GMX MOTORBIKES HAMMER DUNE User Manual

Read and understand this entire manual before riding!
DO NOT RETURN TO STORE!
WWW.GMXMOTORBIKES.COM.AU
ATV OFF ROAD - HAMMER DUNE BUGGY
NOTE: Manual illustrations are for demonstration purposes only. Illustrations man not reflect exact appearance of actual product.
RIDE SAFE
- Never let children ride this product that are meant for adults – even as passengers.
- ATV(s) are not “all-terrain vehicles” so they may not be able to go safely on all types of terrain. Avoid riding on rough terrain or steep slopes.
- Ride on familiar tracks and beware of obstacles.
- Never ride under the inuence of alcohol/drugs.
- Ensure children are supervised at all times on or around any activity on motorised vehicles.
- Always carry a mobile phone or radio device so you can contact help in case of an emergency.
WEAR SAFE
- Always wear a helmet.
- Wear protective clothing and gear such as goggles, long sleeves, long pants, boots and gloves/hand protection.
Ensure that you understand your quad bike by reading & going over the manual before assembly.
PLEASE NOT: MINOR ASSEMBLY IS REQUIRED, BUT IN THE INTEREST OF SAFETY IT IS RECOMMENDED THAT YOU HAVE THIS PRODUCT ASSEMBLED BY A SKILL MOTORCYCLE MECHANIC.
YOU MUST CHECK THAT THE FRONT STEERING IS ADJUSTED CORRECTLY PRIOR TO RIDING.
CHECK BRAKES ARE ADJUSTED CORRECTLY PRIOR TO RIDING.
YOU MUST CHECK THAT THE CHAIN IS ADJUSTED CORRECTLY PRIOR TO RIDING.
Swing tags have been placed on your vehicle for you to identify checks that are located within this manual. Once you have performed the check required remove these swing tags and nylon loops attaching them to the vehicle.
MAKE SURE TO REMOVE THE SWING TAGS AND TAKE SPECIAL NOTICE TO REMOVE THE NYLON LOOP.
The tags and loops that need to be removed from this model: GMX 110cc RIPPER Quad Bike
ONCE SWING TAGS AND NYLON LOOPS ARE REMOVED YOU ARE ACKNOWLEDGING THAT THESE CHECKS HAVE BEEN PERFORMED
There may be a “Spare Parts Package” within the carton so please check all of the packaging and DO NOT THROW OUT
WARNINGS
SWING TAG’S & WARNINGS
BRAKE ADJUSTMENT x3STEERING ADJUSTMENT x2 CHAIN ADJUSTMENT
ALWAYS LEAVE IN THE OFF POSITION WHEN NOT IN USE OR REMOVE KEYS
KEY REMOVAL
WARNING
Please use unleaded fuel
90 Octane or above
UNLEADED FUEL ONLY
WARNING: This product is powered by a 4 stroke engine and comes with transport oil in the engine.
THE OIL NEEDS TO BE DRAINED AND REPLACED WITH MOTORCYCLE OIL 10W/40 or 10W/50 IS REQUIRED IF THE OIL CHANGE IS NOT PERFORMED YOU MAY INTERNALLY DAMAGE THE ENGINE AND CLUTCH AND VOID YOUR WARRANTY DO NOT USE MOTOR CAR OIL DO NOT USE OIL WITH FRICTION MODIFIERS
Oil will need to be changed every 3 months in HOTTER climates or in the NORTHERN HEMISPHERE
- There is an oil drain (SUMP) plug located underneath your PRODUCT and is highlighted with an oil drain sticker.. This is a 14mm bolt.
- DO NOT remove the other bolt located under the engine.
- Place an oil receptacle under the drain hole, undo bolt and let oil drain from the vehicle. Please note: Dispose of oil correctly
- Tighten bolt back up, remove dipstick (oil ll point) and ll the vehicle with suggested correct amount of oil required. Tighten
PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS PRIOR TO ASSEMBLY AND OPERATION OF YOUR VEHICLE.
