Thump TSK50cc, TSX-C 140BW, TSX-C 125SW Owner's Manual

MANUAL # 3627
Owner’s Manual
is vehicle is designed and manufactured for o-road use only.
is manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold.
is publication includes the latest production information available before printing.
No part of this publication may be reproduced without written permission.
is vehicle pictured in this owner’s manual may not match your actual vehicle.
FOR OFF-ROAD USE ONLY
TSK50cc
vr:2
Contents
ese pages give an overview of the contents of your owner’s manual
Quick Reference .................................................................................... 1
Introduction ........................................................................................ 2
Motorcycle Assembly ........................................................................... 3
A Few Words About Safety .................................................................. 6
Motorcycle Safety ................................................................................. 7
Exhaust System ................................................................. 9
Fuel Handling .................................................................... 9
Safety Equipment ................................................................ 10
Message to Riders ................................................................................ 12
Loading, Accessories & Modications ............................................... 14
Safety Labels ........................................................................................ 16
Operating Controls ............................................................................. 17
Operation Component Locations ....................................... 17
Fuel Valve ......................................................................... 18
Choke Knob .................................................................... 19
Ignition Switch ................................................................ 20
Before Riding ..................................................................................... 21
Protective Gears ................................................................................. 22
Is Your Motorcycle Ready ................................................................... 23
Pre-Ride Inspection ........................................................................... 24
Basic Operation & Riding .................................................................. 26
Starting & Stopping the Engine ........................................................... 27
Braking ............................................................................................... 29
Parking ............................................................................................... 30
e Importance of your Maintenance ................................................ 31
Maintenance Safety ............................................................................. 33
Maintenance Schedule ........................................................................ 34
Maintenance ........................................................................................ 37
Front & Rear Breaks ....................................................... 37
Fuel Line and Tank ......................................................... 37
Oil Levels ........................................................................ 37
Replacing the Oil ............................................................. 38
Air Filter .......................................................................... 38
rottle ............................................................................. 39
Chain ................................................................................ 39
Tires ................................................................................. 40
Contents
General Cleanliness .......................................................... 40
Fuel ...................................................................................................... 41
Refueling Procedure .......................................................... 42
Electric Start Wiring Diagram ........................................................... 43
Engine Oil ........................................................................................... 44
Carburetor Adjustment & Tuning Tips ............................................ 48
Air Cleaner .......................................................................................... 53
Cleaning ........................................................................... 54
Clutch System ..................................................................................... 55
rottle ............................................................................................... 56
Valve Clearance ................................................................................... 59
Engine Idle Speed ............................................................................... 61
Component Inspection ....................................................................... 62
Spark Plug ........................................................................ 62
Suspension ........................................................................ 65
Brakes ................................................................................ 67
Wheels .............................................................................. 70
Tires & Tubes .................................................................... 74
Training Wheel .................................................................. 78
Drive Chain ...................................................................... 79
Battery .............................................................................. 84
Appearance Care ................................................................................ 87
Preparing for a Ride ........................................................................... 89
Transporting your umpstar ........................................................... 90
Storing your umpstar ..................................................................... 91
Troubleshooting ................................................................................ 93
You & the Environment ...................................................................... 96
Taking Care of the Unexpected .......................................................... 97
Vehicle Identication ......................................................................... 101
Oxygenated Fuels ............................................................................... 102
Specication ....................................................................................... 103
Spare Part Catalogue ......................................................................... 104
Torque Settings ................................................................................... 119
Parts Finder ....................................................................................... 124
Warranty ............................................................................................ 125
Disclaimer ......................................................................................... 126
Title Ownership ................................................................................ 128
1
Quick Reference
Model Version VR:2 (page 101) Intial Maintenance 2 Hours or 1 month Regular Maintenance 10 hours or 6 month Fuel/Capacity 3L Maximum Load 50kg Oil (TSK 50) 10/30 or 10/40, 4 Stroke, 950mls / 32.1oz Spark Plug Torch A7TC | NGK C7HSA Tire Pressure 20 PSI Front / 20 PSI Rear Tire Size 2.50-10” Valve Clearance (TSK 50) .003” intake / .005” exhaust Air Filter (TSK 50) Airbox Part Number #1.027.0360 Handle Bar 7/8 560-570mm Wheel Bearings 15mm 6202 Swingarm Bearings 10mm 6200 Engine/Mount 1P44FZB/TSmini
Plastics TSmini Brake Pad Front Part number# 4.450.0070 Model# XF50 Brake Pad Rear Part number# 4.450.0060 Model# 145 rottle Cable 650mm+116mm Fuse
2
Introduction
Congratulations in your decision to purchase a Genuine
umpstar Dirt bike. e following manual has been prepared to familiarise you with your motorcycle, and the procedures involved with operating and maintaining the motorcycle.
