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PERIODIC MAINTENANCE AND ADJUSTMENT

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Содержание LX50ATV-2 Kitten

Страница 1: ...old for OFF ROAD USE ONLY Before operating this vehicle read all the instructions for safe assembly and operation as well as the instructions governing the engine and other portions of the vehicle Pay close attention to all caution and warning labels on the ATV MINIMUM RECOMMENDED OPERATOR AGE 6 h t t p w w w m o r t c h c o m ...

Страница 2: ... machine is designed and manufactured for OFF ROAD use only It is illegal and unsafe to operate this machine on any public street road or highway This machine complies with all applicable OFF ROAD noise level and spark arrester laws and regulation in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine SPECIAL MESSAGES We provides many...

Страница 3: ...t if instructions are not followed Indicates special precautions that must be take to avoid damage to the machine NOTE A NOTE provides key information to make precedures easier or clearer The Owner s Manual should be considered a permanent part of your ATV It should remain with the vehicle at all times and stay with the ATV if it is sold B h t t p w w w m o r t c h c o m ...

Страница 4: ...manual includes important safety information It provides information about special techniques and skills necessary to ride your machine It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your machine please consult a our company dealer We wish you many years of safe and enjoyable riding While reading this manual remember...

Страница 5: ...V 2 OFF ROAD OWNER S MANUAL C 2007 by our company 1st Edition Dec 2007 All rights reserved Any reprinting or unauthorized use without the written permission of our company is expressly prohibited Printed In China P N D h t t p w w w m o r t c h c o m ...

Страница 6: ...R SWITCH Start Button Engine Stop Switch Headlight Dimmer Switch Emergency Switch THROTTLE LEVER FRONT AND REAR BRAKES PARKING BRAKE FUEL TANK CAP FUEL VALVE CHOKE KNOB STARTER SEAT PRE OPERATION CHECKS FRONT AND REAR BRAKES FUEL ENGINE OIL TRANSMISSION OIL CHAIN THROTTLE LEVER FITTINGS AND FASTENERS LIGHTS SWITCHES E 1 1 2 1 3 1 3 1 3 1 3 2 3 2 3 3 4 1 4 1 4 2 4 2 4 3 4 3 4 4 4 4 4 5 4 6 4 7 4 8 ...

Страница 7: ...NOT OPERATE AFTER CONSUMING ALCOHOL OR DRUGS PRE OPERATION CHECKS ACCESSORIES NO MODIFICATIONS DURING OPERATION EXHAUST SYSTEM PRACTICING BRAKING TURNING YOUR ATV CLIMBING UP SLOPE RIDING DOWN SLOPE PARKING WHAT TO DO IF WHAT TO DO PERIODIC MAINTENANCE AND ADJUSTMENT PERIODIC MAINTENANCE LUBRICATION F CONTENTS 5 7 5 8 5 10 6 1 6 1 6 3 6 4 6 4 6 5 6 6 6 7 7 1 7 2 7 2 7 3 7 5 7 6 7 7 7 8 7 9 7 9 7 1...

Страница 8: ...CH ADJUSTMENT CABLE INSPECTION AND LUBRICATION WHEEL REMOVAL Wheel installation BATTERY INITIAL SERVICE AND INSTALLATION OF BATTERY BATTERY CHARGING BATTERY REPLACEMENT TROUBLESHOOTING Troubleshooting chart CLEANING AND STORAGE CLEANING STORAGE SPECIFICATIONS NOISE REGULATION MAINTENANCE RECORD INDEX G CONTENTS 8 5 8 8 8 9 8 11 8 12 8 13 8 13 8 14 8 17 8 20 8 20 8 21 8 23 8 24 8 24 8 26 8 27 8 35 ...

Страница 9: ...TION LABELS WARNING SPECIFICATION LABELS 1 1 1 WARNING Operating this ATV if you are under the ageof 6 increases your chance of severe injury or death NEVER operate this ATV if you are under age 6 1 2 4 3 5 h t t p w w w m o r t c h c o m ...

Страница 10: ...NSTRUCTIONS AND WARNINGS Ä Ä Ä Ä Ä Without proper training or instruction At speeds too fast for your skills or the conditions Do not operate the vehicle after consuming ALCOHOL OR DRUGS ALWAYS Use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns For your safety wear gear to include helmet gloves and foot protection Gasoline is flammable shut off engine a...

Страница 11: ...SE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH Recommended Never set tire pressure over the recommended OPERATING TIRE PRESSURE Set with tires cold FRONT 25 30 kpa 0 25 0 3 kgf cm 3 5 4 2 psi REAR 25 30 kpa 0 25 0 3 kgf cm 3 5 4 2 psi h t t p w w w m o r t c h c o m ...

