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.

umpstar reserves the right to make changes at any time
without notice and without incurring any obligation.

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.

27

Starting & Stopping the Engine

Always follow the proper starting procedure described below.

PREPARATIONS

Before Starting, turn the fuel valve ON and make sure bike is in NEUTRAL.

STARTING PROCEDURE

To restart a warm engine, follow the procedure for High Air Temperature
on page 27.

Normal Air Temperature
10° 35°C (50° 95°F)

1. Push the choke knob up all the way to fully ON.

2. Press the start button and begin to warm up the engine by opening and
closing the throttle. (Caution: DO NOT turn the throttle too much other­wise the motorcycle will move forward because of the automatic gearing)

Choke Knob

28

Starting & Stopping the Engine

3. About a quarter-minute aer the engine starts, push the choke
knob in all the way down to fully OFF.

4. If idling is unstable, open the throttle slightly.

High Air Temperature or to restart warm engine
35°C (95°F) or above

1. Do not use the choke.

2. Start the engine (See step 2 under Normal Air Temperature)

Low Air Temperature
10°C (50°F) or below

1. Follow steps 1- 2 under Normal Air Temperature.

2. Warm up the engine by opening and closing the throttle slightly.

3. Continue warming up the engine until it runs smoothly and
responds to the throttle when the choke knob is at fully OFF.

Note: Will take at least 5 to 10 minutes for your engine to be warmed up
and start smoothly

29

Braking

To slow or stop, apply the front brake and rear brake lever smoothly,
while downshiing to match your speed. Gradually increase braking
as you feel the brakes slowing your speed. For support, put your
le foot down rst, then your right foot when you have nished using
therear brake.

For maximum braking, close the throttle and rmly apply the brake
lever and pedal controls.

Applying the brakes too hard may cause the wheels to lock and slide,
reducing control of your motorcycle. If this happens, release the
brake controls, steer straight ahead until you regain control, then reapply
the brakes more gently.

Generally, reduce your speed or complete braking before beginning
a turn. Avoid braking or closing the throttle quickly while turning.
Either action may cause one or both wheels to slip. Any wheel slip
will reduce your control of your motorcycle.

When riding in wet or rainy conditions, or on loose surfaces, the
ability to maneuver and stop will be reduced. All of your actions should
be smooth under these conditions. Rapid acceleration, braking or
turning may cause loss of control. For your safety, exercise extreme
caution when braking, accelerating, or turning.

When descending a long, steep grade, use both brakes.

30

Parking

Lower the side stand to support your motorcycle. Push the kill
switch button. If you’re nished riding for the day, also turn the
fuel valve OFF. Always choose a level place to park.

POST-RIDE INSPECTION

When you return home aer riding, thoroughly clean your
motorcycle and remove any dirt, mud, brush, rocks or other
objects you may have picked up along the way. Aer cleaning,
carefully inspect your motorcycle for leaks or damage.

Servicing Your Thumpstar

Keeping your motorcycle well maintained is absolutely essential
to your safety. It’s also a good way to protect your investment, get
maximum performance, avoid breakdowns, and have more fun.

To help keep your motorcycle in good shape, this section includes
a Maintenance Schedule for required servicing and step-by-step
instructions for specic maintenance tasks. You’ll also nd
important safety precautions, information on oils, and tips for
keeping your umpstar looking good.

Always use the ring
spanner end or socket
when possible

Maintenance Tip: e ring spanner or socket will
extend the life of the bolts

31

The Importance of your Maintenance

A well-maintained motorcycle is essential for safe, economical,
and trouble-free riding. It will also help reduce air pollution.
Careful preride inspections and good maintenance are especially
important because your motorcycle is designed to be ridden over
rough o-road terrain.

To help you properly care for your motorcycle, this section of
the manual provides a Maintenance Schedule. e service intervals
in this schedule are based on average riding conditions.

More frequent service is needed if you subject your motorcycle to s
evere use or ride in unusually wet or dusty
areas.

Frequent servicing of the air cleaner is especially important to
help you avoid a possible costly engine repair.

If your motorcycle overturns or is involved in a crash,
be sure your Certied Motorcycle Mechanic inspects all major parts,
even if you are able to make some repairs.