GMX MOTORBIKES WARRANTY
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. The manufacturer warrants this product to be free of manufacturing defects for a period of 12 months from date of purchase. This Limited Warranty does not cover normal wear and tear (exclusions apply) or any damage, failure or loss caused by improper assembly, maintenance or storage or use of the GMX product. Some parts will have a limited warranty period, please see below. This warranty is a part replacement warranty.
3 Month Parts Replacement Parts
Electrical components, suspension, drivetrain and brakes/ttings.
30 Days Parts Replacement Parts
Bearings, tires, tubes, cables, clutches, brake pads, seats.
Minor assembly is required. In the interest of safety and future warranty claims, it is recommended that you have this product assembled by a qualied, skilled motorcycle mechanic. You may need to provide proof for this product of being assembled by a skilled motorcycle mechanic or small engine mechanic a report dvising of the issues may be needed to process your warranty claims. The warranty is a parts replacement warranty and labor is not included, defective parts may need to be sent back for inspection.
This Limited Warranty will be void if the product is ever;
- Used in a manner other than for recreation.
- Modied in anyway.
- Rented or commercial use. The manufacturer is not liable for incidental or consequential loss or damage due directly or indirectly misuse of this product. Always adhere to the maximum load of the product, over loading the product will void the warranty.
How a claim is made
When making a claim, you will need to provide proof of purchase, condition photos of the item. This information is required to be submitted via the support center and communication is made through the support center. When the claim is created, the customer will receive the claim number and the customer support team will reply within 24 hours.
CONTENT
SAFETY INFORMATION
CONSUMER RESPONSIBILITY
BELT RESTRAINT SYSTEM
PRE-RIDE INSPECTION
ASSEMBLY
SAFETY PRECAUTIONS
RIDING PRACTICES
1.
2.
3.
5.
6.
7.
12.
OPERATING THE PRODUCT
MAINTENANCE & ADJUSTMENT
13.
21.
1.
Turn o
VEHICLE IDENTIFICATION NUMBER
The Vehicle Identication Number (VIN) is stamped on the right hand side of the frame assembly. The Engine Number (EN) is stamped on the left hand side of the crank case.
DESCRIPTION OF VEHICLE
SAFETY INFORMATION WARNING – indicates a potential hazard of high risk that may cause serious
product damage, severe personal injury or death. CAUTION – indicates a potential hazard which may result in product damage or personal injury. NOTE – indicates key information or instructions. Safe Operation WARNING – Exhaust fumes are toxic. Never operate indoors, or in an enclosed area without sucient ventilation. WARNING- This product is for o-road use only. DO NOT operate on ANY public roads, streets, highways, sidewalks or property. This product may only be operated on private property and areas approved by local law. WARNING – This product may not have been supplied fully assembled. To prevent possible injury or death, ensure that the product is assembled by a skilled motorcycle mechanic. WARNING – Always perform pre-ride checks and inspections as outlined in this manual. WARNING – Safety decals must be replaced in the event that they become faded, scratched or damaged. If decals are unreadable, damaged or missing,
10. Air Cleaner
11. Exhaust System
12. Rear Suspension
13. Front Wheels
14. Speedometer
15. Rear Wheels
1.Headlight
2. Front Suspension
3. Frame Assembly
4. Steering Wheel
5. Headlight Unit
6. Seats
7. Engine
8. Tail Light
9. Carburetor
important safety information may be looked over resulting in product damage, serious injury or death. WARNING – This product is not intended for competitive o road use, stunts, racing or any other form of competition. Using this product in competition may void your warranty. WARNING – The safe operation of this product is dependent on the operator of this product. The operator must be of appropriate age, weight & height in order to operate this product. The operator must be of sound mental and physical capacity in order to safely operate this product. Passengers of this product are under the full responsibility of the operator. The passenger must be of appropriate age, weight and height, and must be of sound mental and physical capacity in order to safely be a passenger in this vehicle. WARNING – This cart is to be operated by persons whom are either experi­enced, mature, supervised or under competent instruction in uncongested areas. WARNING – Modifying, adding or removing original equipment from this product may void warranty deeming the product unsafe for operation. NEVER modify, add or remove original equipment UNLESS replacing necessary parts with approved aftermarket components. WARNING – The operator and any passengers of this vehicle must always wear an Australian Approved Motorcycle helmet, face shields/goggles, appropriate motorcycle boots, gloves and any other appropriate protective clothing. WARNING – Long hair, loose clothes and jewellery may get caught in moving parts below and behind the seats. Be sure to remove loose tting clothing, jewellery and tie long hair back. WARNING – Never place hands, feet or any other body parts near the engine, wheels, brakes or any other rotating parts whilst the product is in operation. WARNING – Ensure the restraint system is properly installed, tted and secure before operating this products. DO NOT operate this vehicle without using the restraint system supplied with this product. Secure unused restraint systems as the system may get caught in moving parts, objects and external obstacles such as trees, rocks & logs. WARNING – Routine maintenance must be undertaken to ensure all nuts, bolts and other parts are secure. Not undertaking routine maintenance as outlined in this manual may void your warranty, cause product damage, cause serious personal injury or death.
