Gas gas K2 QUAD 250 2005 User Manual

MANUAL DEL USUARIO

MANUAL DEL USUARIO

SERVICE MANUAL

SERVICE MANUAL

MANUEL D’ENTRETIEN

MANUEL D’ENTRETIEN

LIBRETTO D´USO

LIBRETTO D´USO

SERVICE MANUAL

SERVICE MANUAL

ENGLISH

Brief introduction

250 EC QUAD embodies the experience and essence of world motorcycle technology.
It adopts single-cylinder four-stroke air -cooled engine newly developed by our company,
and employs the devices of carburettor carbruetor, wet automatic centrifugal clutch, five­speed shifting, through driving, reverse driving hand pulled recoil starter and eletric­starter in combination, CDI electric ignition, pressure splash lubrication system, etc, which
are good in performance.This QUAD is novel and bright in design,having moved,
streamlined model and luxury decoration design, and it meet the national standard in
noise and dirt drainage, specially it embodies the great power, reliability, endurance,
being an ideal transportation facility for QUAD funs.
The correct operation and maintenance are the prerequisites at your safety riding of the
QUAD, and also can reduce the fault of the QUAD and keep its best performance. So
please read this manual to understand its basic operation,repair and maintenance
methoels The information contained here in all relates to the QUAD of the current design
and is subject to changes by our company according to the demands of market and users
without notice. If you have any questions, please consult with our motorcycle dealer. We
are welcome for you precious advice and suggestions. Our company has established
many service centers (stations,points), with specially-tranined technical personnel in
operation and maintenance, please contact with our motorcycle dealer and service center
(stations, points). Our company consisitantly adheres to the principle of quality first users
upmost, reputation foremost and be ready to provide you with high quality service.

-1-

IMPORTANT INFORMATION FOR OPERATION

WARNING Injury or death could be result from failure to follow WARNING instructions when you are operating

inspecting or repairing the QUAD.

CAUTION A CAUTION indicates special precautions that must be taken to avoiddamage to the QUAD.

NOTE

A NOTE provides information can make your operation in the QUAD easier or clearer.

-2-

Content

Safety information.....................................................5

Description and machine identification.....................9

Control functions.....................................................11

Main switch.............................................................11

Indicator lights ........................................................11

Handlebar switches ................................................11

Start switches .........................................................11

Light switches.........................................................12

Throttle lever...........................................................13

Speed limiter...........................................................13

Front brake lever ....................................................14

Rear brake pedal and lever ....................................14

Parking brake .........................................................15

Shift pedal...............................................................16

Drive select lever....................................................16

Recoil statrer ..........................................................16

Fuel tank cap..........................................................17

Fuel cock ................................................................17

Seat ........................................................................17

Storage box ............................................................18

Front carrier............................................................18

Rear carrier.............................................................18

Rear shock absorber ..............................................18

Spring preload adjustment......................................18

Pre-operation checkes............................................19

Front and rear brakes.............................................19

Fuel.........................................................................20

Engine oil................................................................21

Lubrication oil of gear case.....................................21

Throttle lever...........................................................21

Fittings and Fasteners............................................21

Lights......................................................................21

Switches .................................................................21

Battery ....................................................................21

Tires........................................................................22

How to measure tire pressure ................................22

Tire wear limit .........................................................23

Operation................................................................24

Starting an engine ..................................................24

Starting a cold engine.............................................24

Starting a warm engine...........................................24

Prewarming ............................................................24

Drive select lever operation

and reverse driving.................................................25

Shifting....................................................................26

To start out and accelerate.....................................26

To decelerate..........................................................26

Engine breakrin ......................................................27

-3-

Accessories ............................................................28

Loading...................................................................28

Ride with care.........................................................28

Speed limit valve ....................................................30

Exhaust silencer ....................................................30

Turning ...................................................................31

Climbing slope........................................................32

Riding downhill .......................................................33

Crossing depression...............................................33

Crossing through shallow water .............................33

Riding over rough terrain........................................34

Slipping...................................................................34

Periodic maintenance and adjustment ...................35

Operation manual and tool kit.................................35

Periodic maintenance /Lubrication .........................36

Engine oil................................................................38

Lubrication oil of gear case.....................................40

Replace of lubrication oil of gear case....................40

Spark plug inspection .............................................41

Air filter cleaning.....................................................42

Carburetor adjustment............................................43

Idle speed adjustment ............................................43

Valve clearance adjustment ...................................44

Throttle lever adjustment........................................44

Front and rear brake shoe inspection.....................44

Front brake lever free play adjustment...................45

Rear brake adjustment ...........................................46

Clutch adjustment...................................................47

Cable inspection and lubrication.............................48

Brake and shift pedal/brake lever lubrication

Steering vertical tube lubrication ............................48

Wheel removal........................................................48

Wheel installation ...................................................49

Fuse replacement...................................................50

Replacing the headlight bulb ..................................51

Spark arrester cleaning ..........................................52

Cleaning and storage .............................................52

Cleaning .................................................................52

Storage...................................................................53

Main data and specification....................................54

Maintenance record................................................56

Electric wiring diagram ...........................................57

-4-

SAFETY INFORMATION

This operation manual includes important safty and
maintenance information. When reselling the QUAD
TO THE NEXT BUYER. The operation manual should
be passed on together with it because the next user
also need the manual. Please read the manual carefully
before driving the new. If failed to conform the
requirements described in the manual. It will be easy
to cause injuries and deaths.

WARNING

- Read this manual carefully and follow the operating
procedures and methods described in this manual.

- Never operate an QUAD without proper
training or instruction.

- A child under 16 years old should never operate an
QUAD. Never allow drive of an QUAD by an individal
person if he or she does not have the abilities to operate
it safely.

- Always avoid driving an QUAD on any paved surfaces,
including sidewalks, driveways, parking lots and streets.

- Never operate an QUAD in any public street, road or
highway.even a dirt or gravel one.

- Never drive an QUAD without wearing an approved

motorcycle helment that fits properly. You should also
wear eye protection (goggles or face shield), gloves,
boots, long-sleeved shirt or jacket.and long pants.

- Never consume alcohol or drugs before or while
operating this QUAD.

- Never operate at speeds too fast.always drive at low
speed on dusty surface.

- Always inspect your QUAD each time you use it to
make sure it is in safe operating condition. Always
follow the inspection and maintenance procedures and
schedules described in this maunal.

- Always keep both hands on the handlebars and both
feet on the footboards of the QUAD during operation.

- Never operate on excessively rough, slippery or loose
terrain unless you have learned and d practiced the
skills necessary to control the QUAD on such terrain.
Always be especially cautious on these kinds of terrain.

- Always follow proper procedures for turning as
described in this manual. Practice turning at low speeds
before attempting to turn at faster speeds. Do not turn
at excessive speed.

- Never drive the QUAD on hills too steep for the QUAD
or for your abilities. Practice on smaller hills before
attempting larger hills.

- Always follow proper procedures for climbing hills as

-5-

described in this manual. Check the terrain carefully
before starting up any hill. Never climb hills with
excessively slippery or loose surfaces. Shift your weight
forward. Never open the throttle suddenly or make
sudden gear changes. Never go over the top of a hill
at high speed.