WARNING

Improperly maintaining this

motorcycle or failing to correct a

problem before you ride can

cause a crash in which you can

be seriously hurt or killed.

Always follow the inspection

and maintenance recommenda-

tions and schedules in this

owner’s manual.

32

The Importance of your Maintenance

Remember, proper maintenance is the owner’s responsibility.
Be sure to inspect your motorcycle before each ride and follow the
Maintenance Schedule in this section.

Note to Parents:
As a parent, it’s up to you to make sure that this motorcycle
is properly maintained and kept in saf e operating condition. For
youngsters, learning how to take care of a motorcycle and perform
basic maintenance can be an important part of their riding
experience. However, if you allow a youngster to perform or assist
in any maintenance task, such as f illing the tank with gasoline, you
should provide close supervision to make sure that it is performed safely.

MAINTENANCE SAFETY

e maintenance section includes instructions on how to perform
some important maintenance tasks. Some of the most important
safety precautions follow. However, we cannot warn you of every
conceivable hazard that can arise in performing maintenance.
Only you can decide whether or not you should perform a
given task.

WARNING

Failure to properly follow

maintenance instructions and

precautions can cause you to

be seriously hurt or killed.

Always follow the procedures

and precautions in this owner’s

manual.

33

Maintenance Safety

Important Safety Precautions

Make sure the engine is o before you begin
any maintenance or repairs.
is will help eliminate several potential
hazards:

• Carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventilation whenever you
operate the engine.

• Burns from hot motorcycle parts.Let the engine and
exhaust system cool before touching.

• Injury from moving parts. Do not run the engine
unless instructed to do so.

• Read the instructions before you begin, and engine unless
instructed to do so. make sure you have the tools and skills
required.

• To help prevent the motorcycle from falling over, park it on a
rm, level surface, using the side stand or a maintenance
stand to provide support.

• To reduce the possibility of a re or explosion, be careful when
working around gasoline. Use only a non-ammable (high
ash point) solvent such as kerosene not gasoline to clean
parts. Keep cigarettes, sparks, and ames away from all
fuelrelated parts.

34

Maintenance Schedule

To maintain the safety and reliability of your motorcycle,
regular inspection and service is required as shown in the
Maintenance Schedule that follows.

e Maintenance Schedule lists items that can be performed
with basic mechanical skills and hand tools. Procedures for
these items are provided in this manual.

e Maintenance Schedule also includes items that involve
more extensive procedures and may require special training,
tools, and equipment. erefore, we recommend that you
have your Certied Motorcycle Mechanic perform these tasks
unless you have advanced mechanical skills and the required tools.
Procedures for items in this schedule are provided in a service manual
available for purchase from your dealer.

Because your motorcycle does not have an odometer, service
intervals in the maintenance schedules are expressed in terms
of hours as well as miles/kilometers. To avoid overlooking required
service, we urge you to develop a convenient way to record the
number of days and/or miles you ride.

If you do not feel capable of performing a given task or need
assistance, remember that your Certied Motorcycle Mechanic knows
your motorcycle best and is fully equipped to maintain and repair it.
If you decide to do your own maintenance, use only umpstar
Genuine Parts or their equivalents for repair or replacement to
ensure the best quality and reliability.

MAINTENANCE PROCEDURES

X: Inspect and clean, adjust, lubricate, or replace, if necessary
C: Clean
A: Adjust
L: Lubricate
R: Replace

35

Maintenance Schedule

ITEMS

NOTE

About

2.5 hours
of use

About

10 hours

of use

About

20 hours

of use

About

30 hours

of use

About

40.0 hours

rottle Inspection

X

Air Filter

1 C

Crankcase Breather

X

Spark Plug

X

Valve Clearance

4 X

Engine Oil

3 X

Engine Idle Speed

X

Drive Chain

X,L R

Drive Chain Slider

X

Drive Chain Roller

X

Drive Sprocket

X

Driven Sprocket

X

Brake Fluid

2 X

Brake Pads Wear

X

Brake System

X

Control Cables

X,L

Exhaust Pipe /
Muer

X

Suspension

X

Nuts, Bolts,
Fasteners

X

Wheels / Tires

X

Steering Head
Bearings

X

36

Maintenance Schedule

is maintenance schedule is based upon average riding condition.
Machines subjected to severe use require more frequent servicing.