SAFETY INFORMATION
3.
WARNING – Never perform maintenance checks on this product while it is in operation. Ensure the engine is turned and appropriate braking systems are on before undertaking maintenance, cleaning or inspections of this vehicle. Never adjust, clean or repair this product whilst it is in motion. Never adjust, clean or repair this product whilst the products engine is still hot. WARNING - Stop operating this product if it starts to make unusual noises, excessive noises or unusual vibrations. This is a sign of loose or worn parts and a service must be undertaken to avoid product damage, serious personal injury or death. WARNING – Never remove guards, roll cage(s), clutch guards, axel guards, hub guards or torque converter. WARNING – Use of this product as excessive speeds may cause product damage, serious personal injury or death to the operator, passenger(s) and others. Never operate at excessively high speeds outside of the operator’s comfort and ability level. WARNING – Never operate this product under the inuence of alcohol or drugs (prescription or illicit). WARNING – Keep the product free from dirt and debris, especially around the steering and throttle systems. Mud, snow, dirt and debris can become stuck in these areas creating steering issues or throttle stick. This may result in the operator losing control which may cause product damage, serious personal injury or death to the operator, passenger(s) and others. WARNING - Never attempt to operate this product without rst checking to see if throttle control is in the idle position, and the park break is on. WARNING – Never start the product unless the operator and its passenger(s) are seated and securely restrained. WARNING – Never tamper or modify the products governor system. Exceeding the limits of the manufacturers set governing settings will cause damage to the engine by exceeding its capacity. This may cause product damage, serious personal injury or death to the operator, passenger(s) or others. WARNING – Always slow down when turning. Attempting to take corners at high speeds may cause product damage, serious personal injury or death to the operator, passenger(s) or others in the event that the operator loses control. WARNING – Never ll the fuel tank whilst the product is on, or still hot. Do not overll the tank. Always allow 4cm of expansion space at the top of the tank.
There should not be any fuel in the breather hose or ller neck. Always use an approved petrol cap for this product. Never rell while inside a building or in a building without appropriate ventilation. Never ll up near extreme sources of heat, live wires, naked ames or any other type of heat source when lling up. Move the product at least 10 feet away from where it was lled up before attempting to start. WARNING – Wet, slippery, rough or sloped terrain is potentially dangerous and may result in product damage, serious personal injury or death to the operator, passenger(s) and others if the product is not operated in a safe and cautious manner. Never attempt to operate this product on terrain that the operator or passenger(s) are not comfortable with. Operator must use mature and responsible decisions when operating this product in terrain that is familiar or unfamiliar. Attempting to turn on slopes may result in a product roll-over which may cause product damage, serious personal injury or death to the operator, passenger(s) and others. Do not attempt anything outside of the skill level of the operator. WARNING – Practice caution when turning on loose gravel or any other similar surfaces at speed. There is an increased chance that the operator will lose control which may result in product damage, serious personal injury or death to the operator, passenger(s) and others. WARNING – All assembly, maintenance & repairs of this product must be undertaken by a skilled and qualied motorcycle mechanic, small motor mechanic or authorised service centres / dealers. Service intervals are outlined in this manual and must be followed. Failure to have this product serviced by the appropriate professionals may void your warranty and / or may cause product damage, serious personal injury or death to the operator, passenger(s) and others. No modication are to be made that are deemed to be practically unsafe, unstable or poorly manufactured. Any modications must be approved by an engineer, installed by the relevant professional and must come with an approved engineer/ modication plate. Failure to do so may void your warranty and may cause product damage, serious personal injury or death to the operator, passenger(s) and others. WARNING – Read and keep supplied printed material. Read and understand all printed material before assembling or operating this product. It is important to keep all these documents for future reference.