Страница 12: ...rmation Anyone who rides the vehicle should read and understand this information before riding Parents of young riders should make sure their youngsters read and understand the hang tag and label information before allowing them to ride The labels should be considered as permanent parts of the vehicle If a label comes off or becomes hard to read contact your our company dealer for replacements h t...

Страница 13: ...ginners should receive training from a certified instructor Always follow the age recommendation A child under 6 years old should never operate an ATV with engine size greater than 70cc Achild under 12 years old should never operate an ATV with engine size greater than 90cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a chi...

Страница 14: ... feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Never operate on excessively rough slippery or loose terrain Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster spe...

Страница 15: ...te over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of ...

Страница 16: ...ion or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo Allow greater distance for braking h t t p w w w m o r t c h c o m ...

Страница 17: ...inity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the machine in another vehicle be sure it is kept upright and that the fuel valve is in the OFF position Otherwise fuel may leak out of the carburetor or fuel tank Gasoline is poisonous and can cause injuries If you should swallow some gasoline or inhale a lot of ...

Страница 18: ...N HOW TO AVOID THE HAZARD Starting or running the engine in a closed area Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time Always operate your machine in an area with adequate ventilation h t t p w w w m o r t c h c o m ...

Страница 19: ...nd model label information in the spaces provided for assistance when ordering spare parts from a our company dealer or for reference in case the vehicle is stolen 1 VEHICLE IDENTIFICATION NUMBER 2 ENGINE SERIAL NUMBER VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the frame 1 1 Vehicle identification number h t t p w w w m o r t c h c o m ...

Страница 20: ...DESCRIPTION MACHINE IDNTIFICATION 3 2 ENGINE SERIAL NUMBER The engine serial number is stamped on the left crankcase 1 ENGINE SERIAL NUMBER 1 h t t p w w w m o r t c h c o m ...

Страница 21: ...SCRIPTION MACHINE IDNTIFICATION 3 3 PARTS LOCATIONS 1 Muffler 2 Cushion 3 Handlebar Switch 4 Ignition Switch 5 Drive Chain Cover 6 Rear Wheel 7 Fuel Tank Cap 8 Front Wheel h t t p w w w m o r t c h c o m ...

Страница 22: ...DESCRIPTION MACHINE IDNTIFICATION 3 4 9 10 11 12 13 9 Bumper 10 Battery 11 Handlebar Cover 12 Headlight 13 Footped h t t p w w w m o r t c h c o m ...

Страница 23: ...5 NOTE The machine you have purchased may differ slightly from those shown In the figures of this manual 14 15 16 17 18 14 Throttle Lever 15 Starter Choke 16 Rear Brake Pedal 17 Rear Fender 18 Front Fender h t t p w w w m o r t c h c o m ...

Страница 24: ...s follows OFF position All electrical circuits are switched off except hazard light The key can be removed in this position ON position With the transmission in neutral and set the parking brake the engine can be started The key can not be removed OFF ON 1 1 Ignition Switch h t t p w w w m o r t c h c o m ...

Страница 25: ... the starter button with the ignition switch ON and the engine stop switch at RUN NOTE If the starter switch is pushed with the ignition switch ON and the engine stop switch OFF the starter motor will be activated but the engine will not start To start the engine be sure to position the engine stop switch at ON h t t p w w w m o r t c h c o m ...

Страница 26: ...OFF to prevent battery discharge Headlight Dimmer Switch Turn the switch to the forward posit on to switch on the headlight Turn the switch to the backward position to switch off the headlight i The headlight can be turned on only when the ignition switch is in the ON position and engine is running The illumination of headlight will be available fully only when the engine speed is more than 2000 r...

Страница 27: ...e emergency switch can stop the machine immediately to protect the rider THROTTLE LEVER It is operated by the thumb Pressing the lever opens the throttle When pressure is released spring tension automatically closes the throttle Regulate the speed of the machine by varying the throttle position 1 Throttle Lever h t t p w w w m o r t c h c o m ...

Страница 28: ...o This could cause an accident Check the operation of the throttle lever before you start the engine If it does not work smoothly check for the cause Correct the problem before riding the ATV Consult a our company dealer if you can t find or solve the problem yourself FRONT AND REAR BRAKES The front and rear brakes are operated by squeezing the brake levers 1 Front Brak Lever h t t p w w w m o r t...

Страница 29: ...it with the lock pin Always set the parking brake when parking and before starting the engine To unlock the parking brake squeeze the rear brake lever until the lock pin releases Using the parking brake in freezing weather may cause the brakes to freeze in the locked position 1 1 Lock Pin h t t p w w w m o r t c h c o m ...

