Harbor Freight Tools 03516 Assembly And Operating Instructions Manual

RIDE-ON ELECTRIC ATV TOY

®

Model 03516

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at: http://www.harborfreight.com

Copyright by Harbor Freight Tools®. All rights reserved. No portion of this

manual or any artwork contained herein may be reproduced in any shape or form

without the express written consent of Harbor F reight Tools.

For technical questions, please call 1-800-444-3353.

PRODUCT SPECIFICATIONS

Item Description

Recommended Age Limits For Children Ages 5 To 7 Years
Recommended

Seating Capacity
Maximum Load Capacity 107 Pounds (Dead Weight)
Electric Adapter Transformer Input: 120 VAC, 60 Hz

Battery 6 VDC Rechargeable

Fuse 40 Amp
Transmission High Speed (6.0 MPH), Low Speed (3.0 MPH)

Accessories 40 Amp Fuses (Qty - 2)

Weight 51.0 Pounds

One Person

Output: 12 VDC

Initial Charge Time: 8 To 12 Hours
Subsequent Charge Times: Under 20 Hours
Quantity: 2

Forward, Reverse

Hand Wrench (Qty - 1)
Ignition Keys (Qty - 2)

SAVE THIS MANUAL

You will need this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures, and parts list. Keep
your invoice with this manual. Write the invoice number on the inside of the front
cover. Keep this man ual and in v oice in a saf e and dry place for future ref erence.

GENERAL SAFETY WARNINGS AND PRECAUTIONS

1. DRESS SAFELY. MAKE SURE THAT CHILDREN ALWAYS WEAR LOCAL,

STATE, AND FEDERALLY APPROVED SAFETY HELMET, ELBOW/KNEE
PADS, AND SAFETY CLOTHING WHEN OPERATING THIS PRODUCT. Do not

allow children to wear loose clothing or jewelry, as they can become caught in
moving parts. Wear a protective hair cov ering to pre vent long hair from becoming
caught in moving parts.

2. STAY ALERT. Make sure the user is watching what he/she is doing at all times.
Adult should be present at all times. Use common sense. Do not allow this
product to be used when child is tired or distracted.

3. CHECK FOR DAMAGED PARTS. Before allowing this product to be used, care-
fully check that it will operate properly and perform its intended function. Check
for damaged parts and any other conditions that may aff ect the operation of this
product. Replace or repair damaged or worn parts immediately .

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4. REPLACEMENT PARTS AND ACCESSORIES: When servicing, use only identi-
cal replacement parts.

5. MAINT AIN THIS PRODUCT WITH CARE. Keep this product clean and dry for
better and safer performance.

6. MAINTENANCE: For your safety, service and maintenance should be performed
regularly by a qualified technician.

7. THERE ARE CERTAIN APPLICATIONS FOR WHICH THIS PRODUCT WAS
DESIGNED. It will perform better and more safely at the rate for which it was
intended. Do not modify this product, and do not use this product for a purpose
for which it was not intended.

8. WARNING: The warnings, precautions, and instructions discussed in this manual
cannot cover all possible conditions and situations that may occur. The operator
must understand that common sense and caution are factors, which cannot be
built into this product, but must be supplied by the operator.

SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS

1. THIS PR ODUCT SHOULD BE ASSEMBLED ONLY BY AN ADULT , AND OP­ERATED ONLY UNDER ADULT SUPERVISION.

2. THE RECOMMENDED AGE LIMITS FOR THIS PRODUCT ARE AGES 5 TO 7
YEARS.

3. DO NOT EXCEED THE MAXIMUM LOAD CAPACITY (107 POUNDS) FOR
THIS PRODUCT. This product is designed only for one rider. Do not allow

passengers on this product. Do not allow product to be jumped on.

4. MAINTAIN A SAFE PLAY ENVIRONMENT. Keep the play area well lit. Make
sure there is adequate surrounding space in which to play. Always keep the play
area free of obstructions, trash, and other debris. Use this product only on open,
flat, terrain. Avoid wet or sandy areas. Do not attempt to use this product on
steep inclines. Use this product only on private proper ty. Avoid sidewalks, al­leys, streets, and other potentially dangerous public areas. Obey all local, state,
and federal laws regarding the use of this product in public areas.