NOTE:

1.Clean aer every heat for dusty riding conditions.

2.Replace every 2 years. Replacement requires mechanical skill.

3.Replace aer the rst break-in ride.

4.Inspect aer the rst break-in ride.

Perform the pre-ride inspection at each scheduled maintenance
period.

Each item on the maintenance schedule requires some mechanical
knowledge. Certain items may require more technical information and
tools. Consult your Certied Motorcycle Mechanic.

SUMMARY OF MAINTENANCE SCHEDULE NOTES AND
PROCEDURES (page 127)

Note: Service more frequently when ridden in wet or dusty conditions.

37

Maintenance

umpstar Motorbikes promote safety as paramount. As such, it is advised
that before each and every use of your bike that you actively walk around
your motorcycle and check that everything appears in order. Maintenance
should be undertaken regularly and servicing should be carried out by the
appropriate persons. umpstar recommend any work being carried out
on any of our range of dirt bikes should be done by an approved mechanic.

e following list has been provided for you by umpstar Motorbikes as
an advisory process before each ride.

FRONT AND REAR BRAKE

When checking the brakes, ensure all cables are in place and there are no
leaks. Check the braking mechanism works manually before riding. Some
brakes are adjustable for performance reasons; brake adjustments are
sensitive and in the interest of safety should only be carried out by a skilled
mechanic. (page 67)

FUEL LINE AND TANK

It is important to check for any fuel leaks around the tanks and along fuel
lines. Bike engines become hot during use and therefore pose a re risk.

(page 41)

OIL LEVELS

Oil Levels Should be checked prior to each usage, the “dipstick” can be
found on the right cover of the crack case, much like a car this is used to
check the oil levels, if the engine is low on oil top up to a suitable level. e
dipstick should always be replaced rmly and securely. e oil supplied
with the motorcycle is transport oil that should be changed aer the rst 4
hours of usage. (page 44)

38

Maintenance

REPLACING THE OIL

-Remove the “sump plug”

-Drain the oil from the engine

-Replace the sump plug

-Rell the engine with a high quality oil suitable for the engine

PLEASE NOTE: Never maintain the engine when it is hot as this can cause
injury, leaks of petrochemicals can cause res, explosions and even death.

Whether your Bike has a 2 – Stroke or 4 – Stroke engine, your bike engine
relies on a good supply of high quality engine oil. Failure to the oil supply
can permanently damage your engine, and oil leaks can cause the loss of
control to your Bike.

SPARK PLUG

. Remove the coil/lead from the spark plug
. Remove the spark plug with the correct tool

-Ensure the Gap at the contactors is 0.6-0.7mm

-Clean around the contactors (where the spark is emitted from) or replace
the unit (page 62)

AIR FILTER

Check the air lter aer each usage of the motorcycle. Where applicable
remove the air lter for cleaning

Wash the lter or soak it with an air lter cleaner or machine oil, if the
lter is in any way damaged, please source a replacement lter appropriate
for tting to the Carburetor.

CAUTION: Make sure the air lter is correctly tted to the bike; failure to
t the lter will result in contaminants entering the engine and cause fatal
damage to the engine components (page 53)

39

Maintenance

THROTTLE

e throttle of your motorcycle directly aects the speed of your bike, it
should be in perfect working order before each time you ride your bike.
Check and ensure that the cable and all mechanical parts included in the
throttle system are moving freely. (page 56)

e Carburetor is also considered part of the throttle system and may also
require adjustment. It is not advised to make adjustments whilst the en­gine is running. Repeat adjustments whilst the engine id o and test each
adjustment aerwards.

To adjust the Carburetor:

-Support the motorcycle by means of the side stand

-Adjust the idling speed using the adjustment screw (recommended r/min
are aprox. 1500 r/min)

PLEASE NOTE: Do not make adjustments to a cold engine as this is the
most changeable state of the engines running. Adjustments should not
be made by unqualied persons, if in doubt please consult a qualied
mechanic. (page 48)

CHAIN

It is advisable to visually check the chain of your bike before each use. Its
general condition is important, there should be no obstructions to the
chain, it should be well lubricated and under the correct tension. (page 79)

40

Maintenance

TIRES

umpstar Motorbikes advise that you should check the condition and
wear of your tires before every ride. Tire pressure should be check inter­mittently (please refer to “Tips for Servicing and Maintenance” for further
information. Tires can be damaged by rough terrain
In the event of any discrepancies or faults discovered during your safety
checks, please refer to “Tips for Servicing and Maintenance” or contact an
approved mechanic. (page 74)

GENERAL CLEANLINESS

e cleaning of your motorcycle can prolong the life of many component
parts such as, plastics brakes and frame etc. Jet washing can cause damage
to certain components i.e Air lters.