Страница 30: ... could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely Always set the parking brake before starting the engine Always be sure you have released the parking brake before begin to ride FUEL TANK CAP After refueling be sure to tighten the fuel tank cap until it clicks Inser...

Страница 31: ...e positions With the lever and mark in this position fuel will not flow Always turn the lever to this position when the engine is not running With the lever in this position fuel mark flows to the carburetor Normal riding is done with the lever in this position This indicates reserve If you run out of fuel while riding turn the lever to this mark position h t t p w w w m o r t c h c o m ...

Страница 32: ...PPORTUNITY After refueling return the fuel valve lever to the ON position 1 Fuel lever 2 mark NOTE After refueling do not operate the ATV with the fuel valve in the RES position If you run out of fuel there will be no reserve supply h t t p w w w m o r t c h c o m ...

Страница 33: ...per operation CAUTION Extended use of the choke may impair piston and cyl inder wall lubrication and shorten the life of the engine Pushing the choke knob too hard to the OFF position may dislodge the choke cable boot If this happens water and dirt may enter the choke cable and cause corrosion If the choke is hard to actuate or feels like it is sticking check the cable boot A B 1 2 3 1 Fully Open ...

Страница 34: ...o install the seat insert the projections on the front of the seat into the seat holder and push down on the seat at the rear NOTE Make sure that the seat is securely fitted 4 11 1 1 Seat Removal Lever Indicates a potential hazard that could result in serious injury or death h t t p w w w m o r t c h c o m ...

Страница 35: ...d in the Owner s Manual WARNING 5 1 ITEM ROUTINE PAGE Brake Check operation condition free play drum brake and brake fluid level disk brake Adjust drum brake if necessary Fill with DOT 4 brake fluid disk brake if necessary Fuel Check fuel level Fill with fuel if necessary Engine oil and Transmission oil Check oil level Fill with oil if necessary Drive chain Check chain slack and condition Adjust i...

Страница 36: ... applied If not have the machine inspected by our dealer 3 Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance inspect the brakes for wear WARNING POTENTIAL HAZARD WHAT CAN HAPPEN Riding with improperly operating brakes You could lose braking ability which could lead to an accident HOW TO AV...

Страница 37: ...ank when necessary and make sure there is sufficient gasoline in the tank Check for leaks Fuel level should be below the filler neck NOTE Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system h t t p w w w m o r t c h c o m ...

Страница 38: ...use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt dust or water in the fuel tank 5 4 WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Improper care when refueling Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is over filled fuel could spill out due to heat from the engine Do not overfill the fue...

Страница 39: ... SG type or higher 5 5 In order to prevent clutch slippage Since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CON SERVING II or higher Make sure that no foreign material enters the crankcase h t t p w w w m o r t c h c o m ...

Страница 40: ...STENERS Check the general condition of the chain and check the chain slack before every ride Lubricate and adjust the chain as necessary Check to see that the throttle lever operates correctly It must open smoothly and spring back to idle position when released Repair as necessary for proper operation Always check the tightness of chassis fittings and fasteners before a ride Take the machine to ou...

Страница 41: ...r operation TIRES WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating this GO KART with improper tires or with improper or uneven tire pressure Use of improper tires on this GO KART or operation of this GO KART with improper or uneven tire pressure may cause loss of control increasing your risk of accident 1 The tires listed below have been approved by us for this model Othe...

Страница 42: ...e from the rim under severe riding conditions The following are minimums Front 25 kpa 0 25 kgf cm 3 5 psi Rear 25 kpa 0 25 kgf cm 3 5 psi 4 Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst HOW TO MEASURE TIRE PRESSURE Use the low pressure tire gauge The low pressure tire gauge is included as standard equipment Mak...

Страница 43: ...ifications Recommended pressure Minimum Maximum Front 28 kpa 2 0 28 kgf cm 3 92 psi 25 kpa 2 0 25 kgf cm 3 5 psi 30 kpa 2 0 3 kgf cm 4 2 psi Rear 28 kpa 2 0 28 kgf cm 3 92 psi 25 kpa 2 0 25 kgf cm 3 5 psi 30 kpa 2 0 3 kgf cm 4 2 psi 1 Low Pressure Tire Gauge h t t p w w w m o r t c h c o m ...

Страница 44: ...PRE OPERATION CHECKS 5 10 Tire Wear Limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire A 3mm 0 12 in h t t p w w w m o r t c h c o m ...

Страница 45: ...understand ask our dealer OPERATION WARNING Indicates a potential hazard that could result in serious injury or death STARTING A COLD ENGINE WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Freezing control cables in cold weather You could be unable to control the ATV which could lead to an accident or collision When riding in cold weather always make sure all control cables work s...

