clean...

Page 54: ...iagnostic tachometer must be used for this procedure 1 Start the engine and warm it up for a few minutes at approximately 1000 to 2000 r min Occasionally rev the engine to 4000 to 5000 r min The engin...

Page 55: ...til the throttle lever free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut The rear brake free play should be 20 25 mm 0 80 1 0 in If the free play is incorrect adjust it as follows 1 Raise the rea...

Page 56: ...SE REPLACEMENT If the fuse is blown turn off the main switch and install a new fuse of the specified amperage Then turn on the switches If the fuse immediately blows again consult your dealer Specifie...

Page 57: ...battery asks for no replenishment Just enjoy easy use and sound performance REPLACING THE HEADLIGHT BULB If the headlight bulb is burnt remove the headlight unit assembly take out the defective bulb...

Page 58: ...51 ATV 125 atv 125CC...

Page 59: ...e by 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 id...

Page 60: ...Release 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 engin...

Page 61: ...ap turn 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...

Page 62: ...n during 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 pre...

Page 63: ...FAMILIARIZATION 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 op...

Page 64: ...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 th...

Page 65: ...ctice 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...

Page 66: ...the 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 th...

Page 67: ...C MAINTENANCE 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...

Page 68: ...h dust 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...

Page 69: ...e for 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...

Page 70: ...is 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 the correct level Make sure that the...

Page 71: ...the 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...

Page 72: ...he Maintenance 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 brak...

Page 73: ...xamined to ensure that the brake oil never be leak Repeat this procedure until the parking brake is properly adjusted 4 Measure the amount of free play needed to click the brake lever Adjust the brake...

Page 74: ...ke sure 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 t...

Page 75: ...air 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 ri...

Page 76: ...e 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 ro...

Page 77: ...dren 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 dama...

Page 78: ...Inspect 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...

Page 79: ...72 ATV 250 atv 250CC...

Page 80: ...switch are as follows ON All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All...

Page 81: ...utral position ENGINE STOP SWITCH This indicator light comes on when the transmission is in neutral position The engine stop switch controls the ignition and stops the engine when it is running Use th...

Page 82: ...ke NOTE Do not use the headlights with the engine turned off for an extended period of time otherwise the battery may discharge to the point that the starter motor will not operate properly If this sh...

Page 83: ...and the maximum speed of the ATV turn the adjusting screw counter clockwise To decrease the maximum engine power available and the maximum speed of the ATV turn the adjusting screw clockwise Do not t...

Page 84: ...To disengage the clutch pull the clutch lever toward the handlebar grip To engage the clutch release the clutch lever The clutch lever should be pulled rapidly and released slowly for smooth clutch o...

Page 85: ...ght side of the ATV To apply the rear brake push down on the brake pedal SHIFT PEDAL This ATV is equipped with a constant mesh 4 speed transmission The shift pedal is located on the left side of the e...

Page 86: ...g turn off the engine and be sure that no one is sitting on the vehicle Never refuel while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights...

Page 87: ...should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills...

Page 88: ...not running ON RES This indicates reserve With the fuel tap lever in this position the fuel reserve is made available Turn the fuel tap lever to this position if you run out of fuel while riding When...

Page 89: ...of the seat and the rear fender pull the seat lock lever upward and pull up the seat at the rear To install the seat Insert the projections on the front of the seat into the seat holders and push dow...

Page 90: ...ity which could lead to an accident Adjust the spring preload as follows Turn the spring preload adjusting ring clockwise to increase the spring preload and thereby harden the suspension and turn coun...

Page 91: ...spring WARNING This shock absorber assembly contains highly pressurized nitrogen gas If the shock absorber assembly is damaged it could explode causing injury or properly damage Shock absorber cylind...

Page 92: ...a dealer perform the service WARNING Turn off engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical pa...

Page 93: ...the month maintenance intervals For ATVs equipped with an odometer or an hour meter follow the km mi or hours maintenance intervals However keep in mind that if the ATV isn t used for a long period of...

Page 94: ...h maintenance intervals For ATVs equipped with an odometer or an hour meter Follow the km mi or hours maintenance intervals However keep in mind that if the ATV isn t used for a long period of time th...

Page 95: ...you are not familiar with vehicle service have a dealer perform the service CHECKING THE SPARK PLUG The spark plug is an important engine component which is easy to check Since heat and deposits will...