- Always follow proper procedures for going down hills
and for braking on hills as described in this manual.
Check the terrain carefully before starting down any
hill. Shift your weight backward.Never go down a hill
at high speed. Avoid going down a hill at an angle that
would cause the vehicle to lean sharply to one side.
Go straight down the hill where possible.

- Always follow proper procedures for crossing the side
of a hill as described in this manual. Avoid hills with
excessively slippery or loose surfaces, shift your weight
to the uphill side of the QUAD. Never attempt to turn
the QUAD around on any hill until you have mastered
the turning technique described in this manual on level
ground .Avoid crossing the side of a steep hill if possible.

- Avoid crossing the steep hills.

- Always use proper procedures if you stall or roll
backwards when climbing a hill. To avoid stalling, use
proper gear and maintaina steady speed when climbing
a hill. If you stall or roll backwards. Follow the special

procedure for braking described in this manual.

- Always check for obstacles before operating in a new
area.Never attempt to operate 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 extremly
slippery surfaces, such as ice. Go slowly and be very
cautious in order to reduce the chance of skidding or
sliding out of control.

- Never operate an QUAD in fast flowing water or in
water deeper than that recommended in this manual.
Remember that wet brakes may have reduced stopping
ability. Test your brakes after wiping water away. If
necessary,apply them several times to let fricting dry
out the linings.

- Always be sure there are no obstacles or people
behind you when operating in reverse. When it is safe
to procceed in reverse, go slowly. Always use the size
and type tires specified in this manual. Always maintain
proper tire procedure as described in this manual.

- Never modify an QUAD through improper
installation or use of accessories.

-6-

- Never exceed the stated load capacity for an QUAD.
Cargo should be properly distributed and securely
attached.

- Reduce speed and follow instructions in this manual
for carrying cargo or pulling a trailer. Allow greater
distance for braking.

- Improper handing of gasoline can cause fire and can
cause injuries and deaths and other serious accident.
So do not refuel right after the engine has been running
and is still every hot. Never refuel while smoking, or
while in the vicinity of sparks, open flames, or other
sources of ignition, when transporting the machine in
another vehicle, be sure it is kept upright and that the
fuel cock is in the "OFF" position, otherwise fuel may
leak out of the carburetor or fuel tank.

-7-

Starting or running the engine in a closed area will cause the breakdown. And exhaust fumes are poisonousus and
may cause loss of consciousness and death within a short time. Always operate your machine in an area with adequate
ventilation.

-8-

DESCRIPTION AND MACHINE IDENTIFICATION 1. Front wheel

2. Headlight

3. Drive select lever

4. Shift pedal

5. Fuel cock

6. Recoil starter

7. Starter(choke)

8. Taillight

9. Rear wheel

10. Rear carrier

11. Spark arrester

12. Seat

13. Fuel tank cap

14. Brake pedal

15. Front carrier

16. Rear brake lever

17. Parking brake

18. Main switch

19. Throttle lever

20. Front brake lever

21. Handlebar switch

The machine you have purchased may differ slightly
fron those shown in the figures of this manual for
progress or other change.

-9-

Identification numbers record

When ordering spare parts from a our dealer or for reference in case the vehicle is stolen record, vehicle identification
number in the spaces provided for assistance.

1. VEHICLE IDENTIFICATION NUMBER:

Vehicle identification number

The vehicle identification number is stamped on crosstube of pedestal.

-10-

CONTROL FUNCTIONS

Main switch

Functions of the respective switch positions are as
follows:

ON:

Engine can be started only at this position and the
headlight and taillight come on when the light swithc
is on.

This indicator light comes on when the transmission is
in reverse.The light is blue in color.

Neutral indicator light " N "

This indicator light comes on when the transmission is
in neutral.

High beam indicator light " "

This light is yellow in color .It comes on when the head
light and high beam light is on.

OFF:

All electrical circuits are switched off. The key can be
removed in this position.

Indicator lights

Reverse indicator light "R"

Handlebar switches
Engine stop switch

Make sure that the engine stop switch is in the " "
position. The engine stop switch controls ignition 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 when this switch
is pushed.
See starting instructions prior to starting engine (see
page for details).

-11-

If the starter switch is pushed with the main switch
" " and the engine stop switch " " , the starter
motor will be activated but the engine will not start. To
start the engine ,be sure to set the engine stop switch
at " ".

Lights swtich "LIGHTS"

Turn the switch to " " for the low beam and taillight.
for the hight beam
Turn the switch to " " for the hight beam and taillight.

1. Neutral indicator light "N"

2.Reverse indicator light "R"

3.Hight beam indicator light " "

1. Lights switch "LIGHTS"

2. Engine stop switch " " " "

3. Start switch " "

-12-

Throttle lever

Once the engine is running .movement of the throttle
lever will increase the engine speed.Adjust the speed
of the machine by changing the throttle position.Because
the throttle is spring-loaded,the machine will
decelerate.and the engine will return to an idle any
time the hand is removed from the throttle lever.Before
starting the engine .check the throttle to be sure it is
operating smoothly .Make sure it returns to the idle
position as soon as the lever is released.
Check the operation of the throttle lever before starting
the engine.lf it does not work smoothly.check
for the cause. Correct the problem before riding the
QUAD. Consult a our dealer if you can't find or solve
the probem yourself.

1 .Throttle lever

Speed limiter

The speed limiter keeps the throttle from fully opening,
even when the throttle lever is pushed to the maximum.
Screwing in the adjusting screw limits the maximum
engine power available and decreases the maximum
speed of the QUAD.

-13-

1. Locknut

2. Adjusting screw a.12mm (047in)

CAUTION

Do not turn the speed adjusting screw out more than
12mm. Always make sure the throttle lever free play
is adjuted to 3-5mm.

Front brake lever

The front brake lever is located on the right
handlebar.Pull it toward the handlebar to apply the
front brake.

Rear brake pedal and lever

The brake pedal is located on the right side of
the machine and the brake lever is located on the left
handlebar. Pull the lever toward the handlebar or tread
slow the pedal to apply the rear brake.

1. Rear brake pedal

-14-

Parking brake

When you have to start the engine or park the machine,
especially on a slope, use the parking brake
Apply the rear brake lever and push down the lock
plate to apply the parking brake,squeeze the rear brake
lever to release the parking brake.

CAUTION

The QUAD could start moving unexpectedly if the
parking brake is out of function before starting the
engine. This could cause loss of control or a collision.
The barke could overheat if you ride the QUAD without
releasing the parking brake. You could lose braking
performance which could cause an accident. You could
also wear out the brakes prematurely.

1. Rear brake lever

2. Lock plate

1. Lock plate

-15-

HOW TO AVOID THE HAZARD

Always set the parking brake before starting the engine.
Always be sure the parking brake have been released
before you begin to ride.

Shift pedal

This machine is equipped with a constant mesh 5­speed transmission. The shift pedal is located on the
left side of the engine. Neutral is at the bottom position.