Страница 46: ...tart ambient temperature below 5C 40F Position 2 Cold engine start ambient temperature at 0C 30F 30C 90F and warming up position Position 3 Cold engine start ambient temperature above 25C 80F and warm engine start position 1 Fully Open 2 Half Open 3 Closed a Starter 5 Completely close the throttle lever and start the engine by pushing the start switch OPERATION 6 2 h t t p w w w m o r t c h c o m ...

Страница 47: ...oke in position 1 the starter choke should be returned to position 2 to warm up the engine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 7 Continue warming up the engine until it idles smoothly and return the starter choke to position 3 before riding See the Engine Brake In section prior to operating engine for the first...

Страница 48: ...new you must not put an excessive load on it for 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 seconds maximum full throttle operation under load does not harm the engine Each f...

Страница 49: ... prolonged operation above 3 4 throttle Rev the machine freely through the gears but do not use full throttle at any time 3 After break in Avoid prolonged full throttle operation Vary speeds occasionally PARKING When parking stop the engine and shift into neutral Turn the fuel lock to OFF and apply the parking brake The rear brake lever has one locked position that allow it to be used as a parking...

Страница 50: ... inclines If you must park on an incline place the machine transversely across the incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on slope that are so steep you could not walk up them easily 1 Bring the machine to a stop by applying the brakes 2 Stop the engine 3 With the rear brake lever applied apply the parking brake 6 ...

Страница 51: ...one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability your to control the ATV Examples include but are not limited to a heavy or bulky object attached to the handlebars whic...

Страница 52: ...RIDING YOUR ATV RIDING YOUR ATV 7 1 h t t p w w w m o r t c h c o m ...

Страница 53: ...empting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual completely and understand the operation of the controls Pay particular attention t...

Страница 54: ... an experienced operator Do not attempt to operate at maximum performance until you are totally familiar with the machine s handling and performance characteristics Riding your machine requires skills acquired through practice over a period of time AGE RECOMMENDATION Take the time to learn the basic techniques well before attempting more difficult maneuvers The minimum recommended age for this ATV...

Страница 55: ... death can result Even though a child may be within the age group for which an ATV is recommended he or she may not have the skills abilities or judgment needed to operate the ATV safely and may be involved in a serious accident A child under 6 should never operate this ATV Never allow a child under 16 to operate an ATV without adult supervision and never allow continued use of t e ATV by a child ...

Страница 56: ...injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your chances of severe injury in the event of an accident Always wear an approved motorcycle helmet that fits properly You should also wear Eye protection goggles or face shie...

Страница 57: ...RNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating this ATV after consuming alcohol or drugs Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident Never consume alcohol or drugs before or while driving this ATV h t t p w w w m o r t c h c o m ...

Страница 58: ...safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pressure may cause loss of control incre...

Страница 59: ...ted on this vehicle Because we cannot test all other accessories you are personally responsible for properly selecting installing and using non our accessories Always follow the loading instructions above plus the following 1 Carefully inspect the accessory to make sure it does not block any lights reduce ground clearance or limit suspension travel steering travel or other controls 2 Make sure the...

Страница 60: ...nuine or equivalent components designed for use on this ATV and should be installed and used according to instruction If you have question consult an authorized ATV dealer No Modifications Modifying this ATV or removing original equipment may render the vehicle unsafe or illegal Spark arresters and mufflers are required in most areas Don t modify your exhaust system or emission control system comp...

Страница 61: ...ving even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall a footpeg your foot or leg may come into contact with the rear wheels which could injure you or cause an accident Always keep both hands on the handlebars and both feet on the footpegs of your ATV during operation h t t p w w w m o r t c h c o m ...

Страница 62: ...ine or overturn WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Attempting wheelies jumps and other stunts Increases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off h t t p w w w m o r t c h c o m ...

Страница 63: ...ne in a place where pedestrians or children are not likely to touch WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Hot exhaust system Someone touching the exhaust system during or after operation could be burned Do not touch the hot exhaust system Do not park the machine in a place where others might be likely to touch it h t t p w w w m o r t c h c o m ...

Страница 64: ...iding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling return the starter knob to the closed position Then release the parking brake Apply the throttle slowly and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds unti...

Страница 65: ... braking may cause the wheels to lock reducing control of the ATV When possible reduce speed or brake before entering a turn Closing the throttle or braking in mid turn may cause wheel slippage which will reduce control of your ATV TURNING YOUR ATV To achieve maximum traction while riding off road the two rear wheels are mounted solidly on one axle and turn together at the same speed Therefore unl...