PLEASE NOTE:

Some cleaning chemicals can remove oils and lubricants that are vital
to the running condition of the Bike. It is highly recommended that all
lubricated areas are treated with the correct lubricants. Do not use corro­sive detergents for the cleaning of the motorcycle. Brakes can be rendered
ineective if wet or contaminated with detergents, please allow for drying
time prior to reusing the motorcycle aer cleaning.

41

Fuel

FUEL RECOMMENDATION

Type Unleaded
Pump Octane Number 86 (or higher)

Your engine is designed to use any unleaded gasoline that has a pump
octane number of 86 or higher. Gasoline pumps at service stations
normally display the pump octane number.

Use of lower octane gasoline can cause persistent ‘‘pinging’’ or ‘‘spark
knock’’ (a louder rapping noise) which, if severe, can lead to engine
damage. (Light pinging experienced while operating under a heavy load,
such as climbing a hill, is no cause for concern.)

If pinging or spark knock occurs at a steady engine speed under normal
load, change brands of gasoline. If pinging or spark knock persists,
consult your Certied Motorcycle Mechanic.

Use only unleaded fuel in your umpstar. If you ride your umpstar in a
country where leaded fuel might be available, take precautions to use only
unleaded fuel.

Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid
getting dirt, dust, or water in the fuel tank.

Getting dirt or dust on your fuel can block you Carburetor which can
cause it to leak and cause other problems as well.

WARNING

Gasoline is highly flammable

and explosive. You can be

burned or seriously injured

when handling fuel. Stop the

engine and keep heat, sparks

and flame away. Handle fuel

only outdoors. Wipe up spills

immediately.

42

Fuel

REFUELING PROCEDURE

Fuel Tank Capacity, including reserve: 1.06 US gal (4.0 )
Reserve Capacity: 0.26 US gal (1.0 )

1. To open the fuel ll cap, pull the breather tube out of the steering stem
nut. Turn the fuel ll cap counterclockwise and remove it.

2. Add fuel until the level reaches the bottom of the ller neck. Avoid
overlling the tank. ere should be no fuel in the ller neck.

Breather Tube

Fuel Cap

Filler Neck

WARNING

Gasoline is highly flammable

and explosive. You can be

burned or seriously injured

when handling fuel. Stop the

engine and keep heat, sparks

and flame away. Handle fuel

only outdoors. Wipe up spills

immediately.

43

3. Aer refueling, turn the fuel ll cap clockwise until it is secure.

4. Insert the breather tube in the steering stem nut.

If you replace the fuel ll cap, use only a umpstar Genuine replacement
part.

Fuel

Electric Start Wiring Diagram

C A

M

H

M

S

STARTER

SOLENOID

BATTERY

FUSE

KEY SWITCH

NATURAL
SAFETY
SWITCH

44

Engine Oil

Using the proper oil, and regularly checking, adding, and changing oil will
help extend your engine’s life. Even the best oil wears out. Changing oil
helps get rid of dirt and deposits held in the engine. Operating the engine
with old or dirty oil can damage your engine. Running the engine with
insucient oil can cause serious damage to the engine and transmission.

OIL RECOMMENDATION

API classication SG or higher except

oils labeled as
energy conserving
on the circular API

service label
viscosity (weight) SAE 10W-30* / 10W-40*
JASO T 903 standard MA
suggested oil** 4-stroke oil, or an

equivalent motorcycle oil

*For normal air temperatures. See next page for additional temperature/
viscosity Information.

**Suggested oils are equal in performance to SJ oils that are not labeled as
energy conserving on the circular API service label.

Your motorcycle does not need oil additives. Use the recommended oil.

• Do not use oils with graphite or molybdenum additives.

• Do not use API SH or higher oils displaying a circular API ‘‘energy

conserving’’ service label on the container.