Page 96: ...f the spark plug is a medium to light tan the ideal color when the ATV is ridden normally NOTE If the spark plug shows a distinctly different color the engine could be operating improperly Do not atte...

Page 97: ...spark plug threads 2 Install the spark plug with the spark plug wrench and then tighten it to the specified torque Tightening torque Spark plug 18Nm 1 8m kgf 13ft lbf NOTE If a torque wrench is not av...

Page 98: ...l level on a cold engine NOTE If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil set tles for an accura...

Page 99: ...ult 6 Insert the dipstick into the oil filter hole and then tighten the engine filter cap TO CHANGE THE ENGINE OIL WITH OR WITHOUT OIL FILTER ELEMENT REPLACEMENT 1 Place the ATV on a level surface 2 S...

Page 100: ...r higher Make sure that no foreign material enters the crankcase 7 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the en...

Page 101: ...ments 1 Air filter case check hose 1 Place the ATV on a level surface 2 Remove the seat 3 Remove the air filter case cover by unhooking the holders 4 Loosen the wing bolt 5 Remove the air filter eleme...

Page 102: ...e and Adjustments 1 Air filter element 2 Washer 3 Wing bolt 6 Remove the wing bolt and washer from the air filter element 7 Remove the sponge material from the air filter element frame 1 Sponge materi...

Page 103: ...re or explode 9 Squeeze the excess solvent out of the sponge material and let it dry NOTE Do not twist the sponge material when squeezing it 10 Check the sponge material and replace it if damaged 11 A...

Page 104: ...ble engine damage Additionally operation without the air filter ele ment will affect carburetor jetting with subsequent poor performance and possible engine overheating 16 Install the air filter case...

Page 105: ...g these settings without sufficient technical knowledge may result in poor performance of or damage to the engine ADJUSTING THE ENGINE IDLING SPEED The engine idling speed must be checked and if neces...

Page 106: ...d in the periodic maintenance and lubrication chart The throttle lever free play should measure 2 0 4 0 mm 0 08 0 16 in as shown Periodically check the throttle lever free play and if necessary adjust...

Page 107: ...t the intervals specified in the periodic maintenance and lubrication chart BRAKES Replacement of the brake components requires professional knowledge Brake service should be performed by a dealer WAR...

Page 108: ...to be removed to check the brake pads REAR BRAKE PADS Each brake pad is provided with two wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake To...

Page 109: ...bolling point of the fluid and may result in vapor lock NOTE Brake fluid may damage painted surfaces or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is normal for...

Page 110: ...play as shown If there is free play have a dealer check the brake system 1 No brake level free play CHECKING THE BRAKE PEDAL HEIGHT The brake pedal height must be checked and if necessary adjusted at...

Page 111: ...maintenance and lubrication chart The clutch lever free play should measure 5 0 10 0 mm 0 20 0 39 in as shown if the free play is incorrect adjust it as follow 1 Loosen the locknut t the clutch lever...

Page 112: ...ride and adjusted if necessary TO CHECK THE DRIVE CHAIN SLACK 1 Place the ATV on a level surface NOTE When checking and adjusting the drive chain slack there should be no weight on the ATV and all tir...

Page 113: ...xle pinch bolt 2 Rod 3 Drive chain tensioner 4 Hole NOTE A rod can be obtained at a dealer to make this adjustment 4 Shift the transmission into neutral 5 To tighten the drive chain push the ATV backw...

Page 114: ...IVE CHAIN The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart otherwise it will quickly wear out especially when riding in dusty...

Page 115: ...when the cable sheaths become damaged and cables can also become frayed or kinked which could restrict the operation of controls and lead to an accident or injury Always make sure all control cables w...

Page 116: ...LUBRICATING THE BRAKE PEDAL The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricated if necessary CHECKING THE WHEEL HUB BEARINGS The front and rea...

Page 117: ...by a dealer at the intervals speci fied in the periodic maintenance and lubrication chart LUBRICATING THE UPPER AND LOWER ARM PIVOTS The upper and lower arm pivots must be lubricated at The intervals...

Page 118: ...111 ATV 250 Periodic Maintenance and Adjustments LEFT SIDE 1 Upper grease nipple 2 Lower grease nipple RIGHT SIDE 1 Upper grease nipple 2 Lower grease nipple...