Страница 66: ...f control causing a collision or overturn Always follow proper procedures for turning as described in this Owner s Manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions Do not turn at excessive speeds h t t p w w w m o r t c h c o m ...

Страница 67: ...control WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating on excessively steep slopes The vehicle can overturn more easily on extremely steep slopes than on level surfaces or small slopes Never operate the ATV on slopes too steep for the ATV or for your abilities Practice on smaller slopes before attempting large slopes It is important when climbing a slope to make sure th...

Страница 68: ...ng slopes as described in this Owner s Manual Always check the terrain carefully before you start up any slope Never climb slopes with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any slope at high speed An obstacle or a sharp drop could be on the other side of the slope h t t p w w w m ...

Страница 69: ...ning on slopes Could cause loss of control or cause the ATV to overturn Never attempt to turn the ATV around on any slope until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any slope Avoid crossing the side of a steep slope if possible When crossing the side of a slope Always follow proper procedures as described in the ...

Страница 70: ...RNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Stalling rolling backwards or improperly dismounting while climbing a slope Could result in ATV overturning Maintain steady speed when climbing a slope If you lose all forward speed Keep weight up slope Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight up slope Never apply the rear bra...

Страница 71: ... brake lever with your left hand 2 Be sure your legs are clear of the wheels 3 Check your footing 4 Then slowly and carefully back the ATV down the slope using the front brake lever to control speed 5 If you lose control of the ATV for your safety get away from the vehicle If the slopeis too steep or too slippery or if you have any doubt whether you can safely walk the ATV back down the slope leav...

Страница 72: ...RIDING YOUR ATV 7 21 h t t p w w w m o r t c h c o m ...

Страница 73: ...to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Going down a slope improperly Could cause loss of control or cause the ATV to over turn Always follow proper procedures for going down slopes as described in this Owner s Manual Note a special technique is re...

Страница 74: ... riding for the day also turn the fuel valve OFF This section is designed to be a reference guide only Be sure to read each section on riding techniques completely If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position your weight over the front wheels for...

Страница 75: ...V around if you still have forward speed If not stop dismount on the up slope side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over on top of you Dismount the ATV on the up slope side h t t p w w w m o r t c h c o m ...

Страница 76: ...ion adjust ment and lubrication are explained on the following pages WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Servicing an engine while it is running Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fire Turn off the engine when performing maintenance unless otherwise specified Have our dealer perform se...

Страница 77: ...r machine to our dealer to check the torque setting and adjust them as necessary WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating this ATV with improper modifications Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situation could lead to an accident Never modify this ATV through improper installation or use...

Страница 78: ...PERIODIC MAINTENANCE AND ADJUSTMENT 8 3 PERIODIC MAINTENANCE LUBRICATION h t t p w w w m o r t c h c o m ...

Страница 79: ...PERIODIC MAINTENANCE AND ADJUSTMENT 8 4 h t t p w w w m o r t c h c o m ...

Страница 80: ...a clean rag Insert the dipstick in the filler hole without screwing it in D Remove the dipstick and inspect the oil level E The oil level should be between the maximum 2 and minimum marks 3 If the level is low add oil to raise it to the proper level NOTE Wait a few minutes until the oil level settles before checking 1 1 Dipstick oil filler cap 2 Maximum level mark 3 Minimum level mark h t t p w w ...

Страница 81: ...acement And Oil Filter Cleaning A Place the machine on a level place B Warm up the engine for several minutes and stop it C Place a container under the engine D Remove the oil filler cap 1 and oil filter cap 2 to drain the oil 1 1 Dipstick oil filler cap 2 2 Oil filter cap h t t p w w w m o r t c h c o m ...

Страница 82: ... O ring oil strainer compression spring and drain plug Tighten the drain plug to specification Before reinstalling the drain plug be sure to install the O ring compression spring and oil strainer H Fill the engine with oil and install the oil filler cap Recommended oil Oil quantity Engine oil Periodic oil change 0 9 L 0 79 lmp qt 0 95 US qt Total amount 1 0L 0 88 lmp qt 0 1 06 US qt I Warm up the ...

Страница 83: ...r leak or carburet problem for that cylinder Do not attempt to diagnose such problems yourself Instead take the machine to our dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive you should replace the spark plug with one of the Standard spark plug D8REA Before ins...

Страница 84: ...G The air cleaner accumulates dust and must be cleaned periodically If the ATV is ridden in dusty areas the air cleaner must be cleaned at more frequent intervals than specified in the Maintenance Schedule If the ATV is submerged in water the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine To Clean The Air Cleaner 1 Remove the air c...