CAUTION – Always stop the engine when not in use. CAUTION – When undertaking routine maintenance or repairs, ensure the
SAFETY INFORMATION 4.
spark plug wire is always disconnected and kept away from the spark plug to prevent unintentional engine starts. CAUTION – Avoid contact with any hot surfaces or objects such as exhaust system, cylinder heads, or any other part of the drive system. CAUTION – Store product where petrol and oil fumes cannot reach an open ame, spark or any other source of ignition. Never store product for a long period of time without rst draining fuel & oil and storing it appropriately out of direct sunlight, in an approved container. CAUTION – The rollbar, brush bars and any other form of protective system will not protect the operator and passenger(s) from all external obstacles protruding into the operator/ passenger(s) compartment. CAUTION – Should the product start making unusual noises, excessive or loud noises, or abnormal vibrations, stop the product, remove spark plug connector and check the vehicle for damage. Any abnormal noises or vibrations are a warning that there are loose or faulty parts. Routine mainte­nance or repair must be undertaken.
SAFETY INFORMATION
1. This product must not be modied from the original manufacturers original design and conguration.
2. This product shall not be used in competitive events such as racing, stunts etc. Such activities may result in loss of control.
3. Prior to each cycle of operation, the operator shall perform the checks outlined in this manual under the “pre-start checks” chapter.
4. This product shall not be started unless operator and passenger(s) are inside the product and secured safely using the restraint system supplied.
5. Long hair, loose clothes, jewellery must be removed, restrained or tied back before using this product, whether you are the operator or passenger.
6. This product shall only be refuelled by the operator or supervisor knowl-
CONSUMER RESPONSIBILITY
edgeable in refuelling techniques.
7. The supervisor or operator shall personally recognise that all persons operating or riding this product are of sound mental and physical capacity, are of suitable age, height and weight, and are capable to operate this product comfortably, responsibly and safely. The operator / supervisor acknowledges that sections 1-6 have been completed and is liable from herein. a. The supervisor / operator shall only allow the use of this product after a demonstration of the product has been completed, and all operators and passengers are comfortable. b. The supervisor / operator shall provide continuous supervision at all times. c. The supervisor shall not allow anyone to operate or ride who has long hair, loose tting clothing or jewellery that has not been secured or removed.
8. The products operators and passengers shall adhere to the manufacturer’s instructions, recommendations and safety information. The products operators and passengers must adhere to all laws and road rules (local, state, national) at all times whether moving or stationary. a. Operators and passengers shall stay seated and secure at all times whilst the product is in operation. b. Operators and passengers shall remain inside the product at all times, with arms, legs and any other products inside the product at all times whilst the product is in operation. c. Operators and passengers shall use appropriate Australian Standard approved motorcycle helmets, boots, & suitable protective clothing. d. Shall observe minimum age restrictions. e. Shall not ride with lose or unsecured clothing, long hair or jewellery that has not been removed or secured. f. Shall not smoke, use alcohol or illicit drugs whilst operating this product. g. Persons under the inuence of alcohol or drugs (illicit or prescrip tion) shall not supervise, operate or be a passenger of this product. h. Shall not operate on terrain not suitable for this product as outlined
5.
in this manual. i. Shall not be operated on any public roads, streets, highways or property as outlined in this manual. j. Shall only operate in adequate lighting in conditions with suitable visibility. k. Shall not operate if persons are pregnant, injured, suer heart conditions, suer from back, neck or head issues or injuries, suer any physical condition that may aect judgement, or suer from mental issues that may aect judgement which in turn, will impair the physical and mental capabilities to recognise, assess, understand all safety instructions and procedures. l. This product shall not be used to transport a passenger, except in the seating area provides, transport materials or goods unless specied by the manufacturer, or transfer animals. m. Single seat units may be used by an operator only. No passengers at any time. n. No operator, passenger or supervisor shall come into contact with the engine until the park break has been activated, engine turned o and spark plug disconnected.