Drive select lever

The drive select lever is used for driving the machine
either forward or in reverse. Refer to page for drive
select lever operation.

1.Shift pedal N.Neutral

1 .Drive select lever

2. Hand start lever

Recoil starter

Firmly grasp the handle and pull slightly up to
engagement can be felt. Then pull forcefully.being
careful not to pull the rope all the way out.

CAUTION

Don't start the engine in non-neutral or without setting
the parking brake system.
Put the transmission in neutral and set the parking
brake before starting the engine.

-16-

Fuel tank cap

Remove the fuel tank cap by turning it counter clockwise.

Fuel cock

The fuel cock supplies fuel from the fuel tank to the
carburetor.

OFF:

If the lever is in this position, fuel will not flow. Always
turn the lever to this position when the engine is not
running

1. Fuel tank cap

ON:

If the lever is in this position.fuel flows to the carburetor.
Normal riding is done with the lever in this position.

RES:

This indicates reserve. If you run out of fuel while
riding.turn the lever to this position. After refuelling,
return the fuel cock lever to the "ON"position.

Seat

To remove the seat, pull the seat lock lever upward
and pull up the seat at the rear.
To install the seat, insert the lobes on the frame and
push down the seat at the rear you should pay attention
to make sure that the seat is securely fitted.

1 .Seat lock lever

-17-

Storage box

Maximum load limit: 2kg

Front carrier

Maximum load limit: 30kg

Rear carrier

Maximum load limit: 60kg

Rear shock absorber

The spring preload can be adjusted to suit the rider's
weight and riding conditions.

Spring preload adjustment

To increase the spring preload turn the adjuster in
direction A.To decrease the spring preload,rum the
adjuster in direction B.
Standard position: B
A-Minimum(Soft)
E-Maxinum(Hard)

-18-

PRE-OPERATION CHECKS

Before using this machine.check the following points:

ITEM

Brakes

Engine oil

Fuel tank

Gear oil
Throttle
Wheels and tires
Fittinqs and fasrteners
Lights
Battery

ROUTINE
Check operation,condition and free play

Adjust if necessary
Check oil level
Fill with oil if necessery
Check fuel level
Fill with fuel if necessary
Check for leakaqe
Check for Draper throttle cable operation
Check tire pressure wear and damage
Check all fittinqs and fasteners
Check for proper operation
Check the voltage

Inspect the QUAD each time you use it to make sure
the QUAD is in safety operationg condition.
Follow the inspection and maintenance procedures
and schedules described in the Operation Manual.

Front and rear brakes

Always check the brakes at the start of every side. Do

PAGE

not ride the QUAD if you find any problem with the
brakes. lf a problem cannot be corrected by the
adjustment procedures. Provided in this manual,have
the QUAD inspected by a our deatler.
Check for correct free play in the brake levers and brake
pedal, If the free play is incorrect adjust it see pages.
Check operation of the levers and pedal They should

-19-

move smoothly and there shoud be a firm feeling when
the brake is applied. If not, have the machine inspected
by a our dealer.
Test the brakes at slow speed after starting out to make
sure they are working properly. lf the brakes do not
provide proper braking performance, inspect the brakes
for wear. See page.

Fuel

Make sure there is sufficient gasoline in the tank.
Recommended fuel: unleaded fuel
Fuel fank capacity:
Total: 12L
Reserve: 1.6L
Unleaded fuel will give a longer spark pulg life and
reduce maintenance cost. If unleaded gasoline is not
available the leaded regular gasoline can be used.

1. Brake levers and brake pedal

2. Brake operation

CAUTION

Fuel can spill, causing a fire and severe injury.
Fuel will expand when it heats up if the fuel tank is
overfilled .fuel could spill out due to heat from the
engine or the sun.So, do not overfill the fuel tank .Be
cerful. Not to spill fuel,especially on the engine or
exhaust pipe wipe up any spilled fuel immediately.
Be sure the fuel tank cap is closed securely. Do not
refuel right after the engine has been running and is
still very hot.

-20-

Enegine oil

Make sure the engine oil is at the specified level. Add
oil as necessary.(See pape)
Recommended oil
SAE20W40
SAE10W30
SAE5W30
Recommended engine oil classfication:
SE, SF, SG type or higher.
Oil quantity:
Periodic oil change: 1.5L
With oil filter replacement: 1.6L
Total amount: 1.8L

Lubrication oil of gear case

Make sure the lubrication oil of gear case is at the
specified level. Add oil as necessary.(see page for
defails).

Recommended oil

SAE80 API GL Hypoid gear oil

Throttle lever

Check to see that throttle lever operates correctly. It
must open smoothly and spring back to idle position

when released.Repair as necessary for proper
operation.

Fittings and Fastenerns

Always check the tightness of chassis fittings and
fasteners before a ride.Refer to the Service . Manual
for correct tightening torque.

Lights

Check the headlight and taillight to make sure they are
in working condition. Repair as necessary for proper
operation.

Switches

Check the Operation of the headlight switch, engine
stop switch and any other switches.Repair as necessary
for proper operation.

Battery

- The battery is an enclosed one and unnecessary to
fill water (see page)

- Don't take off the closing bolt when charging.

- When charging,please obey the charging current and
time as shown on the following table.
Charge criteria: Charge the battery with ten percent of

-21-

capacity of battery for 5 to 10 hours,or quickly charge
the battery with 2A to 3A for 2 hours.

Tire

The size and type (in low pressure condition) of hollow
tire used for 250 QUAD are listed below.

Size

Type

Front wheel
AT22X7-10

Zheng xin or wuxi

Rear wheel

AT22 x 10-10

Zheng xin or wuxi

warning

Use of improper tires on this QUAD, or operation of
this QUAD with improper tire pressure may increase
your risk of accident.
Use of improper tires on this QUAD, or operation of
this QUAD with improper tire pressure may cause loss
of control.
Pay attention to choose the Size and type of used tire
according to the description in the above chart and
make sure that the tire pressure is normal.

2. The tires should be set to the recommended pressure.
Front 20KPa(0.20kgf/cm22,2.8pai)
Rear 25KPa(0.25kgf/cm22,3.6pai)
Check and adjust tire presssure when the tires are
cold.
Tire Pressure below the minimum specified could cause
the tire to dislodge from the rim under severe riding
conditions.the following are minimums:
Front 17KPa(0.17kgf/cm2)
Rear 22KPa(0.22kgf/cm2)
Higher pressures may cause the tires to burst. Inflation
could cause the tires to burst

How to measure tire pressure

Use the low-pressure tire gauge.