is manual also outlines general safety recommendations. We strongly advise that you take safety in mind at all times when maintaining and operating you dirt bike.
umpstar condone safe riding and do not take any responsibility for any damages caused to any persons or property due to inappropriate riding and safety precautions umpstar Strongly recommends reading this manual thoroughly BEFORE attempting any assembly or operation of the bike. umpstar Strongly recommends the use of the correct safety gear and safety procedures.
Warning: umpstar is only recommend riding privately on closed
course tracks by experienced riders and is not for general oroad recreational use, before riding anywhere other than on private land umpstar advise contacting your local road authority for further information, laws and restrictions.
Please note: umpstar produce a range of dirt bikes, some photographs and diagrams specic to component parts may dier slightly from the model you have purchased/received. If in doubt at any point, please contact a qualied mechanic or contact us for support.
Whenever you ride, tread lightly. By only riding in private closed course tracks and approved riding areas, you help protect the environment and keep o-road riding areas open for the future.
Please report any change of address or ownership to your dealer so we will be able to contact you concerning important product information.
HAPPY RIDING!
3
Motorcycle Assembly
Always have a Qualied Mechanic Assemble Your New Motorcycle
Tools Required:
• Bike Stand
• Liing Jack
• 8, 10, 12, 13, 14, 17, 19mm socket
and spanner
• 5, 6mm Allen Key/Hex Tool
• Rubber Mullet
• WD 40
Tick box once task has been completed
Remove Bike & all accessories from crate
Install handlebars and route cables and front brake hose before install-
ing fork
Front brake hose(1) should be at front, then throttle cable(2), last the
kill switch wire(3)
e longer front wheel (1) spacer will always be installed on the le/disc
side (page 70)
Fork Standard setting is 10mm out of clamp but depending on rider
preference, use copper grease on triple clamp bolts to prevent damage to the alloy threads & then rmly tighten.
1
1
2
4
p
• Lubricant
• Grease
• Paint Pen
• read Lock Glue
• Zip Tie
• Tire Pressure Gauge
4
Motorcycle Assembly
Use thread lock compound on front brake calliper bolts and torque to
9.9 N.M Pump front brake lever until rm (bleed if necessary). Check front braking system for potential leaks or damage by pulling brake lever very hard several times. Visually inspect all joints for leaks (page 67)
Grease front axel - Recommend using “Anti Seize Grease” (page 71)
Front wheel should spin freely, spin wheel to ensure calliper is releasing
from disk (page 67)
Test rear brake pedal & repeat procedure described for front brake
(page 69)
Check uid levels, top up with DOT4 where necessary (page 67)
Fit front mudguard and ensure step washer are installed correctly.
Fit foot pegs and use grease on foot peg pins
Ensure the correct pressure in tires – (page 74)
Loosen rear wheel & adjust chain tension. (page 80)
Working from front to rear, ensure all nuts & bolts are tight. Safety
areas: Wheel nuts, brake calliper bolts, Top & rear engine bolts, chain tensioners, rear shock bolts, triple clamp bolts (yokes), Handlebars, brake/ throttle, swing-arm, front & rear sprocket.
Aer checking the torque settings (page 119), please reference mark
each bolt with paint marker. If any bolt does comes loose the lines will not line up.