• Do not use non-detergent, vegetable, or castor based racing oils.

45

Engine Oil

Other viscosities shown in the following chart may be used when the aver­age temperature in your riding area is within the indicated range.

JASO T 903 standard
e JASO T 903 standard is an index for engine oils for 4-stroke
motorcycle engines. ere are two classes: MA and MB. Oil conforming
to the standard is labeled on the oil container. For example, the following
label shows the MA classication.

(1) oil code
(2) oil classication

46

Engine Oil

CHECKING & ADDING OIL

1. Park your motorcycle on a rm, level surface.

2. Clean around the oil ll cap/dipstick and nearby surfaces.

3. Start the engine and let it idle for 3-5 minutes. Stop the engine. Wait
2-3 minutes.

4. Unscrew and remove the oil ll cap/dipstick. Wipe it clean.

5. Hold the motorcycle upright.

6. Insert the oil ll cap/dipstick until it seats, but do not screw it in.

7. Remove the oil ll cap/dipstick and check the oil level.

8. Insert the oil ll cap/dipstick and screw it in tightly.

9. Check for oil leaks.

Oil Filler Cap/Dipstick Oil Checker

47

Engine Oil

CHANGING ENGINE OIL

1. If the engine is cold, start it and let it idle for 3-5 minutes. Turn the

engine o. Wait 2-3 minutes for the oil to settle.

2. Park your motorcycle on a rm, level surface.

3. Remove the oil ll cap/dipstick.

4. Place a drain pan under the crankcase.

5. Unscrew and remove the oil drain bolt .

6. Aer most of the oil is drained, gently tilt the motorcycle from side to

side to drain the remaining oil.

7. Pour the drained oil into a suitable container and dispose of it in an

approved manner.

8. Remove the old sealing washer and install a new sealing washer

on the drain bolt.

9. Install the oil drain bolt and tighten to the specied torque:

18 lbf· (24 N·m , 2.4 kgf·m)

10. Pour the recommended oil into the crankcase, approximately:

1.1 US qt (1.0 )

11. Install the oil ll cap/dipstick securely.

12. Start the engine. Let it idle 3-5 minutes, then turn it o.

13. With the motorcycle held upright on level ground, check the oil level.

If needed, add oil until it reaches the upper level mark. (Do not overll.)

14. Check for oil leaks.

Washer

Oil Drain Bolt

48

Carburetor Adjustments & Tuning Tips

HIGH ALTITUDE CARBURETOR ADJUSTMENT

At high altitude, the standard carburetor airfuel mixture will be too rich.
Performance will decrease, and fuel consumption will increase. A very rich
mixture will also foul the spark plug and cause hard starting. Operation
at an altitude that diers from that at which this engine was certied, for
extended periods of time, may increase emissions.

High altitude performance can be improved by specic modications to
the carburetor. If you always operate your engine at altitudes above 6,500
feet (2,000 meters), have your servicing dealer perform this carburetor
modication. is engine, when operated at high altitude with the
carburetor modications for high altitude use, will meet each emission
standard throughout its useful life.

Even with carburetor modication, engine horsepower will decrease
about 3.5% for each 1,000-foot (300-meter) increase in altitude. e eect
of altitude on horsepower will be greater than this if no carburetor
modication is made.

49

Carburetor Adjustments & Tuning Tips

CARBURETOR CIRCUIT FUNCTIONS

e carburetor has several circuits, each providing the fuel/air mixture over
a given portion of throttle valve opening.

ese circuits overlap as show below.

MAIN JET

e main jet aects fuel/air ratio from half (1/2) to full throttle (4/4). e
size should be reduced at higher altitudes.

MAIN JET

JET NEEDLE (TAPERED SECTION)

JET NEEDLE

(STRAIGHT SECTION)

SLOW JET

PILOT SCREW

1/8 1/4 1/2 3/4

FULLY
CLOSED

FULLY
OPEN

50

Carburetor Adjustments & Tuning Tips

JET NEEDLE

e jet needle controls fuel/air mixture over fully closed to 3/4 throttle. e
straight section aects throttle response at smaller throttle openings. By
changing the position of the clip in its groove, you can improve acceleration
at medium low and medium speed.