-22-

Caution:

The low-pressure tire gauge is included as standard
equipment, conduct two measurements if the tire
pressure and use the second reading. Dust or dirt in
the gauge would cause the First reading to be incorrect.
Set pressure when tires are in cold and set tire pressures
to the condition following specifications:

1. Low-pressure tire gauge:

Front

Rear

Recommended

pressure

20Kpa

(0.20kgf/cm2)

25Kpa

(0.25kgf/cm2)

Minimum

17Kpa

(0.17kgf/cm2)

22Kpa

(0.22kgf/cm2)

Maiximum

23Kpa

(0.23kgf/cm2)

23Kpa

(0.28kgf/cm2)

Tire wear limit

When the tire groove decreases to 3mm due to wear.

a. 3mm (0.12 in)

-23-

OPERATION

WARNING

Never operate QUAD until you are familiar with all
controls.
Read the operation Manual carefully. If there is a
controls or function you do not understand, ask your
our dealer.
WARNING
Never ride the QUAD in cold weather,always make
sure all control cables work smoothly before you begin
ridding. Please read the engine brake-in section before
you operate the engine at first time.

Starting a cold engine:

1. Set the parking brake.

2. Turn the fuel lock to "ON” and the engine stop switch
to " ".

4. Shift the transmission into neutral.

WARNING

The engine can be started in any gear if the rear brake
lever is applier. However.it is recommended to shift
into neutral before starting the engine.

5. Use the starter(choke)in reference to the figure.

NOTE

If the engine fails to start release the start switch, then
push the start switch again, pause a several secords
before the next attempt. Each cranking should be as
short as possible to preserve battery energy. Do not
crank the engine more than 10 secords for each starting.
If the battery is discharged, pull the recoil starer to start
ergine.

Starting a warm engine

The throttle should be opened slightly when starting a
warm engine.

Prewarming

To get maximum engine service life, prewarm the
engine before startting off. Never accelerate forcefully
with a cold engine.

-24-

Drive select lever operation and reverse driving.
CAUTION

Before shifting, stop the machine and return the throttle
lever to its closed position. Otherwise the transmission
may be damaged.
When shifting into reverse the transmission must be
in the first gear. Do not shift the Reverse Handle Bar
before you make sure that the QUAD is in the Firest
Gear or you may break the Handle Bar.

1. Reverse Handle Bar

2. Hand start lever

a. Forward
b. Reverse

1. Stop the machine completely and return the throttle
lever to the closed position.

2. Apply the rear brake pedal.

3. Shift the transmission into first gear.

4. Press the lock-button of the Reverse Handle Bar
hard into the socket the you can shift the Reverse
Handle Bar. After it is moved to the proper position,

move the Handle Bar and softly to make sure the spring
of the lock-button is released and the Handle Bar is
locked.

5. In case the lock-button can not be released
after the Handle Bar is shifted to it's position, ask the
repair shop help.
NOTE
When in reverse the reverse indicator light should be
on. If the light does not come on ask a our dealer to
inspect the machine.

6. Check for people or obstacles behind you, then
release the rear brake pedal.

7. Open the throttle lever gradually and continue to
watch to the rear while backing.

WARNING

When shifting into reverse, make sure there are no
obstacles or people behind you when it is safe to
proceed, go slowly.

-25-

Shifting:

This machine has a 5-speed forward and 1-speed
reverse transmission with centrifugal automatic clutch.
To shift into neutral when driving, return the throttle
lever to its original position and repeatedly depress the
shift pedal until it stops .

CAUTION

Always close the throttle while shifting gears. Otherwise,
the engine and drive train may be damaged.

2. Shift into first gear and release the shift pedal.

3. Open the throttle gradually once the machine has
obtained adequate speed release the throttle lever.

4. Shift into second gear and release the shift pedal.

5. Open the throttle gradually. Follow the same
procedure. When shifting to the next higher gear.

1 .Shift pedal

CAUTION

Do not coast for long periods with the engine off, and
do not tow the machine a long distance. Even when
gears are in neutral, the transmission is only.Properly
lubricated when the engine is running. Inadequate
lubrication may damage the trarsmission.

To start and accelerate:

1. Release the throttle lever.

To decelerate:

When slowing down or stopping, release the throttle
and apply the brakes smoothly and even. As you slow
down, shift to a lower gear, Be sure that the engine
has sufficiently slowed before engaging a lowe gear.
lmproper use of the brakes or control can cause the
tires to lose traction, reducing control and increasing
the possibility of an accident.

-26-

Engine break-in

There is never a more important period in the left of
your machine than the period between zero and 20
hours. During this period prolonged full throttle operation
or any condition which might result in excessive engine
heating must be avoided after every full throttle
acceleration the engine should run at lower speed for
a rest so as to rid itself of the temporary build up of
heat. lf any abnormality is found during this period
consult a our dealer.

1. 0-10 hours:
Avoid continuous operaton above half throttle. A allow
a cooling off period of five to ten minutes after every
hour of operation. Vary the speed of the machine from
time to time. Do not operate it at one set throttle position.

2. 10-20 hours:
Avoid prolonged operation above 2/4throttle revolving
the machine can freely through the gears durin running
of engine but do not use full throttle any time.

3. After break-in
Avoid prolonged full throttle operation change speeds
occasionally.

Parking

When parking, stop the engine and shift into neutral.
Turn the fuel to "OFF" and apply the parking brake.

1. Lock plate

Avoid parking on hills or other inclines .If you have to
park on an incline put the machine in low gear.apply
the parking brake and block the front and rear wheels
with rocks or other object.Do not park the QUAD on
the hills that are so steep that you could not walk up
them easily.

1. Appling the brakes in low gear to stop the machine.

2. Stop the engine. With the rear brake lever and pedal
applied, apply the parking brake and slowly release
the rear brake pedal.

-27-

Accecsories:

Pay attention to the following points.
Choose only accessories designed for you QUAD. Our
dealer has a variety of genuine accessories . Choose
a genuine accessory.

WARNING

1. Accessories should be rigidly and securely installed.

2. Do not install an accessory where it could interfere
with your ability to control the QUAD. Examples include
a heavy or bulky object attached to the handle bars
which could make steering difficult an accessory that
limits your abitiy to move around on the seat or one
that limits you view. Use extra caution when riding an
QUAD with accessories.

Loading

Never exceed the weight limits shown An overloded
QUAD can be unstable.
You must use common sense and good judgement
when earring cargo or towing a trailer, keep the following
points in mind:

Maximum loading limit

Vehicle Loading limit (total weight of cargo rider and

accessories):165kg
Front luggage carrier:30kg
Rear luggage carrier:60kg
Tool kit: 2kg
Pulling load (total weight of trailer and cargo): 330kg
Vertical weight on trailer hook: 15kg
Do not exceed the maximum pulling weight.
Adjust the load in the trailer.
Cargo should be put as close to the center of the QUAD
as possible. Put cargo at the front of the rear
luggage carrier. Put the cargo on the middle position
and fix it on the carrier firmly.
Make sure cargo in the trailer is loaded firmly and
safety. Otherwise an accident would be happen.
Make sure the load does not interfere with controls or
your sighting.
Ride more slowly than you would with a load. The more
weight you carry, the slower you should go. Although
conditions is different, it is not allowed to exceed 2nd
gear whenever you are carrying heavier loads or when
towing a trailer. Allow more braking distance. A heavier
vehicle takes longer to stop. Avoid making sharp turns
unless at very slow speeds.
Avoid riding on hills and rough road surface. And
choose terrain carefully. Extra weight will affects the

-28-

stability and operation of the QUAD.
This machine could be used to carry cargo and
passengers is prohibited.