Ensure nothing is touching the exhaust system.
Ensure all cables pipes & wiring are away from moving components
such as the wheels, use cable/zip ties where necessary
Fuel bike & check for fuel leaks (page 44)
5
Check oil level with bike in upright position using dipstick (page 46)
Check throttle is working correctly with freeplay adjusted correctly
(page 57)
Ensure wheel spokes are tight & wheels run true (page 70)
Inspect bike for any other defects
Start engine & warm up (using choke if necessary). Set idle speed so
engine ticks over comfortably without stalling or racing. (page 61)
Test machine ensuring that all controls are uid & functional. Ensure
brakes are working eciently (bearing in mind that the pads will need to bed in prior to optimum performance).
Engine break-in
Run bike at no more than three quarter throttle & do not allow engine to rev to a high speed. Engine break-in should be no less than one hour. Aer one hours carry out the following checks & procedures:
Drain oil & replace with 950mls quality 10w 30w or 10w 40 4-stroke
engine oil (page 47)
Check all nuts & bolts & tighten where necessary (page 119) Check wheel spokes (especially rear wheel drive side) & tighten where
necessary
Re-Adjust throttle cable if required (page 56) Re-tension chain and lubricate Check wheel bearings for any sign of wear of free-play Check brake calliper operation & brake pad wear (page 67) Check tire pressures (page 74)
Remember to do pre-ride inspection each time you ride (page 24)
Motorcycle Assembly
6
A Few Words About Safety
Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility.
WARNING
Always use an
approved helmet &
protective gear
Never use
public roads
Never use with
drugs or alcohol
Never carry
passengers
is section presents some of the most important information and recommendations to help you ride your motorcycle safely. Please take a few moments to read these pages. is section also includes a special message for parents and location information for the safety labels on your motorcycle.
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
7
Motorcycle Safety
umpstar Motorbikes strongly recommend that anyone considering operating any of our products follow these instructions to avoid serious injury and/or death:
Read this manual carefully and follow the operating procedures described.
Follow the age recommendation of the specic umpstar model.
Children under the age of 16 should be supervised by an adult at all times. (Safety is the sole responsibility of parental guardians)
Never operate a bike without wearing an approved motorcycle helmet that ts correctly.
umpstar strongly recommends the use of eye protection (goggles and/or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.
Never consume alcohol or drugs before or while operating any bike.
Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is appropriate for the terrain, visibility and your experience.
Never attempt any kind of stunts
Always inspect your bike before each use to make sure it is in safe operating condition.
Always keep both hands on the handlebars and both feet on the footboards of the dirt bike during operation.
Always be alert to changing conditions of terrain, weather and visibility whenoperating the bike.
8
Motorcycle Safety
Never operate on excessively rough, slippery or loose terrain.
Always follow proper procedures for turning as described in this manual.
Never attempt to turn the bike around on any slope until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep slope if possible.
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.
Never operate a bike in fast owing water Wet brakes may have reduced operating ability. Test your brakes aer contact with water. If necessary, apply them several times to let friction dry out the linings.
Always use the correct size and type of tires specied in this manual.
Always maintain proper tire pressure as described in this manual.
Never modify any bike through improper installation or use of accessories.
Never exceed the stated load capacity for any umpstar Motorbikes product.
Ensure the safe handling of ANY petrochemicals required for the maintenance of your umpstar product.
umpstar Motorbikes will not be held responsible for violations of local road laws
9
Motorcycle Safety
EXHAUST SYSTEM
umpstar Motorbikes advise that the exhaust on the machine can become very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the machine in a place where Pedestrians or children are not likely to come in at contact.
FUEL HANDLING
Precautions should be taken when handling any type of petrochemicals. Gasoline can catch re, and is toxic to life and the environment. umpstar motorbikes recommend the following safety tips to avoid accidents, injury/death:
Always turn o the engine when re-fuelling. Do not refuel right aer the engine has been running and is still very hot.
Do not spill gasoline on the engine or exhaust pipe/muer when refuelling.