Page 119: ...ery lead connections need to be checked and if necessary tightened WARNING Battery electrolyte is poisonous and dangerous as it contains sulfuric acid which can cause severe burns Avoid contact with s...

Page 120: ...ery lead connections need to be checked and if necessary tightened WARNING Battery electrolyte is poisonous and dangerous as it contains sulfuric acid which can cause severe burns Avoid contact with s...

Page 121: ...TTERY 1 Remove the seat 2 Unhook the band securing the owner s tool kit and then remove the battery holding plate by removing the bolts 3 Disconnect the negative battery lead first then the positive b...

Page 122: ...y a special constant voltage battery charger is required Using a conventional battery charger will damage the battery TO STORE THE BATTERY If the ATV will not be used for more than one month remove th...

Page 123: ...ling the battery the main switch must be off and the positive lead must be connected before the negative lead 3 Install the battery holding plate by installing the bolts and then hook the band to secu...

Page 124: ...Always use a fuse of the specified rating and never use a substitute object In place of the proper fuse An improper fuse or substitute object can cause damage to the electrical system which could lea...

Page 125: ...rns out replace it as follows 1 Remove the headlight unit by removing the bolt 2 Disconnect the headlight coupler 3 Remove the headlight bulb holder cover 4 Remove the headlight bulb holder by pushing...

Page 126: ...will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 6 Install the headlight bulb holder by pushing it in an...

Page 127: ...make this adjustment To raise a headlight beam turn the headlight beam adjusting bolt count er clockwise To lower a headlight beam turn the adjusting bolt clockwise REPLACING THE TAIL BRAKE LIGHT BULB...

Page 128: ...4 Remove the nuts from the wheel 5 Remove the wheel NOTE 1 Place the ATV on a level surfaces 2 Install the wheel and nuts 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torque...

Page 129: ...te engine stop 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 130: ...ole 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 1 Ma...

Page 131: ...ble 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...

Page 132: ...125 POOR PERFORMANCE AT LOW AND UNSTABLE IDLE SPEED CHECK POSSIBLE CAUSES Troubleshooting...

Page 133: ...126 Troubleshooting BLOCKED NOT BLOCKED...

Page 134: ...mportant 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 or...

Page 135: ...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 136: ...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 137: ...130 Circuit Diagram ATV 70 ATV 125...

Page 138: ...cleaner degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your ATV If your ATV is still warm from recent operation...

Page 139: ...e 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 brakes several times Th...

Page 140: ...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 141: ...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 142: ...formance and may be illegal Choose Sensible Cleaners Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluorocarbon CFCs which damage the atmosphere...

Page 143: ...decide 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...

Page 144: ...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 145: ...ir 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 f...

Page 146: ...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 147: ...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 148: ...um Brakes Rear Disc Single Piston Dual Park Brake Wheel Tyre Front Steel Rim Tubeless 145 70 6 Wheel Tyre Rear Steel Rim Tubeless 145 70 6 Wheelbase 830mm 33 Seat Height 620mm 24 Carton Dimensions 120...

Page 149: ...Single Piston Dual Park Brake Wheel Tyre Front Steel Rim Tubeless 19x7 00 8 Wheel Tyre Rear Steel Rim Tubeless 18x9 50 8 Wheelbase 1000mm 39 Seat Height 700mm 28 Carton Dimensions 1200 760 640mm 60m3...

Page 150: ...isc Brakes Rear Hydraulic Disc Wheel Tyre Front 20x7 00 10 Wheel Tyre Rear 19x10 00 9 Wheelbase 1090mm 43 Seat Height 790mm 31 Carton Dimensions 1625 1060 1065mm 1 83m3 Weight n w g w 117kg 158kg Tank...

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Page 159: ...152 Spare Part Catalogue NOTE For full ATV 70 Manual please check ATV 70 product page or database at the Thumpstar Website...

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Page 169: ...162 Spare Part Catalogue NOTE For full ATV 125 Manual please check ATV 125 product page or database at the Thumpstar Website...

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Page 177: ...170 Spare Part Catalogue NOTE For full ATV 250 Manual please check ATV 250 product page or database at the Thumpstar Website...

Page 178: ...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 179: ...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 180: ...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 on...

Page 181: ...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...

Page 182: ...175 Title Ownership NAME BUYER SIGNATURE SELLER SIGNATURE DATE OF PURCHASE by Thumpstar All rights reserved...

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