OPERATION

1. Get training if you are unexperienced.
Beginners should be trained at the guide of professional
person. Drive with this QUAD with low speeds first to
familiar with its performance even if you are an
experienced rider do not attemp to operate at maximum
performace until you are totally familiar with QUAD´'abs
performance.

2. Dress
Always wear a motorcycle helment when riding. Also
wear the following protective tools eye protection
(goggles or dust-proof shield, gloves, boots long-sleeved
shirt or jacket pants)

3. Do not operate after drinking alchohol or drugs
containing sleeping pill composition, because operator
would be slow in driving in such way.

4. Always check your QUAD each time before you ues
it to make sure the reliability of QUAD. AIways follow
the inspection and maintenance procedures in the
operation manual to protect you QUAD.

5. Always select the size and type of tires specitied in
the operation manual for this vehicle to keep the normal
tire pressure.

-29-

6. Speed limit valve
This valve is used for beginners to limit the max speed
of the QUAD. Rotate the bolt clockwise to incresase
max speed, and rotate it coutercloclwise to decrease
max speed.

7. Always keep your feet on the footboards during
operation otherwise your feet may contact the rear
wheels.
Never attempt stunts such as wheelies or jumps.

WARNING

Don't try to show off

8. Improper installstion of accessories or modification
of this vehicle may cause changes in harding which in
some situations could lead to an accident.

Never modify this QUAD through improper installation
or use of accessories. All parts and accessories added
to this vehicle should be genunie our or equivalent
components designed for using on this QUAD and
should be installed and used according to instructions
our dealer. If you have questions cousult an.authorized
QUAD dealer.

9. Exhaust silencer
The exhaust silencer is very hot during driving. To avoid
burn, do not touch the exhaust cylinder. Park the machine
where pedestrians or children can not touch it.

10. Know where you should ride
This machine is designed to drive on off-road. Riding
on asphalt road may lose control.
Don't ride the QUAD on asphalt road, including
sidewalks, driveways, parking lots and walk streets.
Prohibit to drive the machine on any driveway, streets
or highways.

-30-

Know the terrain where you ride

Ride carefully in complicated terrain, stay alert for
holes, rocks or roots or roots in the terrain otherwise
may cause the machine to tip over.
When riding in an area where you might not easy to
be seen, such as dune and hilly land, must
mount a caution flag on the machine to remind other
vehicles. Do not ride in areas of forbidding pass. Do
not ride on private property. Operation course

CAUTION

Do not shift gears without releasing the throttle.
Otherwise may cause damage to the engine or drive
gear.

When slowing down or stopping, release the throttle
and brake gradually. As you brake, shift to lower gear.
Ensure that the engine has sufficiently slowed Improper
use of the brakes or shifting can cause the tires slidding
to lose the control.
Must make the engine to slow down fully before
engaging a lower gear.

Turning

Must make the turning practice in low speed before
making a turn.
Turn your QUAD according to procedures in operation
manual. Practice should be done before turning in high
speed.
The turning speed should not be too high.
As you approach a curve, slow down and begin to turn
the direction rod. Then put you gravity center on the
footboard to the outside of the curve and lean your
body inside. Make the engine to maintain an even
speed when passing the curve. This maneuver will let
the tire on the inside of the curve slip slightly.
The turning practice should be in flat area with out any
obstacles. Improper operation may make your QUAD
to go straight. lf the QUAD doesn't turn stop it and
practise again. If the riding surface is loose and slippery

-31-

move your weight forward.
Once you have learn this technique you can turn your
QUAD at higher speed.
The sudden acceleration, brake incorrect body position
and too high speed will cause the QUAD to slip. If the
QUAD slips while passing a curve and the
QUAD machine leans inward, you should release the
throttle and move your body gravity center to outside
of the curve to avoid tipping over.
Remembenride at higher speed only after you are
thoroughly familiar with the operation of your QUAD

Climbing slope

Don't ride on slope before you are very familiar with
QUAD operation skill otherwise it will cause accidents.
Neccessary practice is required when climbing the hill,
move your body gravity center forward and operation
manual.
Climb the hill according to the method in manual.
Climb the hill according to the method in manual.
Check carefuly before climbing.
Do not drive on slippery and loose slope.
Transfer your body gravity center forward and avoid
abrupt acceleration and shift.
Drive in low speed when climbing the hill.

WARNING

There may be other vehicles and persons on the other
side of slope.
If your QUAD can not climb the slope turn round your
QUAD.
Make turning practice according to procedures in
operation manual. Do not make turn on slope. Be more
careful when making a turn on slope. Be more careful
when making a turn on slope and avoid to climb steep
slope when possible when climbing the slope:
Do not drive on depression and slippery slope and
drive according to procedures in operation manual.
Ensure the QUAD not to slip when stop it on slope.
The shift should be proper and speed shuld be stable
when climbing slope losing traction force you should
transfer the gravity center forward and brake the
machine. Close the brake closing piece after stopping
the machine.

If the machine slips backward

Transfer you gravity center backward;
Use front brake
Do not use rear brake
Close the brake closing piece after stopping the
machine.

-32-

Riding downhill

Move your gravity center backward, when riding QUAD
downhill your and grisp steering bar and drive at low
speed.
Note: The brake performance is very important.
Whenever possible, ride your QUAD straight. Turing
may cause the QUAD to tip over. Avoid too high speed
so that you have time to deal with accident.

CAUTION

Practise the braking skill when decending the hill look
over the terrain carefully before decending
and transfer your body gravity center backward. Ride
in low speed when decending the hill turning speed
should not be too high when making a turn, and keep
driving straight as far as possible.

Crossing depression

When crossing depression, balance your QUAD with
body gravity center. You should be familiar with basic
skills before crossing depression. Avoid to lose balance
to cause accident.
Don't make a turn on a slope before grasping turning
skill totally. You should be careful and cautious if making
a turn on any slope.

When crossing procedure

Always follow proper prouclures in operation manual;
Avoid slope with slippery or loose surface.
Lean your gravity center in the slope direction.

Crossing through shallow water

The QUAD can be used to cross shallow water of
maximum distance of 35cm. Check your path carefully

-33-

before crossing and avoid of ride where there is sharp
drop off. Drive slowly and carefully.
Pay attention that wet brakes may reduce brake ability.
Check your brakes after leaving water. lf necesary,
apply them to let friction dry out the linings several
times.

Riding over rough terrain

Be careful when riding on rough terrain when riding
over terrain which may damage the QUAD lay your
feets on the foot pedals to avoid jumping and loss of
control.
Don't try to ride over big obstacles such as rock and
tree on the road. Follow the proceduces in operation
manual when riding over obstacles.

Slipping

The QUAD may lose control when driving on loose
and slippery surface. Moving you gravity center forward
is helpful to control the slipping of front wheels. when
the rear wheel begin to slipsteer direction properly
.Apply the brake only until you have stopped the slipping.

Practise safely control slipping at low speed, on very
slippery surefaces, such as ice, drive slowly to avoid
loss of control.
The above introduction is only for reference. Read it
carefully and act according to circumstances.

