Coolster POCKET BIKE QG-40 User Manual

WWW.POWERDIRTBIKES.COM

USER MANUAL

POCKET BIKE QG-40

WWW.POWERDIRTBIKES.COM

Pocket Bike

SERVICE MANUAL FOR USE AND MAINTENANCE AND SPARE PARTS
LIST For your own safety and the safety of others Follow these recommendations
in order to use your POCKET BIKE safely and correctly. Read the instructions
CAREFULLY, failure to do so may place yourself and others in extreme and or
ultimate DANGER. If you do not understand the instructions and Data then, you
are not to attempt to operate this Pocket bike under any circumstances. It may
be used for show purposes only!

CONTENTS

PAGE

INTRODUCTION……………………………………………………………………2
TECHNICAL DATA………………………………………………………………2
UNPACKING AND SETTING UP BEFORE RIDING……………………………...3
SAFETY…………………………………………………………………………..3
BEFORE STARTING……………………………………………………………...3
STARTING THE ENGINE .FIG. 2………………………………………………….4
CARBURETOR.FIG. 3…………………………………………………………….4
RIDING……………………………………………………………………………..4
PERIODIC MAINTENANCE……………………………………………………...5
CHAIN SETTING AND MAINTENANCE………………………………………..5
CENTRIFUGAL CLUTCH REPAIR OR REPLACEMENT………………………...5
BRAKES ADJUSTING .FIG. 4…………………………………………………….6
FRONT BRAKES PADS REPLACEMENT .FIG. 7………………………………..6
REAR BRAKES PADS REPLACEMENT.FIG. 7……………………………………6
REMOVE AND REFIT THE FRONT WHEEL.FIG. 5……………………………..7
REMOVE AND REFIT THE REAR WHEEL . FIG. 5………………………………7
REPLACEMENT OF SPROCKET -FK3.9………………………………………..7
ENGINE……………………………………………………………………………..8

POCKET BIKE PB-G0 2 .FJG. 5…………………………………………………9, 10

PARTS LIST……………………………………………………………………11 12
FRONT AND REAR BRAKES .FIG. 7…………………………………………….13
REPLACEMENT OF TIRE .FIG. 5…………………………………………………14
DISMANTCING AND ASSEMBLY OF AIR FFLTER-FIG.3…………………..

14

WHAT TO DO BEFORE A PERIOD OF IDLENESS……………………………14

1

2

INTRODUCTION

The Pocket bike -PB-G02 is designed and built for use on a paved closed
circuit track. The track should be clean and without obstacles of any kind.
Qualified adults and younger persons can drive the pocket bike. Children
can drive the pocket bike only under the supervision of a responsible
adult person. The pocket bike is constructed especially for racing competitions on
special racing tracks. The pocket bike uses a single-cylinder two-stroke, Gasoline
combustion engine, and has an air filter and exhaust silencer. Transfer of power to
the rear wheel is through a drive chain. The overall drive ratio to the rear wheel
can be changed by the replacement of chain sprockets. The front and rear wheel
is equipped with disk brakes. The rear brake is controlled with the left fever
and the front brake is controlled with the right lever on the handlebars.

BASIC TECHNICAL DATA

ENGINE: MT-A1……………………………………………TWO-STROKE

NUMBER OF CYLINDERS…………………………………….1
SIZE, CAPACITY…………………………………………...47 cc
ENGINE COOLING SYSTEM……………………AIR COOLED
POWER OUTPUT………………………………2.5kW at 8700rpm

CARBURETOR………………………………………DELL’ORTO
FUEL ADMISION……REED VALVE DIRECT TO CRANKCASE
IGNITION…………………………………………...ELECTRONIC

SPARK PLUG………………………………………….NGK B9 ES
STARTING……………………….HAND PULL TYPE, MANUAL
CLUTCH…………………………….CENTRIFUGAL, FRICTION

FRAME: WELDED…………………………HIGH STRESS STEEL TUBES

BRAKES: FRONT WHEEL…………………………………..DISC BRAKES

REAR WHEEL………………………..MECHANICAL BRAKES

WHEELS: FRONT……………………………OF LIGHT ALLOY 6, 5" - 63

REAR……………………………..OF LIGHT ALLOY 6, 5" - 63

TIRE: FRONT……………………………………….SIZE 90/65 - 6, 5"

REAR…………………………………110/50 - 6,5", 90/65 - 6,5"

FUEL: PETROL (GASOLINE)……….OCTANE 92 +SYNTHETIC OIL

MIXING RATIO (after break in period)……………………..50:1

25:1 (brand new bike) Somewhere around 5.5 - 6oz of oil to one
gallon of gas for a new bike and something like 3.5 - 4oz of oil to
one gallon of gas for a bike that’s already broken in.

TANK CAPACITY………………………………………..1 Litre

UNLOADED WEIGHT:…………………………………………(41.5lbs.) 19 kg
CARRYING CAPACITY:………………………………………..(240lbs) 110 kg
BASIC DIMENSIONS:

LENGTH…………………………………………………950 mm
WIDTH……………………………………………………500mm
HEIGHT…………………………………………………..565 mm

3

UNPACKING AND SETTING UP BEFORE RIDING

The pocket bike is delivered in a cardboard carton and packed with folded
handlebars and brake levers. After unpacking, set up the handlebars into the position,
that suits the best for driving. The maximum pulled brake lever position should not
touch on the handlebar grip. After setting up, tighten the handlebar nuts 1, brake
lever bolts 2, and the throttle assy. Bolts. See, Fig. 1. The level of foot rest's can be
regulated by loosening the bolt M5 (914.003.01) on the handle of the foot rest
(139.001.01). The foot rest can be moved to the front or back position. It is
recommended to try and check the position of handlebars and foot rest's individually.
While tightening the bolts and nuts, do not use an excessive force as to not damage the
threads, or distort the tubes and other parts. Verify the smooth and perfect function of
the Bowden cables to throttle and both brakes. Fill the fuel tank with fuel. (Gas-oil
mix) Failure to use the proper oil mix ratio will result in Engine damage for which you
will be responsible.

Operating controls:

Fig. 1

1. Handlebar nut

2. Brake lever bolts

3. Throttle Assy. bolts

4. Stop switch

5. Front brake lever

6. Rear brake lever

Range of adjusting handlebars
function position

SAFETY

The pocket bike is unsuitable for public road use. It does not comply with valid
Safety Standards. Unsafe and careless use of a pocket bike can result in serious
injuries. The driver can minimize the potential risks by wearing the Safety
Equipment The driver must wear safety helmet, goggles, gloves, elbow pads,
kneepads, and firm footwear. The pocket bike cannot be used on wet, icy or oily
surfaces. Avoid uneven surfaces and obstacles. Drive with two hands on the
handlebars.

BEFORE STARTING

It is strongly recommended to follow all the instructions about the break-in period to
promote engine reliability and long life. Break-in period of the pocket bike is
complete after the consumption of five full fuel tanks. It Is important to use petrol 91 or
92 Octane fuel with synthetic oil in the ratio 25:1 and after break-in period a ratio of
50:1. Mix the gas and oil completely before putting it into the fuel tank. During th e
break-in period do not run the engine at maximum RPM and do not allow the
engine to overheat Check the tire inflation - 200 kPa (2 bars) or (28 to 30psi) to be
commensurate with the driver's weight Th e Tyre pressure should never exceed 2,5
bars, (38psi) in either the front or rear wheel.