Страница 85: ...lement If damaged replace it 6 Apply quality foam air filter oil to the element If foam air filter oil is not available motor oil may be used 7 Reinstall the element to the air filter case 8 Reinstall the element assembly and parts removed for access 1 2 3 1 Air Cleaner Case 2 Foam 3 Air Cleaner Cover Do not twist the filter element when squeezing it NOTE The element should be wet but not dripping...

Страница 86: ...0 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Connect the tachometer and set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in to increase engine speed and out to decrease engine speed Specified idle speed 2000 RPM 1 Throttle Stop Screw 1 h t t p w w w m o r t c h c o m ...

Страница 87: ...e lock nut 3 then turn the adjuster to obtain the correct free play 1 4 mm or0 04 0 16 in 3 Tighten the locknut and reinstall the sleeve Other checks Check the throttle cable for kinks and signs of wear that could cause stretching or failure Lubricate the throttle cable with a commercially available lubricant to prevent premature wear and corrosion 1 Rubber sleeve 2 Cable adjuster 3 Locknut 4 Thro...

Страница 88: ...check the position of the indicator If the indicator reaches the wear limit line 2 ask our dealer to replace the shoes as a set 1 Wear Indicator 2 Wear Limit REAR BRAKE PADS INSPECTION A wear indicator is provided on each brake The indicators allow checking of brake pads wear Check the position of the indicator If the indicator reaches the wear limit line ask our dealer to replace the pads h t t p...

Страница 89: ...ar Limit FRONT BRAKE LEVER FREE PLAY ADJUSTMENT The front brake lever free play should be adjusted to 10 20 mm 0 4 0 8 in at the tip of the brake lever If the free play is incorrect adjust as follows A Free play 10 20 mm 0 4 0 8 in h t t p w w w m o r t c h c o m ...

Страница 90: ...r adjusting bolt 2 2 Loosen the lower locknut 3 3 Turn the lower adjusting bolt 4 until specified free play is obtained Specified free play 10 20 mm 0 4 0 8 in 4 Tighten the lower locknut 5 While applying the front brake turn out the upper adjusting bolt until the upper and lower cable lengths are equal The cable joint 5 will become vertical h t t p w w w m o r t c h c o m ...

Страница 91: ...ly serviced or adjusted brakes You could lose braking ability which could lead to an accident After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag R e p l a c em e n t o f b ra k e c o mp o n e nt s r e qu i r e s professional knowledge These procedures should be performed by our dealer h t t p w w w m o r t c h c o m ...

Страница 92: ...pads for wear and the brake system for leakage Observe these precaution When checking the brake fluid level make sure the top of the brak fluid reservoir is level Use only the designated quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor brake performance WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Brake fluid contacting the skink or eyes M...

Страница 93: ...uid and may result in vapor lock Brake fluid may deteriorate painted surface or plastic parts Always clean up spilled fluid immediately Have our dealer check the cause if the brake fluid level goes down Complete fluid replacement should be done only by trained our service personal Have our dealer replace the following components during periodic maintenance or when they are damaged or leaking Repla...

Страница 94: ... worn beyond the recommended limit page 97 There is probably air in the brake system and it must be bled See your authorized dealer for this service To prevent damage to the brake system use only fluid from a sealed container Never allow contaminants dirt water etc to enter the brake fluid reservoir Brake fluid can damage paint and plastic so handle the fluid with care When adding brake fluid be s...

Страница 95: ...touching the ground Check the slack at the position shown in the figure The normal vertical deflection is approximately 10 20 mm 0 4 0 8in If the deflection exceeds 20 mm 0 8 in adjust the chain slack Drive chain slack adjustment 1 Loosen the upper and lower axle holding bolts 1 h t t p w w w m o r t c h c o m ...

Страница 96: ...e upper and lower axle holding bolts Too little of chain slack will overload the engine and other important parts Keep the slack within the specified limit CLUTCH ADJUSTMENT 1 Loosen the locknut 2 Slowly turn the adjusting bolt counterclockwise until resistance is felt Then turn it 1 8 turn clockwise h t t p w w w m o r t c h c o m ...

Страница 97: ...ut 2 Adjusting Bolt 3 Tighten the locknut to specified Tighten Torque 15N m 1 5 m kgf 11 ft lbf NOTE Turn the adjusting bolt counterclockwise to decrease the clutch free play and turn it clockwise to increase the free play h t t p w w w m o r t c h c o m ...

Страница 98: ...ARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Damaged control cables Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask our dealer to replace th...

Страница 99: ...the nuts from the wheel 3 Remove the wheel assembly 1 Wheel Nuts Wheel installation When reinstalling a wheel tighten the wheel nuts in a crisscross rather than a circular pattern Wheel nut torque Front Rear 45 Nm 4 5 m kg 32 ft lb Be sure the tapered side of the wheel nuts 1 face the wheel rim 2 h t t p w w w m o r t c h c o m ...