-34-

PERIODIC MAINTENANCE AND ADJUSTMENT

Periodic inspection, adjustment, and lubrication will keep your machine in the safety and most efficient condition. The
points of machine inspectionadjustment and lubrication are detailed in following.

NOTE

Turn off the engine when maintaining unless specified. Have a our dealer perform service if you are not familiar with
maintenance.

Operation manual and tool kit

You are recommended to put this operation manual in the vinyl bag and lay it under the seat as shown. Put the tool
kit and low pressure tire gauge in the storage case.
The maintaining information included in this manual is provided you with the necessary information for completing
preventive maintenance and minor repairs by yourself. The tools provided in the tool kit are sufficient for this purpose
except a torque wrench necesary to tighten nuts and bolts.

NOTE

If you do not have a required torque wrench during maintenance take you machine to a our dealer to check the torque
settings and adjust them as necessary.

-35-

PERIODIC MAINTENANCE/LUBRICATION

ITEM

Valves

Spark plug

Air filter

Carburetor

Cylinder head
breather
system

Exhaust
system

Spark arrester

Fuel line

Engine oil

Engine oil filter

Engine oil
strainer

ROUTINE

Check valve clearance. Adjust if necessary.

Check condition. Adjust gap and clean. Replace if necessary.

Clean. Replace if necessary.

Check idle speed/Starter operation. Adjust if necessary.

Check breather hose for cracks or damage. Replace if necessary.

Check for leakage. Retighten if necessary. Repace gasket if
necessary

Clean

Check fuel hose for cracks or damaqe. Replace if necessary.

Replace (Warm engine before draining).

Clean

Clean

INITAL

1 month

Every 20-40 hours(more often in wet or dusty areas)

3months

6months

EVERY

6months

1Year

Final gear oil

Check oil level/oil leakage. Replace.

-36-

PERIODIC MAINTENANCE/LUBRICATION

ITEM

Brakes

Clutch

Wheels

Wheel bearings

Front and rear
suspension

Steering
system

Steering
system

Steering shaft

Fittings and
Fasteners

ROUTINE

Check operation. Adjust if necessary.

Check operation. Adjust if necessary.

Check balance/damage/run out. Replace if necessary.

Check balance assembly for looseness/damage.
Replace if damaged.

Check operation. Correct if necessary.

Check operation.Correct if necessary. Check toe-in.

Adjust if necessary.

Lubricate every 6months. (use Li grease)

Check all chassis fittings and fasteners. Correct if necessary.

1 month

INITAL

3months

6months

EVERY

6months

1Year

-37-

Engine oil

1. Engine oil level measurement
a. Place the machine on a flat surface wram up the
engine for several minutes and turn off it. Wait more
than 10 minutes for the oil to drain back into the
crankcase before checking the oil level.

1. Dipstick

2. Maximum level mark

3. Minimum level mark

b. Wipe the dipstick off with a clean rag. Insert the
dipstick in the filler hole.
c. Remove the dipstick and inspect the oil level.
d. The oil level should be between maximum and
minmum marks. If level is low, add oil to raise it to
proper level.

1. Drain plug

2. O-ring

3. Compression spring.

4. Oil strainer

1. Oil filter cover

2. OH filter

3. O-ring

-38-

2. Engine oil replacement and oil fitter element cleaning
a. Place the machine in a flat suface. Warm up the
engine for several minutes and turn off place a container
under the engine. Remove the dipstick and open the
drain plug to drain the oil.
b. Remove the oil fiter cover and oil filter clean the oil
strainer and oil filter with solvent.
c. Inspect the O-ring and replace if damaged.
d. Reinstall the oil filter, O-ring and oil filter cover.
Replace the oil strainer compression spring, O-ring
and drain pulg. Then tighten the drain plug and filter
cover bolts to the specified torque.

Tightening torque:
Drain pulg (engine): 43Nm(4.3m.kg)
Filer cover bolt:10Nm(1.0m.kg)
e. Add oil to the engine with oil and install the dipstick.

CAUTION

Be sure no foreign material enters the crankcase.
f. Warm up the engine for several minutes at
idle speed. Check for oil leakage when warming up.

CAUTION

If oil leakage is found, turn off the engine promptly and
check for the cause.
Recommended oil: see page 11
Oil quantity:
Periodic oil change:

1.5L(1.3mpqt)
With oil filter replacement:

1.6L(1.4mpqt)
Total amout:

1.8L(1.6mpqt)

3.0il pressure inspection
a. Wrap the cylinder with a cloth.

1 .oil gallery bolt

-39-

b. Slightly loosen the oil gallery bolt in the cylinder
head.
c. Start the engine and keep it at idle speed unil begins
to seep fron the oil gallery bolt.lf no oil comes out after
one minute.stop the engine to find cause.
d. Restart the engine and check the oil pressure.
e. After checking.tighten the oil gallery bolt to the
specified torque 7Nm (0.7m.kg)
f. Remeber to inspect oil pressure after replacing the
engine oil.

Lubrication oil of gear case

a. Measurement of lubrication oil of gear case.
Place the machine on a level place. Remove the oil
filler bolt and check the oil level. lt should be up to the
brim of the hole. If should be up to the brim of the

Hole. If the level is too low add oil to raise it to the
proper level.
b. lnstall the oil filler bolt and tighten to the specified
torque: 23Nm(2.3.kg,17ft.lb)

Lubrication oil replacement of gear case

a. Remove the gear case cover.
b. Place the machine on a flat surface.
c. Place a container under the final gear case.
d. Remove the oil filler bolt and the drain plug to drain
the oil.
e. Install the drain plug and tighten to the specified
torque: 23Nm(2.3m.kg)
f. Fill the gear case with oil.

-40-

Recommended oil:
SAE 80API"GL-4" Hypoid gear oil
Oil quality
Periodic oil change:

0.25L(0.21lmpqt,)
Total amount:

0.27(0.23lmp qt.)

1.Drain plug

g. Install the filler bolt and tighten to the specified torque
:2.3Nm(2.3m.kg)
h. Check for oil leakage.lf oil leakage is found, check
for the cause
i. Reinstall the final gear case cover.

Spark plug inspection

You should periodically remove and check the spark
plug because heat and deposits will cause slow damage
and erosion of the spark plug if electrode erosion is
excessive, you should replace the spark plug with one
of the propet type D7RTC
Before installing the new spark pulg measure the
electrode gap with a feeler gauge and adjust to
spectifcation.

1.Spark plug gap
Spark plug gap:

0.6-0.7mm

When installing the spark pulg, generally clean the
gasket surface and use a new gasket. Clean off any
grime from the threads and tighten to specification.
Spark plug torque: 17.5Nm (1.75m.kg)

-41-

Air fillter cleaning

There is a check hose at the bottom of the air fillter
case.if there are dust or water collects in this hose,
empty the hose and clean the air filter element and air
filter case.