When transporting the machine in another motorcycle, 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.
10
Motorcycle Safety
Never refuel in any proximity to any sources of ignition such as smokers, open ames or embers etc.
Gasoline is poisonous and can cause injuries, in the case of swallowing gasoline, inhaling gasoline vapours or contact with eyes, see your doctor immediately.
In the case of gasoline contact on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.
SAFETY EQUIPMENT
umpstar Motorbikes promote the use of safety equipment during the use of your bike; the following list is an advisory guideline of the equipment that should be obtained before using your bike for the rst time, and to be used for every ride regardless of experience and skill level.
HELMET
A helmet is the most important piece of protective equipment and
should be worn at all times the motorcycle is being ridden.
Select a helmet that complies with the Standard Protective helmets for motorcycle users. ese helmets meet the requirements for on-road and o-road use.
Ensure the helmet ts the operator snugly, is securely fastened and provides good, all-round visibility. A poorly-tting or loose helmet can become dislodged in an incident and then oer no protection at all.
11
Motorcycle Safety
EYE PROTECTION
Recommended to prevent eye injuries and prevent branches, bugs, dust or sand hitting your face and distracting you. Sunglasses are unlikely to provide adequate physical protection.
GLOVES
Recommended to provide protection from abrasions and help to
keep your hands from getting sore, tired or cold. Note that gloves may become slippery when wet and are not advisable for use
FOOTWEAR CLOTHING
Sturdy footwear is recommended (preferably boots that come up past your ankle with strong material for gear changes.)
Arms and legs should be covered to reduce abrasions to the body, even in hot weather.
Trousers should be close-tting and in good condition.
12
Message To Riders
Your safety is very important to umpstar. at’s why we urge you to read this message before riding this motorcycle. O-road riding can be fun. But, as with riding a bicycle, bad judgment can result in injury, and we don’t want that to happen! You can help prevent accidents by making good decisions about if, when, and how you rides this motorcycle.
THINGS TO CONSIDER WHEN RIDING
e rst decision you’ll need to make is whether you’re ready to ride. Riding readiness varies widely from one person to another, and age and size are not the only factors. Remember this model is designed for experienced riders only.
PHYSICAL ABILITY
An important consideration that riders must be big enough to hold the motorcycle up, get on, and comfortably sit on the seat with both feet touching the ground. ey should also be able to easily reach and work the brakes, throttle, and all other controls.
ATHLETIC ABILITY
A necessary trait for riding a motorcycle. Generally speaking, you should be good at riding a bicycle before getting on a motorcycle. Can you judge speeds and distances while riding a bicycle and react with proper hand and foot actions? Anyone who does not have good coordination, balance, and agility is not ready to ride this motorcycle and is not considered an experienced rider.
13
Message To Riders
MENTAL AND EMOTIONAL MATURITY
Do you think through problems and come to logical solutions? On a bicycle, do you obey safe riding rules? Be honest! Anyone who makes unnecessary risks, make bad judgments, and don’t obey rules are not ready to ride this motorcycle.
If you decide that you’re ready to safely operate this motorcycle, make sure you carefully read and understand the owner’s manual before riding. Also be sure that you have a helmet and other appropriate riding equipment, and always wears it when operating the motorcycle or sitting on it.
SAFE AND RESPONSIBLE RIDING
When you put safety rst, you can enjoy more peace of mind, and you can enjoy more hours of safe oroad riding.
14
Loading, Accessories & Modifications
umpstar was designed as a rider-only motorcycle. It was not designed to carry a passenger or cargo. A passenger or cargo could interfere with your ability to move around to maintain your balance and control of the motorcycle
In addition, exceeding the weight limits or carrying an unbalanced load can seriously aect your motorcycle’s handling, braking, and stability. Adding accessories or making modications that change this motorcycle’s design and performance can also make it unsafe. Also, the weight of any accessories will reduce the maximum load the motorcycle can carry
LOADING
How much weight you put on your motorcycle, and how you load it, are important to your safety. is is a single rider bike and not recommended for taking extra passengers.