CONSUMER RESPONSIBILITY
BELT RESTRAINT SYSTEM
Belt restraint system use and maintenance. This product has been shipped with a combination lap and shoulder restraint system for each occupant location. The restraint system must be installed as per the manufacturers assembly and installation instructions provided with this cart. The proper use of the combination restraint system can reduce the chance and / or severity of injuries in the event of an accident. The restraint system must be used by ALL occupants of this product. WARNING – The number of occupants must never exceed the amount of restraint systems tted in this product. Failure to follow these instructions may cause product damage, serious personal injury or death to the operator, passenger(s) and others. To properly fasten and adjust the restraint system, please refer to gure below.
1. Adjust the seat location to the position that allows full operation of the break & throttle pedals, and steering wheel by the operator.
2. Find the long strap of the restraint system (1A & 1B), and run it across the shoulder, chest and lap, inserting the metal tongue (2) on the strap into the buckle provided (3). You may need to adjust the shoulder portion of the strap (1A) to its maximum length, whilst unwinding the webbing of the web winder (4). To adjust the shoulder strap to the maximum length, locate the metal tab (5A) on the adjuster (5) and pull down on the strap.
3. For two seat products, follow the above instructions. Always use the buckle closest the hip.
4. Adjust the lap part of the belt (1B) by pulling up on the belt whilst fastening as low as possible around the hip.
5. Adjust the shoulder part of the belt (1A) by pulling down on the end of the shoulder belt (6). Make sure that all of the webbing (4) has been unwound from the web winder (4) and chest with no more than one inch of space between the chest of the occupant and the belt.
6. For a two seat product, the passenger must be restrained in the same manner as outlined in steps 2 to 5. If the occupants are not capable of accomplishing steps 2 to 5 as outlined above, adult supervision and installation is required.
WARNING - The lap belt portion of the restraint system must t snugly and as low as possible around the occupants’ hips. If the combination lap and shoulder belt restraint system are not used properly, the risk of injury in an accident greatly increases. WARNING - Use the shoulder portion of the bell over the shoulder only. Never place the shoulder belt under the arm. Never place it behind the neck and over the other shoulder. Failure to follow these warnings could increase the risk and/or severity of injury in an accident. WARNING - Never use a combination lap and shoulder belt restraint system for more than one person. Failure to follow this warning could increase the risk and/or severity of injury in an accident.
To unfasten the restraint system, follow the steps below.
1. Push the red release button on the buckle that allows the tongue to
6.
See page 9 for diagram image
BELT RESTRAINT SYSTEM
unlatch from the buckle system.
2. While the belt retracts, guide the tongue to its original retracted position. If the tongue is not guided, it may cause the occupant injury.
Ensure to check the restraint system prior to every use for loose bolts, cut threads, faulty retraction systems and anything else that is not working correctly. Ensure the buckle and tongue system is working correctly, the web winder is clean and retracting correctly, the plastic sleeves are not damaged in anyway, nuts and bolts are tight, and that the belt itself is not frayed, cut or damaged in anyway.
DO NOT use this product if the restraint system is faulty in anyway.
PRE-RIDE INSPECTION
Inspect the product before every ride, ensuring it is in a safe and working order.
WARNING – If proper inspection is not performed, product damage, serious personal injury or death may occur.
- Always inspect the product before operation.
- Before riding the product, inspect all operation controls and parts.
- Allow the engine to cool before replacing / adding oil and fuel.