1. Check hose

1. Remove the seat.

2. Remove the air filter case cover.

1. Air filter element

2. Foam cover

3. Remove the air filter element.

4. Remove the foam cover from the air filter element.

5. Tap the element lightly to remove most of the dust
and dirt. Blow out the remaining dirt with compressed
air. If the element is damaged, replace it.

6. Wash the foam cover gently thoroughly in water or
solvent.

-42-

7. Squeeze the excess water or solvent out of the foam
cover and let it dry. Do not twist the foam
cover when squeezing it.

8. Check the foam cover if damaged, replace it.

9. Reinstall the foam cover to the air filter element.

10. Reinstall the removed air filter unit and parts
removed.

CAUTION

The carburetor was set at the our factory after many
tests. If the settings are disturbed by somenone without
sufficient technical knowledge, poor engine performance
and damage may result.

CAUTION

Never run the engine with the air filter element removed.
This will let unfiltered air enter.causing rapid wear and
possible damage of engine. Additionally, operation
without the filter element will weak the performance of
carburetor and cause overheating of engine.

Carburetor adjustment

The idle speed may be performed by customer as a
part of the routine maintenance.

Idle speed adjustment

1. Start the engine and warm it up for a few minutes
at approximately 1,000 to 2,000 r/min, increase the
speed of engine to 4000 to 5000r/min .

2. Set the specified idle speed by adjusting the throttle
adjusting screw. Turn the screw into increase engine
speed, and out to decrease engine speed.
Specified idle speed: 1450-1550 r/min

1. Throttle adjusting screw

-43-

Valve clearance adjustment

Incorrect valve clearance will result in improper fuel/air
supply or engine noise. To prevent this, the valve
clearance must be adjusted regularly, but the adjustment
should be done by a professional mainterance
technician.

Throttle lever adjustment
NOTE

Adjust the engine idle speed before adjusting the throttle
lever.

1. lossen the locknut.

2. Rotate the adjusting bolt until the throttle lever free
play is 3-5mm(0.12-0.20in)

3. Tighten the locknut.

1. Adjusting bolt

2. Locknut a. 3-5mm
(0.12-0.20in)

Front and rear brake shoe inspection

A wear indicator is mounted on each brake. The wear
of brake shoe could be checked under the condition
of disassembling brake. If the indicator reaches the
wear limit line, ask a our Group dealer to replace the
shose as a set.

1. Wear indicator

2. Wear limit

-44-

Front brake lever free play adjustment

Inspect the front brake shoes before adjusting the
brake.
The front brake lever free play should be adjusted to
5-7mm (0.2-03in) If the free play is incorrect, adjust as
following steps:

1. Locknut

2. Adjusting nut

1. Loosen the locknut and fully turn in the adjusting
bolt of the front brake lever.

2. Make sure the cable joint of the balancer is straight
when applying the brake. If not, rotate the adjusting
nut at the front hubs until the cable joint becomes
straight.

1. Adjusting nut
(front hub)

3. Retate the adjusting bolt at the front brake lever to
make the free play satisfy the requirement.

4. Tighten the locknut. After maintaining, pay attention
to: Make sure the brakes operate smoothly and the
free play meet the requirement.
Make sure the brakes do not skid.
Replacement of brake components requires professional
knowledge.
These procedures should be done by our Group dealer.

-45-

Rear brake adjustment

1. Brake pedal
a. Fully loosen the adjusting nut on the brake cable.
b. Rotate the adjusting nut on the brake rod untill free
play is 20-30mm.

2. Brake lever
a. Loosen the locknut and fully turn in the adjusting nut
on the handlebar.
b.Turn in the adjusting nut on brake cable to get a gap
of 0-1 mm between the lever and pin of pivot.

1. Brake cable adjusting nut

2.Brake rod adjusting nut

a. 20-30mm

1. Locknut

2. Adjusting nut

-46-

1. Brake cable adjusting bolt a. 0-1mm(0-0.4 in)
c. Rotate the adjusting nut until free play is 5-7mm.
d. Tighten the locknut.

1. Locknut

2.Adjusting nut a.5-7mm

After maintaining, pay attention to: Make sure the
brakes operate smoothly and the free play is correct.
Make sure the brakes do not skid. Replacement of
brake components requires professional knowledge.
These procedures should be done by our Group dealer.

Clutch adjustment

1. Loosen the lock nut

2. Slowly rotate the adjusting bolt counterclockwise
until resistance is felt then, rotate it by1/8 turn clockwise,
i.e.45º.

1. Locknut

2. Adjusting bolt

3. Tighten the locknut to specified value .Tightening
torque:15Nm(1.5m.kg)

-47-

NOTE

Turn the adjusting bolt counterclockwise to decrease
the clutch free play and turn it clockwise to increase
the free play.

cable inspection and lubrication

The damage of outer covering of control cable
can cause corrosion, fray or kink of cable. Operation
of cables could be strictly executed, which could cause
an accident or injury.
Inspect cable frequently and replace damaged cables.
Lubricate the inner cables and the cable joints. If the
cables do not operate smoothly, ask a our Group dealer
to replace them.
Recommended lubricant: SAE 10W30
Steering vertical tube lubrication
Use a grease gun to lubricate the pivots. Revommended
lubricant: Lithium-base grease

Wheel removal

1. Lift the wheel by placing a suitable support under
the frames.

2. Remove the nut on the wheel.

3.Remove te wheel assembly.

-48-

Wheel installation

When installing the wheel reverse the removal
procedure. Pay attention to the following points:

1. Arrow mark

1. The arrow mark " " on the tire must point to the
rotation direction of the wheel.

2. Tapered wheel nuts are used for both front and rear
wheels. Install tapered side of the nut towards the
wheel.

3.Tighten the wheel nut.

1.Tapered nut

Wheel nut torque:
Front wheel: 55Nm (5.5m.kg)
Rear wheel: 55Nm (5.5m.kg)

Battery

WARNING
Avoid contact with skin, eyes or clothing. Always shield
eyes when working near batteries. Keep out of reach
of children.

-49-

Use and maintenance

1. Don't remove electrolyte cover after enclosed battery
being used. Please obey the operation instruction on
battery to use the battery.

2. If QUAD is suspended from use for a month or much
longer time, remove the battery and store in a cool and
dark place, charge fully before reusing.

3. If the battery is stored over the above mentioned
time, check the voltage at least one month. Charge
the battery when the voltage is lower than 12 V.

1 .Battery

1. Main fuse

2.Start relay

Fuse replacement

1. The fuse case is put under the seat.

2. If the fuse is blown, switch off the main switch and
replace with a new fuse of the same specifiction. If the
fuse immediately blows again consult a our Group
dealer.
Specified fuse: 20A

CAUTION

To prevent accidental short-circuting, switch off the
main switch when checking or replacing a fuse.

-50-

Replacing the headlight bulb

If the headlight bulb burns out, replace the bulb as
following steps:

1.Remove the headlight cover.

2.Remove the cover and rotate the bulb holder
counterclockwise and remove the defective bulb.

1.Headlight

1. Cover (x2)

1.Bulb holder

-51-

WARNING

Wait for the bulb to cool before removing it. 3. lnstall
a new bulb to the bulb holder.