We recommend that you do not carry any cargo on this motorcycle.
15
Loading, Accessories & Modifications
ACCESSORIES & MODIFICATION
Modifying your motorcycle or using non-umpstar accessories can make your motorcycle unsafe.
ACCESSORIES
We strongly recommend that you use only umpstar Genuine Parts and Accessories that have been specically designed or approved and tested for your motorcycle. Because umpstar cannot test all other accessories, you must be personally responsible for proper selection, installation, and use of non-umpstar accessories. Check with your dealer for assistance and always follow this guideline:
Make sure the accessory does not reduce ground clearance and lean angle, limit suspension travel or steering travel, alter your riding position, or interfere with operating any controls
MODIFICATIONS
We strongly advise you not to remove any original equipment or modify your motorcycle in any way that would change its design or operation. Such changes could seriously impair your motorcycle’s handling, stability, and braking, making it unsafe to ride.
We also advise you not to make any modications or remove any equipment that would make the motorcycle illegal in your area.
16
Safety Labels
WARNING
Not wearing a helmet increases
thechance of serious injury or
death in acrash. Be sure you
always wear a helmet,eye
protection and other protective
apparel when you ride.
17
Operating Controls
When you ride o-road, you need to operate the throttle, brakes, and other controls without stopping to look at them. Read this section carefully before you ride. It describes the location, function, and operation of all the basic controls on your motorcycle.
OPERATION COMPONENT LOCATIONS
Throttle Grip
Adjustable Throttle
Start Button
Engine Stop Switch
Front Brake Lever
Rear Brake Lever
Lanyard
START BUTTON
e start button is used for starting the engine. Pushing the button in starts the engine. When the start button is pushed, the starter motor will crank the engine.
ENGINE STOP SWITCH
e engine stop switch is used to turn the engine o during normal riding situations. To operate, turn the switch to the OFF position. e switch must be in the RUN position to start the engine.
FRONT BRAKE LEVER
e front brake lever is used to slow or stop your motorcycle. To operate, pull the lever.
18
Operating Controls
THROTTLE
e throttle controls engine rpm (speed). To increase engine rpm, rotate the grip toward you. To reduce engine rpm, rotate the grip away from you. e throttle will automatically return to the closed position (engine idle) when you remove your hand.
FUEL VALVE
e two way fuel valve is used to control the ow of fuel from the fuel tank to the carburetor.
ON Turning the fuel valve ON before attempting to start the engine allows fuel to ow from the fuel tank to the carburetor.
OFF Turning the fuel valve OFF aer stopping the engine prevents the ow of fuel from the fuel tank to the carburetor.
ON
OFF
19
Operating Controls
CHOKE KNOB
e choke knob is used for starting the engine. e choke increases the percentage of fuel in the fuel/air mixture delivered to the engine
ON Used to start a cold engine with air temperature
below 35°C (95°F).
OFF Used for normal operation, for restarting a warm engine, or starting a cold engine with air
temperature above 35°C (95°F).
20
Operating Controls
IGNITION SWITCH
e ignition switch is used to prevent unauthorized use of the motorcycle. Before riding, insert the key and turn it to the right for the ON position.
Key Position Function Key Removal
OFF e engine cannot be
operated.
e key can be removed
ON With the engine stop
switch at RUN and the transmission in neutral, the engine can be started.
e key cannot be removed
ON
OFF
21
Before Riding
Before each ride, you need to make sure you and your umpstar are both ready to ride. To help get you prepared, this section discusses how to evaluate your riding readiness, and how to perform the recommended pre-ride inspection of your umpstar.
PREPARE TO RIDE
Before you ride your motorcycle for the rst time, we strongly recommend that you:
• read this owner’s Manual properly
• make sure you understand all the safety messages
• learn how to operate all the necessary controls
Before each ride, we also suggest that you make sure you:
• are in good mental & physical condition
• are free of alcohol and drugs
• are wearing an approved motorcycle helmet (with chin strap tightened
securely), eye protection, and other protective gears.