5. NEVER STAND ON THIS PRODUCT. Serious injury could result if the ATV is
tipped.

6. ALWAYS KEEP HANDS, FINGERS, AND FEET, AWAY FROM THE MOVING

PARTS OF THIS PRODUCT.

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7. DO NOT ATTEMPT TO REMOVE DEBRIS OR FOREIGN MATERIAL CAUGHT
IN THE MOVING PARTS OF THIS PRODUCT WHILE THE ATV’s IGNITION IS
IN THE “ON” POSITION. Turn the Ignition Switch to its “OFF” position and

remove the Ignition Key.

8. GROUND THE ELECTRIC ADAPTER TRANSFORMER OF THIS PRODUCT.
The 12 Volt DC Adapter Transfor mer (part #14) for this product is equipped with a
2-Prong Plug and requires the use of a grounded, 3-Prong Adapter Plug (not
included). To comply with the National Electric Code, and to provide additional
protection from the risk of electrical shock, this product should only be connected
to a 120 Volt, 3-hole electrical outlet that is protected by a Ground Fault Circuit
Interrupter (GFCI). (See Figure A.)

12 VOLT DC

ADAPTER TRANSFORMER (#14)

3-PRONG ADAPTER PLUG

(NOT INCLUDED)

GROUNDED, 120 VOLT AC

FIGURE A

ELECTRICAL OUTLET

9. REDUCE THE RISK OF ACCIDENTAL STARTING. Make sure the ATV’s Ignition
Switch is in the “OFF” position and the Ignition Key is removed before plugging
the 12 Volt DC Adapter Transfor mer into a grounded, 3-hole, 120 Volt, electrical
outlet.

10. DO NOT ABUSE THE 12 VOLT DC ADAPTER TRANSFORMER CORD. Do
not use the Cord to pull its Plug from an electrical power outlet. Keep the Cord
away from heat, oil, shar p edges, and moving parts. Route the Cord safely. Do
not route the Cord where it can be walked on or tripped over. Replace a dam­aged Cord immediately.

11. IF AN ELECTRICAL EXTENSION CORD (not included) IS USED WHEN

CHARGING THIS PRODUCT, MAKE SURE TO USE ONLY UL APPROVED
CORDS HAVING THE CORRECT GAUGE AND LENGTH.
(See Figure B, next page.)

12. PROPER BATTERY CARE: Battery leakage may occur under extreme usage or
temperature conditions. Never allow children to handle the two 6 Volt DC
Batteries for this product. If Battery fluid comes in contact with skin, wash with

SKU 03516 PAGE 4

REQUIRED MINIMUM EXTENSION CORD GAUGE – 120 VOLT

NAMEPLATE

AMPERES

(At Full Load)

0 - 25

Feet

0 - 5 16 16 16 12 12

5.1 - 8 16 16 14 10 -

8.1 - 12 14 14 12 - -

12.1 - 15 12 12 10 - -

15.1 - 20 10 10 10 - -

EXTENSION CORD LENGTH

25 - 50

Feet

50 -100

Feet

100 – 150

Feet

150– 200

Feet

FIGURE B

soap and water and rinse with lemon juice and vinegar. If the fluid comes into
contact with the eyes, flush with water for several minutes and contact a doctor
immediately. Never burn Batteries, as they can explode in a fire. Do not charge
the ATV with a leaking Battery. Only a qualified technician should replace or
perform maintenance on the Batteries. Contact local solid waste authorities for
instructions on correct disposal or recycling of the Batteries.

13. THE INITIAL CHARGING TIME FOR THE BATTERIES IS 8 TO 12 HOURS.
The Batteries for this product have been
and therefore require an
ceed 12 hours

initial

initial

charging time of only 8 to 12 hours. Do not ex-

charging time. THEREAFTER, each subsequent charging

partially

charged by the manufacturer,

time for the Batteries may take up to 20 HOURS. Do not exceed 20 hours for
any subsequent charging of the Batteries.