4.Reinstalll the cover and headlight cover. Ad-just the
headlight beam if necessary.

Spark arrester cleaning

Select a well-ventilated area free of combustible
materials and make sure the exhaust and silencer are
cool.

1. Remove the bolt.

2. Start the engine, block the end of sillencer with a
dowel, which will increase the speed about twenty
times by momentarily producing exhaust system back
pressure.

3. Stop the engine and cool the exhaust pipe.

4. lnstall the bolt and tighten it.

CLEANING AND STORAGE

CLEANING

General speaking thorough cleaning of your QUAD
Will improve its runing performance and prolong the
service life of many components.

1. Before cleaning the QUAD:
a. Block off the exhaust pipe with plastic bag or strong
rubber band to prevent water entry.
b. Make sure the spark plug and all filler caps are
properly installed.

2. If the engine case is excessively dirty.wash with
degreaser. Do not use degreaser for wheel axles.

3. Rinse the dirt and remove oil dirt on the soft hose.

CAUTION

Excessive water pressure may cause water
seepage and deterioation of wheel bearings, brakes,
transmission seals and electrical equipment.

4. When rinsing dirty material for many times, use warm
water and mild, detergent-type soap. Use old toothbrush
or bottle brush to wash hard -to-get-at places.

5. After cleaning QUAD with clean waterimmediately
dry all surfaces with a chamois clean towel or soft
absorbent cloth.

-52-

6. Clean the seat with a vinyl upholstery cleaner to
keep the cover pliable and glossy.

7. Apply automotive type wax to all chrome plated
surfaces. Avoid use combination cleaner -waxes- After
using abrasives to protect scratched surface, let the
engine idle for several minutes.
After washing the brakes let engine brake several times
at slow speeds to dry the linings.
B. Storage
Long term storage (60 days or more) of your QUAD
will require some protective procedures to prevent
QUAD from damage. After thoroughly cleaning the
QUAD, adopt the following protective measures:

1. Add fresh fuel into fuel tank.

2. Add one tablespoon of SAE 10W30 or 20W40 motor
oil in the spark plug. Ground the spark plug wire and
run the engine over several times to coat the cylinder
body with oil.

3. Lubricate all control cables.

4. Elevate the engine body to raise all wheels off the
ground.

5. Seal with plastic bag over the exhaust pipe outlet to
prevent moisture from entering.

6. If storing QUAD in a humid or salt-air atmosphere,
cover all exposed metal surfaces with a light plastic

film of oil. Do not apply oil to any plastic parts or the
seat cover.

7. Take out the battery and store it in a dry place. The
battery should be stored in the place where the ambient
temperatrue should be 30ºC maximum and 0ºC
minimum.

-53-

MAIN DATA AND SPECIFICATIONS

Item specification
Dimension:

Overall length 1940mm
Overal width 1050mm
Overall height 1160mm
Seat height 810mm
Wheel base 1160mm
Minimum ground clearance 1160mm
Minimum turning radius 2900mm

Basic weight:

With oil and full fuel tank 220kg
Engine Air cooled,4-stroke,single-cylinder
Displacement 229.6ml
Bore x Stroke 71 x 58mm
Compression ratio 8.7:1
Starting system Electric starter or recoil starten
Lubrication system Pressure splash

Item specification
Engine oil:

Periodic oil change 1.5L
With oil fillter replacement 1.6L
Total amount 1.8L
Total amout of gear oil 0.27L
Main fuel tank capacity 12L
Reserve fuel tank capacity 1.6L

Carburetor:

Type Vacuum film piece type
Spark plug type D7RTC
Spark plug gap 0.6-0.7mm
Clutch type Wet.centrifugal automatioc

Transmission:

Primary reduction system Spur gear
Primary reduction ratio 73/22(3.318)
Secondary reduction system Shaft drive
Secondary reduction ratio 19/18 x 46/11 (4.414)
Transmisson type Constant mesh,5-speed

forward-speed reverse

Operation left foot operation

-54-

MAIN DATA AND SPECIFICATIONS

Item specification

Gear ratio:
1st 34/12(2.833)
2nd 34/19(1.789)
3rd 29/22(1.318)
4th 26/25(1.040)
5th 23/28(0.281)
Reverse 73/22 x34/12 X 19/18 X 46/11(41.5)
Frame
Frame type Steel tube
CasterA angle 4°
Trail 20mm
Tire:
Type Vacuum
Size:Front AT22 x 7-10
Size:Rear AT22X 10-10
Brake:
Front brake type Drum brake
Operation Right hand operation
Rear brake type Drum brake
Operation Left hand and right foot operation

Item specification

Suspension Supporting rod
Front Rotary rod
Rear
Shock absorber:
Front Spring/oil damper
Rear Spring/oil damper
Wheel travel:
Front 135mm
Rear 135mm
Electrical:
Ignition system CDI
Generator system A.C.Magneto
Battery type/voltage,capacity 12N14-BS/12V.14AH
Headlight 12v,30W/30Wx2
Taillight 12V.10WX 1
Neutral indicator 12V.3W X 1
Reverse indicator 12V.3W X 1
Hight beam indicator light 12V.3W X 1

-55-

MAINTENANCE RECORD

Maintenance times, receipts of purchased componects and assembly will be required to be recorded, which should
be done according to the warranty. The chart below only acts as maintenance record, not as maintenance proof:

MAINTENACE

INTERVAL

TIME

1 Month
3Months
6Months

12Months
18Months
24Months
30Months
36Months
42Months
48Months
54Months
60Months

DATE

OF

MAINTENACE

DRIVING MILEAGE

SERVICING DEALER NAME AND ADDERSS

REMARKS

-56-

ELECTRIC WIRING DIAGRAM

1. Headlight switch

2. Position light

3. Headlight

4. Fr.R.winker

5. Fr.L.winker

6. Neutral indicator

7. Reverse gear indicator

8. L.winker indicator

9. R.winker indicator

10. Short distance indicator

11. Long distance indicator

12. Meter background light

13. Position light switch

14. Reverse indicator
switch

15. Flasher

16. Turning signal switch

17. Emergency light switch

18. Starting motor

19. Ignition switch

20. Horn switch

21. Horn

22. Relay

23. Fan

24. Fan

25. Rectifier

26. Relay

27. Magneto

28. Neutral switch

29. CDI

30. lgnition coil

31. Spark plug

32. Handle brake

-57-

33. Foot brake clutch switch

34. Total switch

35. Fuse

36. Battery

37. Total tlameout switch

38. Flameout switch

39. Tail light

40. Rr.R.winker

41. Rr.L.winker

Mayo / May / Mai / Maggio 2005

RECOMIENDA EL USO DE ACEITE:

RECOMMENDS THE USE OF OIL:

RECOMMANDE L’USAGE DE L’HUILE:

CONSIGLIA L’USO D’OLIO:

PU010538046

C/ UNICEF nº 17 · Poligon Industrial Torremirona · 17190 Salt (Girona) SPAIN · Tel: [phone] Fax: [phone]

E-mail: [e-mail] / [e-mail]