BEFORE using the product, follow the following steps; ENGINE OIL - Check oil level
- Fill or replace oil if necessary FUEL - Check fuel level
- ll or replace fuel if necessary WHEELS & TYRES - Check tyre pressure
- Check tyre wear & damage
- Inate or replace if necessary CHAIN - Check chain condition and chain slack
- replace or tension chain if needed.
THROTTLE - Check for proper throttle operation
FITTINGS - Check all ttings and fastenings BRUSH BARS - Make sure all brush bars are in place and securely
attached STEERING - Check steering function.
- Check wheel “toe-in”
FRAME/CHASSIS - Check for bends, dents and cracks in tubing and welds BATTERY - Check clamp bar and battery charge LIGHTS - Check for proper operation BRAKES - Check operation, free play and condition
- Perform brake test as per operation instructions below PARK BRAKE - Check operation, condition and cable length
- Perform brake test as per operation instructions below
WARNING – Failure to inspect the product before operation may result in product damage, serious personal injury or death. Front and rear brakes – Check operation of the brake pedal & insure it moves smoothly and has a rm stop at the end of the stroke. If this is not the case, have the product inspected by a qualied professional. Brake uid level – Check the brake uid level and all uid if necessary. If you are unsure on how to do this, please have the product inspected by a qualied professional. Brake uid – Check hoses and lines to see if there are any leaks around connections and ttings. Apply the brakes rmly for one minute, if it loses pressure, or there is a uid leak, please have the product inspected by a qualied professional. Fuel – Make sure there is sucient fuel in the tank with a minimum of 4cm breathing space. Use only unleaded fuel. Leaded petrol will cause severe damage to internal engine parts such as valves and pistons and the exhaust system. Recommended Fuel – Unleaded Petrol Capacity – 6.8 Litres Reserve – 0.9 Litres
Engine Oil – Make sure the oil level is at its specied capacity. Recommended Oil – AE 10W/30
7.
PRE-RIDE INSPECTION
Chain – Check the general condition of the chain. If the chain is worn, check
the condition of the drive sprockets. Adjust chain slack and lubricate if necessary. Throttle Pedal – Check to see that the throttle pedal operates correctly. The action must be smooth and responsive, and must spring back to idle position when released. If this is not the case, have the product inspected by a qualied professional. Fittings – Check the tightness of all ttings and bolts, especially the ttings around the steering, wheels and chassis. If you are unable to do this, have the product inspected by a qualied professional. Lights – Check that head and tail lights are in full working order. Repair or replace if necessary. If you are unable to do this, have the product inspected by a qualied professional. Switches – Check the operation of all switches. Have the product inspected by a qualied professional if necessary. Tyre Pressure – Use an accurate, low pressure tyre gauge. Inate only when tyres are cold where possible. Inate to appropriate pressures as indicated on the sidewall of the tyre. Tyre Wear – When tyre tread is at 3mm of height, tyres must be replaced. If you are unable to do this, have the product inspected by a qualied profes­sional.
Engine Break-In
There is never a more important period in the life of your machine than the period between zero and 20 hours.
For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put excessive load on the engine for the rst several hours of operation. During the rst 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances.
During this period, prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided.
However, momentary (2-3 second maximum) full throttle operation under
load does not harm the engine. Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r/min so the engine can rid itself of the temporary build-up of heat. If any abnormality is noticed this period, consult your dealer.
0-10 Hours
- Avoid continuous operation above half throttle. Allow a cooling o period of ve 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.
10-20 Hours
- Avoid prolonged operation above 3/4 throttle. Rev the machine freely through the gears but do not use full throttle at any time.
After brake-in
- Avoid prolonged full throttle operation. Vary speeds occasionally.
Operation WARNING: Prior to operating the Fun-Kart, review the assembly instructions
to make sure the Fun-Kart has been assembled properly.
Operating Controls WARNING - DO NOT attempt to start or operate this product until you are
completely familiar and understand the user manual and product, including the locations of each operation control.
You must know how to stop this product before you start it.
Check throttle assembly to make sure it is working smoothly and returns to idle when released.
Check brake system to make sure it is working properly before starting engine.
Check the engine stop switch to make sure it is working properly before operating the product.
8.
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