14. BEFORE OPERATING, START THE ATV AND CHECK FOR EXCESSIVELY
LOOSE PARTS OR MACHINE VIBRATION. If this is found, turn off the ATV and
correct the problem before operating.

15. ALWAYS HAVE CHILDREN WEAR LOCAL, STATE, AND FEDERALLY AP-

PROVED SAFETY HELMET, ELBOW/KNEE PADS, AND SAFETY CLOTHING
WHEN OPERATING THIS PRODUCT.

16. TO AVOID ACCIDENTAL INJURY, INSTRUCT USERS TO AVOID MAKING
SUDDEN STARTS, STOPS, AND TURNS. DO NOT ALLOW THIS PRODUCT
TO BE USED ON STEEP INCLINES, WET, OR SANDY AREAS.

17. AL W AYS TURN THE IGNITION SWITCH TO ITS “OFF” POSITION AND RE­MOVE THE IGNITION KEY BEFORE PERFORMING ANY INSPECTION, AD­JUSTMENTS, MAINTENANCE, OR CLEANING PROCEDURES.

18. THIS PRODUCT IS EQUIPPED WITH AN AUTOMATIC SHUTDOWN DEVICE.
During overload or improper operation, the ATV will automatically shutdown for
approximately 15 to 20 minutes. After this period, the ATV may be started again.

SKU 03516 PAGE 5

19. WARNING: People with pacemakers should consult their physician(s) before
being around this product. Operation of electrical equipment in close proximity to
a heart pacemaker could cause interference or failure of the pacemak er.

UNPACKING

When unpacking, check to make sure all the parts shown on the Parts List (page 12) are
included. If an y parts are missing or broken, please call Harbor Freight Tools at the num­ber shown on the cover of this manual as soon as possible.

PRODUCT FEATURES

NOTE: The supervising adult must make sure the child is taught and thoroughly
understands the following procedures
toy.

The Instrument Panel:

1. The Instrument Panel (part #18) consists of an Ignition Switch, Low/High
Speed Switch, and a Forward/Reverse Switch. (See Figure C, next page.)

before the child is allowed to ride the ATV

2. To turn on the ATV, insert the Ignition Key into the Ignition Switch, and turn the
Key

counterclockwise

Key

clockwise

3. The ATV features two speed settings; Low Speed (approx. 3 mph), and High
Speed (approx. 6 mph). Make sure the ATV is at a
ing the desired speed on the Low/High Speed Switch. Do not attempt to
change speeds while the ATV is in motion. (See Figure C.)

4. Make sure the ATV is at a
Reverse Switch. Do not attempt to change directions while the ATV is in
motion. (See Figure C.)

to its “OFF” position and remove the Ignition Key. (See Figure C.)

to the “ON” position. To turn off the ATV, turn the Ignition

complete stop

complete stop

prior to depressing the Forward/

prior to select-

The Throttle Pedal:

1. The Throttle Pedal (part #19) allows the ATV to start and stop. To start the ATV
moving, step on and keep the Throttle Pedal in its
Pedal features an automatic breaking mechanism and will stop the ATV when
downward pressure on the Throttle Pedal is released. (See Figure C.)

down

position. The Throttle

The Head Light And Tail Light:

1. The ATV features one Head Light (part #16) and one Tail Light, (part #17) both of
which automatically turn on when stepping on the Throttle Pedal. Once pressure

SKU 03516 PAGE 6

OFF

ON

IGNITION SWITCH

BACK

REST

(#20)

LIGHT

FIGURE C

LOW SPEED

HIGH SPEED

TAIL

(#17)

FORWARD

REVERSE

INSTRUMENT PANEL (#18)

HEAD

LIGHT

(#16)

SEAT (#15)

FRONT

BUMPER

(#5)

WHEEL (#1)

THROTTLE PEDAL (#19)

on the Throttle Pedal is released, the Head Light and Tail Light will automatically
turn off. (See Figure C.)

