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16.

MAINTENANCE & ADJUSTMENT

FRONT AND REAR BRAKE PAD INSPECTION

A wear indicator is provided on each brake pad. The indicator allows checking 

the brake pad wear without disassembling the calliper. If the brake pads are 

worn to the wear limit they will need to be replaced.

BRAKE FLUID LEVEL INSPECTION

Insufficient brake fluid may let air enter the brake system. Possibly causing the 

brakes to become ineffective.

Before riding, check the brake fluid is above the minimum level mark and 

replenish if necessary. A low brake fluid level may indicate a worn brake pads 

and/or brake system leakage. If the brake fluid level is low be sure to check 

brake pads for wear and brake system for leakage.

 

• When checking the brake fluid level, make sure the top of the brake  

 

   fluid reservoir is level

 

• Use only DOT 4 Brake fluid, otherwise the rubber seal may deterio 

 

  rate, causing leakage and poor brake performance

 

• Refill with the same type of brake fluid. Mixing fluid may result in  

 

  harmful chemical reaction and lead to poor brake performance

 

• Be careful no water enters the brake fluid reservoir when refilling.  

 

   Water will significantly lower the boiling point of the fluid and may  

 

   result in a vapour lock

 

• Have your dealer check the cause if the brake fluid level goes down

PARKING BRAKE ADJUSTMENT

Parking brake adjustment may be required if the parking brake does not hold 

properly. The cable length (A in diagram) should be adjusted to 50-55mm.

 

 

1. Fully loosen the locknut 1 at the rear caliper

 

2. Tur the adjusting nut 1 on the brake lever counter clockwise to  

 

increase the cable length or clockwise the cable length

 

3. Tighten the lock nut at the rear caliper

DRIVE CHAIN SLACK CHECK

Inspect the drive chain while all tyres are touching the ground. Check the 

slack of the drive chain. The normal vertical deflection is approx.. 15-25mm. If 

the deflection exceeds 300, adjust the chain slack.

DRIVE CHAIN SLACK ADJUSTMENT

 

1. Loosen the locknut of the engine install bolt

 

2. Turn the adjusting nut on the engine install bolt clockwise to tighten  

 

    the drive chain or counter clockwise to loosen

 

3. Tighten the locknut of the engine install

 

4. Adjust nut torque – 45Nm

LUBRICATING THE DRIVE CHAIN

The drive chain must be checked prior to every ride and if required cleaned 

and lubricated. Otherwise it will quickly wear out. Especially when riding in 

dusty or wet areas. Service the drive chain as follow:-

CAUTION: 

The drive chain must be lubricated after washing the product

FRONT UPPER AND LOWER ARM PIVOT LUBRICATION 

Recommended lubricant is a Lithium-soap-based grease

Содержание HAMMER DUNE

Страница 1: ...ire manual before riding DO NOT RETURN TO STORE WWW GMXMOTORBIKES COM AU ATV OFF ROAD HAMMER DUNE BUGGY NOTE Manual illustrations are for demonstration purposes only Illustrations man not reflect exact appearance of actual product ...

Страница 2: ...of alcohol drugs Ensure children are supervised at all times on or around any activity on motorised vehicles Always carry a mobile phone or radio device so you can contact help in case of an emergency WEAR SAFE Always wear a helmet Wear protective clothing and gear such as goggles long sleeves long pants boots and gloves hand protection Ensure that you understand your quad bike by reading going ov...

Страница 3: ...F POSITION WHEN NOT IN USE OR REMOVE KEYS KEY REMOVAL WARNING Please use unleaded fuel 90 Octane or above UNLEADED FUEL ONLY WARNING This product is powered by a 4 stroke engine and comes with transport oil in the engine THE OIL NEEDS TO BE DRAINED AND REPLACED WITH MOTORCYCLE OIL 10W 40 or 10W 50 IS REQUIRED IF THE OIL CHANGE IS NOT PERFORMED YOU MAY INTERNALLY DAMAGE THE ENGINE AND CLUTCH AND VO...

Страница 4: ...s required In the interest of safety and future warranty claims it is recommended that you have this product assembled by a qualified skilled motorcycle mechanic You may need to provide proof for this product of being assembled by a skilled motorcycle mechanic or small engine mechanic a report dvising of the issues may be needed to process your warranty claims The warranty is a parts replacement w...

Страница 5: ...ONTENT SAFETY INFORMATION CONSUMER RESPONSIBILITY BELT RESTRAINT SYSTEM PRE RIDE INSPECTION ASSEMBLY SAFETY PRECAUTIONS RIDING PRACTICES 1 2 3 5 6 7 12 OPERATING THE PRODUCT MAINTENANCE ADJUSTMENT 13 21 ...

Страница 6: ...1 ...

Страница 7: ...Turn off ...