PROTECTIVE GEAR
For your safety, we strongly recommend that you always wear an approved motorcycle helmet, eye protection, boots, gloves, long pants, and a long-sleeved jersey, shirt, or jacket whenever you ride. Although complete protection is not possible, wearing the proper gear can reduce the chance of injury when you ride.
Following are suggestions to help you choose the proper gear.
22
Protective Gears
HELMETS AND EYE PROTECTION
Your helmet is your most important piece of riding gear because it oers the best protection against head injuries. A helmet should t your head comfortably and have a chin strap that can be tightened securely.
An open-face helmet oers some protection, but a full-face helmet oers more. Regardless of the style, look for a DOT (Department of Transportation) sticker on any helmet you buy. Always wear a face shield or goggles to protect your eyes and help your vision.
ADDITIONAL PROTECTIVE GEAR
In Addition to a helmet and eye protection, we also recommend the following:
• Sturdy o-road motorcycle boots to help protect your feet, ankles and lower legs.
• O-road motorcycle gloves to help protect your hands.
• Riding pants with knee and hip pads, a riding jersey with padded
elbows, chest and shoulder protectors.
WARNING
Not wearing a helmet increases
thechance of serious injury or
death in acrash. Be sure you
always wear a helmet,eye
protection and other protective
apparel when you ride.
23
Is Your Motorcycle Ready
Before each ride, it’s important to inspect your motorcycle and make sure any problem you nd is corrected. A pre-ride inspection is a must because o-road riding can be tough on a motorcycle and you don’t want to have a breakdown far from help.
NOTE TO PARENTS:
If a youngster will be performing any of the following pre-ride inspection procedures, it’s your responsibility to provide careful supervision and make sure they are performed safely.
WARNING
Improperly maintaining this
motorcycle or failing to correct a
problem before riding can cause
a crash in which you can be
seriously hurt or killed.
Always perform a pre-ride
inspection before every ride and
correct any problems.
24
Pre-Ride Inspection
Check the following items before you get on the motorcycle:
Tires Use a gauge to check the air
pressure. Adjust if needed. Also look for signs of damage or excessive wear (page 74)
Spokes & Rims Make sure the spokes are tight.
Also check the rims for damage (page 70)
Leaks Look under the motorcycle for
signs of leaking uids (fuel, engine oil). (page 41 & 67)
Engine Oil Check the level and add oil if
needed (page 44)
Fuel Check the level and add fuel if needed. Also
make sure the fuel ll cap is securely fas­tened. (page 41)
Drive Chain Check the condition and slack.
Adjust and lubricate if needed. Also check the chain slider for wear and replace if needed (page 79)
Cables Check the cable housings for
wear. Check the ttings for looseness. Replace or tighten as needed. (page 55 & 56)
Nuts & Bolts Use a wrench tomake sure all
accessible nuts, bolts, and fasteners are tight. (page 119)
Spark Plug & Cap Check for looseness (page 62)
25
Pre-Ride Inspections
rottle Check the freeplay and adjust if
needed. Rotate the throttle to make sure it moves smoothly without sticking, and snaps shut automatically when it is released, in all steering positions (page 56)
Brakes Squeeze the front brake lever
and step on the rear brake pedal to check that the controls operate normally. Adjust freeplay, if necessary. (page 67)
Remember, be sure to take care of any problem you nd or have your Certied Motorcycle Mechanic correct it before you ride.
26
Basic Operation & Riding
is section gives basic information on how to begin riding your motorcycle. It includes how to start and stop your engine, how to use the throttle and brakes, and what to do when you’re through riding.
SAFETY RIDING PRECAUTIONS
Before riding your motorcycle for the rst time, please review the
Motorcycle Safety.
Even if you have ridden other motorcycles, take time to become familiar with how this motorcycle works and handles. Practice in a safe area until you build up your skills and get accustomed to your motorcycle’s size and weight.
For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your motorcycle’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.
Your motorcycle is not equipped with ttt.
Do not ride at night.
Loading...
+ 102 hidden pages