ASSEMBLY INSTRUCTIONS

CAUTION: THIS PRODUCT SHOULD BE ASSEMBLED ONLY BY AN ADULT.

To Assemble The Steering Linkage:

1.

2. Insert a Washer (part #3) on each side of the Front Steering Linkage (part #2).

3. Insert the Front Steering Linkage (part #2) upward through the Front Chassis

4. Insert a Vibration Muffler (part #6) on each side of the Front Steering Linkage

SKU 03516 PAGE 7

With assistance, raise and hold

the front end of the ATV off the ground surface.

(See Figure D, next page.)

(part #4) and Front Bumper (part #5). (See Figure D.)

(part #2). (See Figure D.)

5. Continue inserting the Front Steering Linkage (part #2) upward through the
Sleeve (part #7). (See Figure D.)

6. Insert a Washer (part #3) on each side of the Front Steering Linkage.

(See Figure D.)

7. Hammer a Cap Nut (part #8) firmly onto each end of the Front Steering Linkage
(part #2). (See Figure D.)

8. Connect the middle portion of the Front Steering Linkage (part #2) to the Steering
Rod (part #9), and secure the Front Steering Linkage to the Steering Rod with a
Cotter Pin (part #10). (See Figure D.)

CAP NUT (#8)

WASHER (#3)

SLEEVE (#7)
VIBRATION MUFFLER (#6)

FRONT BUMPER (#5)

FRONT CHASSIS (#4)

STEERING ROD (#9)

FIGURE D

COTTER

PIN

(#10)

WASHER (#3)

FRONT STEERING LINKAGE (#2)

WHEEL (#1)

To Install The Back Rest:

1. Insert the Back Rest (part #20) into the two mounting holes located at the rear of
the ATV. Then secure the Back Rest to the ATV, using four Screws (part #21).

(See Figure E, next page.)

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REAR VIEW MIRROR

HANDLE

FIGURE E

HANDLE

BACK REST (#20)

SCREW (#21)

To Charge The Batteries:

1. THE INITIAL CHARGING TIME FOR THE BATTERIES IS 8 TO 12 HOURS.
The Batteries for this product have been
and therefore require an
ceed 12 hours

initial

initial

charging time of only 8 to 12 hours. Do not ex-

charging time. THEREAFTER, each subsequent charging

partially

charged by the manufacturer,

time for the Batteries may take up to 20 HOURS. Do not exceed 20 hours for
any subsequent charging of the Batteries.

2. To charge the Batteries (part #11), remove the Seat (part #15) and temporarily
set it aside to expose the Battery Compartment. (See Figure C.)

3. Disconnect the Battery Electric Supply Line (part #12) from the Wiring Harness
(part #13). (See Figure F, next page.)

4. Plug the 12 Volt DC Adapter Transformer Output Line (part #14) into the Battery
Electric Supply Line (part #12). (See Figure F)

SKU 03516 PAGE 9

5. Plug the 12 Volt DC Adapter Transformer (par t #14) into a grounded, 3-Hole, 120
Volt electric outlet. (See Figure A.)

6. Follow the directions in Step #1 to fully charge the Batteries (part #11).

7. When the charging process is completed, disconnect the 12 Volt DC Adapter
Transformer (part #14) from the grounded, 3-Hole, 120 Volt electric outlet.

(See Figure A.)

8. Disconnect the 12 Volt DC Adapter Transformer Output Line (par t #14) from the
Battery Electric Supply Line (part #12). (See Figure F.)

9. Plug the Battery Electric Supply Line (part #12) back into the Wiring Harness
(part #13). (See Figure F.)

10. Re-install the Seat (part #15) on the ATV. (See Figure C.)

FIGURE F

ADAPTER

TRANSFORMER

OUTPUT LINE

(#14)

OPERATING INSTRUCTIONS

WIRING

HARNESS

(#13)

BATTERY ELECTRIC SUPPLY LINE (#12)

BATTERIES (#11)

1. Once seated on the ATV, select the desired speed (Low or High) and direction
(Forward or Reverse) on the Instrument Panel (part #18). (See Figure C.)