Страница 8: ...rator of this product The operator must be of appropriate age weight height in order to operate this product The operator must be of sound mental and physical capacity in order to safely operate this product Passengers of this product are under the full responsibility of the operator The passenger must be of appropriate age weight and height and must be of sound mental and physical capacity in ord...

Страница 9: ...any fuel in the breather hose or filler neck Always use an approved petrol cap for this product Never refill while inside a building or in a building without appropriate ventilation Never fill up near extreme sources of heat live wires naked flames or any other type of heat source when filling up Move the product at least 10 feet away from where it was filled up before attempting to start WARNING ...

Страница 10: ... supervisor knowl CONSUMER RESPONSIBILITY edgeable in refuelling techniques 7 The supervisor or operator shall personally recognise that all persons operating or riding this product are of sound mental and physical capacity are of suitable age height and weight and are capable to operate this product comfortably responsibly and safely The operator supervisor acknowledges that sections 1 6 have bee...

Страница 11: ...hat allows full operation of the break throttle pedals and steering wheel by the operator 2 Find the long strap of the restraint system 1A 1B and run it across the shoulder chest and lap inserting the metal tongue 2 on the strap into the buckle provided 3 You may need to adjust the shoulder portion of the strap 1A to its maximum length whilst unwinding the webbing of the web winder 4 To adjust the...

Страница 12: ...all fittings and fastenings BRUSH BARS Make sure all brush bars are in place and securely attached STEERING Check steering function Check wheel toe in FRAME CHASSIS Check for bends dents and cracks in tubing and welds BATTERY Check clamp bar and battery charge LIGHTS Check for proper operation BRAKES Check operation free play and condition Perform brake test as per operation instructions below PAR...

Страница 13: ...urs of operation During the first 20 hours the various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided However momentary 2 3 second maximum full throttle operation under load does not harm the engine Each full throttle acceleration ...

Страница 14: ...rake system Steering 3 The steering wheel system provides the product with the ability to turn Make sure the steering operates properly and freely Lubricate all bearing points periodically Engine Stop Switch 4 WARNING DO NOT operate the product unless the engine stop switch is functioning properly This product is equipped with a toggle type two position engine stop switch located on the side of th...

Страница 15: ...essure Use a tyre pressure guage and adjust accordingly to the optimum tyre pressure on the sidewall of the tyre Engine Stop Switch Test 1 Set the parking brake PRE RIDE INSPECTION 11 2 Place engine stop switch in the on position 3 Start Engine 4 With the engine running move the engine stop switch to the off position 5 If the switch does not stop the engine contact your dealer for assistance Brake...

Страница 16: ... may be an issue or an indica tion of a malfunction or errors in the starting procedure DO NOT continue to start the engine pause a few seconds and then try again If the engine fails to start contact dealer for assistance RUNNING Operate the product in a large level open space in order to learn to start steer and stop properly Operate the product at low speed until you are comfortable and confiden...

Страница 17: ...pavement is dangerous because the product may regain traction suddenly and unexpectedly which can cause the product to overturn Slippery surfaces reduce braking force and distances 1 If the front wheels tend to skid in mud sand or snow you may be able to improve control by releasing the throttle and allowing the product to coast through the turn 2 If the rear wheels skid sideways correct the slide...

Страница 18: ...r minute and then turn the engine off 3 Place an empty container under the drain bolt 4 Remove the dipstick and drain bolt to drain the oil 5 Inspect the o ring and replace if damaged 6 Install the drain bolt and tighten to specification 7 Fill the engine oil and install the dipstick 8 Warm up the engine for several minutes at idle speed checking for leaks SPARK PLUG GAP When installing the spark ...

Страница 19: ...ling speed by adjusting the throttle stop screw Turn the screw clockwise to increase the engine speed And counter clockwise to decrease the engine speed 15 MAINTENANCE ADJUSTMENT THROTTLE CABLE ADJUSTMENT The throttle cable housing may need to be adjusted periodically because the cable stretches when fully depressed the throttle pedal activates full engine speed adjust the throttle cable housing 1...

Страница 20: ...lt in a vapour lock Have your dealer check the cause if the brake fluid level goes down PARKING BRAKE ADJUSTMENT Parking brake adjustment may be required if the parking brake does not hold properly The cable length A in diagram should be adjusted to 50 55mm 1 Fully loosen the locknut 1 at the rear caliper 2 Tur the adjusting nut 1 on the brake lever counter clockwise to increase the cable length o...

Страница 21: ... your dealer 1 When the machine is not in use for month or longer remove the battery and store in a dry cool dark place Completely recharge the battery before re installation 2 Always make sure the connections are correct when putting the battery back in the machine CAUTION A special battery charger with a cut off once in it charged is required to charge a sealed lead acid battery Using a conventi...

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Страница 25: ...ASSEMBLY DUNE BUGGY ASSEMBLY INSTRUCTIONS 1 Remove the M8 40 bolts and nuts from the main frame attach the front plastic protector with the bolt holes lines up and place the bolts in fasten tightly 21 ...