Страница 100: ...el Rim WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Installing wheels improperly A wheel may come loose possibly leading to an accident Carefully follow the instructions in this Owner s Manual when installing h t t p w w w m o r t c h c o m ...

Страница 101: ...to check the electrolyte level or add distilled water If the battery seems weak see your authorized LONGTING dealer for information on recharging or replacement If you replace the battery choose one that is sealed and equivalent to the original Be sure to read and follow all safety precautions indicated on the battery 1 h t t p w w w m o r t c h c o m ...

Страница 102: ...L CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED Contains sulfuric acid Avoid contact with skin eyes or clothing To prevent accidents rinse empty container with water External flush with water Internal Call physician immediately Drink large quantities of water or milk Follow with milk of magnesia beaten eggs or vegetable Eyes Flush with water for 15 minutes and get prompt medi...

Страница 103: ...ery s containing separate electrolyte pack Most battery s will come with the electrolyte already sealed into the battery Preparing the battery Place battery on level surface Remove sealing tape from top Take the electrolyte container out of the plastic bag h t t p w w w m o r t c h c o m ...

Страница 104: ...Place electrolyte container upside down with the sealed silver mouths of the electrolyte bottles in line with the six filler holes of the battery Push the container down strongly enough to break the silver seals h t t p w w w m o r t c h c o m ...

Страница 105: ...it is draining Never cut or pierce electrolyte container After all the electrolyte has drained from the bottles into the battery pull plastic electrolyte bottles gently out of the battery Discard empty electrolyte bottles in a waste area that is inaccessible to children and animals After filling let battery stand for at least 30 minutes before charging This allows the electrolytes to penetrate pla...

Страница 106: ...IODIC MAINTENANCE AND ADJUSTMENT 8 31 How to Initially Charge the battery 1 Connect the red positive cable to the red positive pole of the battery See the following picture h t t p w w w m o r t c h c o m ...

Страница 107: ...g picture NOTE The red positive cable has a larger diameter than the black negative y cable 3 Charging rate Charge battery 0 7 Amps for 5 10 hours After charging is complete press down firmly with both hands to seat the caps Do not pound or hammer The battery is now sealed see the following two pictures h t t p w w w m o r t c h c o m ...

Страница 108: ...PERIODIC MAINTENANCE AND ADJUSTMENT 8 33 h t t p w w w m o r t c h c o m ...

Страница 109: ... on the battery should be facing the warning label on the gray tray See the following picture WARNING NEVER REMOVE TE STRIP OF CAPS NOR ADD ANY WATER OR ELECTROLYTE Once battery is firmly seated in gray tray with rubber mat under it attach the red positive wire to the red positive terminal on the battery h t t p w w w m o r t c h c o m ...

Страница 110: ...ttery Then remove the red positive Å lead from the battery Remove the battery from the battery tray Check the battery voltage with a meter If the voltage reading is below 12 3V recharge the battery Battery Service Limit Fully Charged 12 8 V Needs Charging 12 3 V How To Charge The Battery Connect the red positive cable to the red positive pole of the battery See the following picture h t t p w w w ...

Страница 111: ...PERIODIC MAINTENANCE AND ADJUSTMENT 8 36 Connect the black negative cable to the black negative pole of the battery See the following picture h t t p w w w m o r t c h c o m ...

Страница 112: ... turn off the charger first in order to prevent electric spark and explosion Charge in a well ventilated area DO NOT smoke around batteries and keep away from open flame BATTERY REPLACEMENT Ä Ä Ä Remove old battery Mark which cable is connected to the positive terminal Å and which cable is connected to the negative y terminal Clean cable connectors with wire brush or sandpaper to remove oxidation ...

Страница 113: ...ng battery can cause serious injury or death Batteries contain sulfuric acid Always shield eyes with protective eyewear when working around battery acid Battery acid is poisonous and can cause severe burns DO NOT smoke around batteries and keep away from open flame NOTE When the ATV is to be stored for an extended period remove the battery from the vehicle and charge it fully Then store it in a co...

Страница 114: ... and know how to properly service your machine Imitation parts may look like our parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Checking the fuel system while smoking or near an open flame Fuel can ignite or explode causing severe injury or property damage Do not...

Страница 115: ...PERIODIC MAINTENANCE AND ADJUSTMENT 8 40 h t t p w w w m o r t c h c o m ...

Страница 116: ...les 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes trans mission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car washers 4 Once the majority of...

