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102

ATV 250 - Periodic Maintenance and Adjustments

WARNING!

Improper maintenance can result in loss of braking ability.

Observe these precautions:

Insufficient brake fluid may allow air to enter the brake system, reducing

braking performance.

• Clean the filler cap before removing. Use brake fluid from a sealed

container.

• Use only the specified brake fluid; otherwise, the rubber seals may

deteriorate, causing leakage.

• Refill with the same type of brake fluid. Adding a brake fluid other may

result in a harmful chemical reaction.

• Be careful that water does not enter the brake fluid reservoir when

refilling. Water will significantly lower the 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 the brake fluid level to gradually go

down. A low brake fluid level may indicate worn brake pads and/or brake

system leakage; therefore, be sure to check the brake pads for wear and the

brake system for leakage. If the brake fluid level goes down suddenly, have

a dealer check the cause before further riding.

CHANGING THE BRAKE FLUID

Have a dealer change the brake fluid at the intervals specified in the TIP

after the periodic maintenance and lubrication chart. In addition, have

the oil seals of the master cylinders and calipers as well as the brake hoses

replaced at the intervals listed below or whenever they are damaged or

leaking.

Содержание ATV 125CC

Страница 1: ...MANUAL 3627...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 17: ...10 Safety Labels 6...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 44: ...37 ATV 70 atv 70CC...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 133: ...126 Troubleshooting BLOCKED NOT BLOCKED...

Страница 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...

Страница 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...

Страница 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...

Страница 137: ...130 Circuit Diagram ATV 70 ATV 125...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 151: ...144 Spare Part Catalogue...

Страница 152: ...145 Spare Part Catalogue...

Страница 153: ...146 Spare Part Catalogue...

Страница 154: ...147 Spare Part Catalogue...

Страница 155: ...148 Spare Part Catalogue...

Страница 156: ...149 Spare Part Catalogue...

Страница 157: ...150 Spare Part Catalogue...

Страница 158: ...151 Spare Part Catalogue...

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

Страница 160: ...153 Spare Part Catalogue...

Страница 161: ...154 Spare Part Catalogue...

Страница 162: ...155 Spare Part Catalogue...

Страница 163: ...156 Spare Part Catalogue...

Страница 164: ...157 Spare Part Catalogue...

Страница 165: ...158 Spare Part Catalogue...

Страница 166: ...159 Spare Part Catalogue...

Страница 167: ...160 Spare Part Catalogue...

Страница 168: ...161 Spare Part Catalogue...

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

Страница 170: ...163 Spare Part Catalogue...

Страница 171: ...164 Spare Part Catalogue...

Страница 172: ...165 Spare Part Catalogue...

Страница 173: ...166 Spare Part Catalogue...

Страница 174: ...167 Spare Part Catalogue...

Страница 175: ...168 Spare Part Catalogue...

Страница 176: ...169 Spare Part Catalogue...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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