Страница 26: ...tach the front and rear mudguards to the frame so locate the four mudguard in the second carton Remove the nut on the end of the mudguard holder line the bolt up in the correct position on the frame attach nut and tighten ASSEMBLY 22 ...

Страница 27: ...ght will be wrapped and attached to the rear frame near the petrol tank Remove packaging and nuts and washers from the back of the light place in the correct position on the frame attach the washer nuts and tighten ASSEMBLY 23 ...

Страница 28: ... rod end and remove the nut Line up the end of the tie rod end with the steering axle bracket place the tie rod end in the correct position attach nut tighten and place the cotter pin Warning These cotter pin is for safety so make sure these are correctly placed and bent over so the bolt cannot come loose ASSEMBLY 24 ...

Страница 29: ...Absorber Locate the two front shocks in the second package and the M10 35 nuts and bolts Align the shock absorber with the correct holes on the frame slide bolts and top and bottom attach nuts and tighten ASSEMBLY 25 ...

Страница 30: ... the wheels Remove the four M8 20 wheel flange bolts from the wheel flange then lift up the rim and tyre line up the holes on the rim and slide on to the bolts attach the nuts These nuts will need to be tightened very carefully and tight and also checked and tightened before EVERY ride Repeat for left and right 26 ...

Страница 31: ...ASSEMBLY 7 Seat Remove the four self locking bolts from the bottom of the seat place the seat on the frame in the correct position place bolts back in and tighten 27 ...

Страница 32: ...8 Steering Wheel Remove the 3 bolts from the steering column place steering wheel in correct position attach with 3 bolts and tighten ASSEMBLY 28 ...

Страница 33: ...oll Cage Remove the M8 35 bolts from the end of the roll cage support bars and place in correct position insert bolts and attach Repeat with the front support bar with the lights attach wiring and tighten bolts 29 ...

Страница 34: ...VEHICLE MAINTENANCE ...

Страница 35: ...ck the fuel oil and coolant every time before use with the engine off Visually inspect Check for damaged or loose parts Check for fuel or oil leaks Wheels and Tyres Check tyres for damage Ensure tyre pressure is correct and even in each tyre Check wheel nuts Throttle Check the throttle operates smoothly across its range Accumulated mud and dirt can restrict cable movement and prevent the throttle ...

Страница 36: ... oil leakage Look and feel for loose parts with the engine off Rough terrain will loosen chassis parts Steering Check the steering moves freely but without undue looseness Other checks required Maintenance actions required into operation Done Checked by Date VEHICLE MAINTENANCE BEFORE YOU RIDE CHECKLIST ...

Страница 37: ... bike tyres Chassis and suspension Shock absorbers for leaks and wear Suspension operation Safety guards for looseness Handlebars foot decks and major fasteners use tension wrench Steering Smooth movement from lock to lock Linkages for wear Throttle operation Test while moving handlebars fully to the left and fully to the right Gear selectors Gear levers for damage and excessive slack Splines on g...

Страница 38: ...adjustment as per the operator s manual Sprockets not worn Battery Battery terminals for corrosion and tightness Electrolyte levels Damaged casing Lever controls Check smoothness of operation Check for broken sharp or bent levers Other Check for attachment and condition of Load carriers Foot decks Seat Additional routine maintenance checks required On the back of this sheet list 1 Maintenance acti...

Страница 39: ...VEHICLE MAINTENANCE ...

Страница 40: ...ck the fuel oil and coolant every time before use with the engine off Visually inspect Check for damaged or loose parts Check for fuel or oil leaks Wheels and Tyres Check tyres for damage Ensure tyre pressure is correct and even in each tyre Check wheel nuts Throttle Check the throttle operates smoothly across its range Accumulated mud and dirt can restrict cable movement and prevent the throttle ...

Страница 41: ... oil leakage Look and feel for loose parts with the engine off Rough terrain will loosen chassis parts Steering Check the steering moves freely but without undue looseness Other checks required Maintenance actions required into operation Done Checked by Date VEHICLE MAINTENANCE BEFORE YOU RIDE CHECKLIST ...

Страница 42: ... bike tyres Chassis and suspension Shock absorbers for leaks and wear Suspension operation Safety guards for looseness Handlebars foot decks and major fasteners use tension wrench Steering Smooth movement from lock to lock Linkages for wear Throttle operation Test while moving handlebars fully to the left and fully to the right Gear selectors Gear levers for damage and excessive slack Splines on g...

Страница 43: ...adjustment as per the operator s manual Sprockets not worn Battery Battery terminals for corrosion and tightness Electrolyte levels Damaged casing Lever controls Check smoothness of operation Check for broken sharp or bent levers Other Check for attachment and condition of Load carriers Foot decks Seat Additional routine maintenance checks required On the back of this sheet list 1 Maintenance acti...

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