2. Insert the Ignition Key (part #22) into the Ignition Switch, and turn the Ignition Key

counterclockwise

to turn on the ATV. (See Figure C.)

3. Then, step on the Throttle Pedal (part #19) to move the ATV at the pre-selected
speed and in the pre-selected direction.

SKU 03516 PAGE 10

4. To stop the ATV, release pressure on the Throttle Pedal (part #19) and the ATV
will automatically stop. (See Figure C.)

5.

NOTE: To avoid damage to the ATV, make sure to completely stop the ATV prior
to changing speeds (Low or High) and directions (Forward or Reverse).

6. When finished riding the ATV, make sure to turn the Ignition Key (part #22)

wise

to its “off” position and remove the Ignition Key. (See Figure C.)

clock-

INSPECTION, MAINTENANCE, AND CLEANING

1. NOTE: ALL INSPECTIONS, MAINTENANCE, AND CLEANING SHOULD BE
PERFORMED ONLY BY AN ADUL T.

2. CAUTION: Always turn the Ignition Switch to its “OFF” position and remove
the Ignition Key before performing any inspection, adjustments, mainte­nance, or cleaning.

3. BEFORE EACH USE, inspect the general condition of the ATV. Check for loose
screws, misalignment or binding of moving parts, cracked or broken parts, dam­aged electrical wiring, excessively loose wheels, and any other condition that
may affect its safe operation. If abnor mal noise or vibration occurs, have the
problem corrected before further use.

Do not use this product if it is damaged.

4. BATTERY AND FUSE REPLACEMENTS: For your personal safety, it is recom-
mended that only a qualified technician replace the 6 Volt DC Batteries (part #11)
and 40 Amp Fuses (part #24).

5. DAILY: With a soft brush, cloth, or vacuum, remove all dirt and debris from the
ATV. If necessary, a mild detergent may be used. Do not expose the electrical
system of this product to water or any other liquids. When necessary, use a
premium quality, lightweight oil to lubricate all moving parts.

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUF ACTURER AND/OR DISTRIBUT OR HAS PRO VIDED THE PARTS LIST AND ASSEMBL Y
DIAGRAM IN THIS MANUAL AS A REFERENCE T OOL ONLY. NEITHER THE MANUFACTURER OR
DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER
THA T HE OR SHE IS QU ALIFIED T O MAKE ANY REP AIRS T O THE PR ODUCT , OR THA T HE OR SHE
IS QUALIFIED T O REPLACE ANY PARTS OF THE PRODUCT. IN F ACT, THE MANUF ACTUER AND/
OR DISTRIBUTOR EXPRESSLY ST A TES THA T ALL REP AIRS AND PARTS REPLACEMENTS SHOULD
BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NO T BY THE BUYER. THE
BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE
ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER
INST ALLATION OF REPLACEMENT P ARTS THERETO .

SKU 03516 PAGE 11

PARTS LIST

NOTE: To view illustrations of the following parts, refer to Figures A, C, D, E, and F of

this manual. Parts #22, #23, and #24 are not shown in this manual.

Part # Description Qty. Part # Description Qty.

1 Wheel 4 14 Adapter Transformer 1
2 Front Steering Linkage 1 15 Seat 1
3 Washer 4 16 Head Light 1
4 Front Chassis 1 17 T ail Light 1
5 Front Bumper 1 18 Instrument Panel 1
6 Vibration Muffler 2 19 Throttle Pedal 1
7 Sleeve 2 20 Back Rest 1
8 Cap Nut 2 21 Screw 4
9 Steering Rod 1 22 Ignition Key (not shown) 2
10 Cotter Pin 1 23 Wrench (not shown) 1
11 Battery 2 24 Fuse (not shown) 2
12 Battery Electric Supply Line 1
13 W iring Harness 1

Some parts are listed and shown for illustration purposes only, and are not avail­able individually as replacement parts.

SKU 03516 PAGE 12