Страница 117: ...pping ability increasing the chance of an accident Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings STORAGE Before storing your ATV for an extended time be sure you thoroughly check the vehicle for needed repairs and have them corrected Otherwise the repairs may be forgotten by the time you remove the vehicle from storage In addition e...

Страница 118: ...tank Be careful not to spill fuel when refueling After refueling make sure the fuel fill cap is closed properly and securely If any fuel is spilled make sure the area is dry before starting he engine WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Prolonged contact of fuel with the skin Breathing fuel vapor The fuel can cause skin irritation Fuel vapor could cause lung damage Avoi...

Страница 119: ...L HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Allowing open flames or sparks near the battery Gases may explode and possibly cause injury Do not allow open flames or sparks near the battery 5 Wash and dry the ATV and wax all painted surfaces 6 Inflate the tires to their recommended pressures 7 Place the ATV on blocks to raise all four tires off the ground 8 Lbricate all control cables 9 Tie a p...

Страница 120: ...m Type Single Cylinder 4 Stroke Air Cooled Bore x Stroke 39mm 41 4mm Displacement 49 46 cc Compression ratio 9 4 1 Carburetor PZ16 Output Power 2 2KW 8500r min Maximum Torque 3 0Nm 7000 8000r min Starting Electric Ignition C D I Lubrication Force Splash Transmission Single Stage Automatic Clutch Spark Plug D8REA Plug gap 0 6 0 7mm Fuel type RQ90 unleaded Lubricate oil h t t p w w w m o r t c h c o...

Страница 121: ...s Climbing 15 Battery 12V 4Ah Head Light 12V 16W Brake Track 7m 20miles h Top speed 25km h or limited as customers require Front Rear Brake Drum Disc Right Left Hand Control Front tire AT14 5 7 6 Rear tire AT14 5 7 6 Final Drive Chain Chain Drive Front 25 kPa Rear 25 kPa Net Weight 74 KG h t t p w w w m o r t c h c o m ...

Страница 122: ...ent of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW Exhaust system Muffler Exhaust pipe Silence...

Страница 123: ...ance with the warranty The chart below is printed only as a reminder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MONTH SERVICE DEALER NAME AND ADDRESS REMARKS 150 km 1000 km 2000 km 3000 km 4000 km 5000 km 6000 km 7000 km 8000 km 9000 km 10000km 12 1 h t t p w w w m o r t c h c o m ...

Страница 124: ...ANING APPAREL B BATTERY BRAKES C CABLE INSPECTION AND LUBRICATION CHOKE KNOB CLEAN I NG CLIMBING UPHILL CONTENTS CONTROL FUNCTIONS CROSSING A SLOPE D DRIVE CHAIN E ENGINE BREAK IN ENGINE OIL Engine stop switch EXHAUST SYSTEM 13 1 h t t p w w w m o r t c h c o m ...

Страница 125: ...NK CAP FUEL VALVE FUSE REPLACEMENT H HANDLEBAR SWITCHES HEADLIGHT SWITCH I IDENTIFICATION NUMBER IDLE SPEED ADJUSTMENT IGNITION SWITCH IMPORTANT NOTICES INSTRUMENTS L LABELS LIGHTS M MODIFICATIONS O OPERATION 13 2 h t t p w w w m o r t c h c o m ...

Страница 126: ... REAR FINAL GEAR CASE OIL REAR SWING ARM LUBRICATION RECOIL STARTER RIDING DOWNHILL RIDING OVER ROUGH TERRAIN RIDING YOUR ATV S SAFETY INFORMATION SEAT SLIDING AND SKIDDING SPARK ARRESTER CLEANING SPARK PLUG INSPECTION SPECIAL MESSAGES SPECIFICATIONS SPEED LIMITER STARTING ENGINE Stater button STORAGE STORAGE COMPARTMENT SWITCHES 13 3 h t t p w w w m o r t c h c o m ...

Страница 127: ...X 13 4 T THROTTLE LEVER TI RES TOOL KIT TRAILER HITCH TRANSMISSION OIL TROUBLESHOOTING Troubleshooting chart TURNING YOUR ATV W WARMING UP WHEEL V VALVE CLEARANCE ADJUSTMENT h t t p w w w m o r t c h c o m ...

Страница 128: ...OW ALL INSTRUC TIONS AND WARNINGS Without proper training or instruction At speeds too fast for your skills or the conditions On public roads a collision can occur with another vehicle With a passenger passengers affect balance and steering control Use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns Avoid paved surfaces pavement may seriously affect hand...

Страница 129: ...LX ATV 2 USER S MANUAL 1st Edition Dec 2007 All rights reserved Any reproduction or unauthorized use is expressly prohibited Printed in China 50 h t t p w w w m o r t c h c o m ...

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