LEANER

RICHER

1st
2nd
3rd

4th
5th
6th
7th

SLOW JET AND AIR FUEL /
PILOT SCREW

e slow jet and pilot screw aects
fuel/air ratio over fully closed to 1/4
throttle. Adjust the pilot screw tot
obtain the best o-idle performance.

•Iftheengineblubbers(rich)

exiting a corner, turn the pilot screw
clockwise to lean the mixture.

•Iftheenginesurges(lean)exiting

a corner, turn the pilot screw
counterclockwise to richen the
mixture.

e minimum to maximum range of
pilot screw adjustment is 1 to 1 3/4
turns out from the lightly seated position.
If you exceed 1 3/4 turns out, the next
larger slow jet is needed. If you are under
1 turns out, the next smaller slow jet is
needed.

Drain Screw

51

STANDARD TUNING RECOMMENDATIONS

For the following recommendations to be accurate, you must use the
standard settings as a baseline. Also, don’t change any of the settings
until you’ve determined what changes are necessary.

Adjustment TSK 50

Standard Settings

Pilot / Air Fuel Screw Opening

Slow/Pilot Jet

Needle Clip Position

Main jet

ADJUSTMENTS FOR ALTITUDE & TEMPERATURE

All jetting recommendations are based on standard jetting with an
unmodied engine. e following conditions can aect the fuel mixture

Condition Mixture Will Be Adjus t To Component

Aected

Cold
Temperature

Lean Richen

Main Jet

(Jet Needle Stage)

War m
Temperature

Rich Lean

Dry Air Lean Richen
High Humidity Rich Lean
High Altitude Rich Lean

Carburetor Adjustments & Tuning Tips

52

Carburetor Adjustments & Tuning Tips

SPECIAL TUNING CONDITIONS

ere are some unique atmospheric conditions or situations that may
require additional adjustments. It should not be necessary to go more
than one jet size richer or leaner to ne tune your umpstar. If larger
jetting changes are necessary, check for air leaks, blocked or restricted
exhaust or fuel systems, or a dirty air cleaner.

Condition Main Jet Adjustment
Long Straights

Next Larger

Uphill Sections
Sand
Mud
High Humidity

Next Smaller

Raining
Hotter an 113 °F (59 °C)

53

Air Cleaner

Proper air cleaner maintenance is very important for o-road vehicles.
A dirty, watersoaked, worn-out, or defective air cleaner will allow dirt,
dust, mud, and other impurities to pass into the engine.

Service the air cleaner more frequently if you ride in unusually wet or
dusty areas. Your Certied Motorcycle Mechanic can help you determine
the correct service interval for your riding conditions.

Your motorcycle’s air cleaner has very specic performance requirements.
Use a new umpstar Genuine air cleaner specied for your model or
an air cleaner of equal quality.

NOTICE:

Using the wrong air cleaner may result in premature engine wear.

Proper air cleaner maintenance can prevent premature engine wear or
damage, expensive repairs, low engine power, poor gas mileage, and
spark plug fouling.

Improper or lack of proper air cleaner maintenance can cause poor
performance and premature engine wear.

54

Air Cleaner

CLEANING

1. Unscrew Bolt

2. Remove the air cleaner

3. Gently wash the air cleaner in clean, nonammable(high ash point)
solvent such askerosene not gasoline. Aer cleaning,gently squeeze out
the remaining solvent.Avoid twisting or wringing the air cleaner.is
can tear the foam.

4. Inspect for tears or cracks in the foam orseams of the air cleaner. Re­place the aircleaner if it is damaged.

5. Allow the air cleaner to dry thoroughly before applying oil. A wet air
cleaner will not fully absorb the oil.

6. Check anti-ame mesh for damages

7. Pour clean No Toil Biodegradabe or an equivalent over the entire sur­face of the air cleaner. Use both hands to evenly spread the oil into the
air cleaner. Gently squeeze out any excess oil.

8. Install the air cleaner and screws back again.

Air Filter Bolt

55

Clutch System

INSPECTION

e engine should start easily with the kickstarter without the clutch slip­ping. When shiing gears, the clutch operation should be smooth
and light, especially when shiing into neutral.

ADJUSTMENT

1. Remove cover.t

2. Turn the clutch adjuster clockwise one turn; do not turn excessively.

3. Slowly turn the adjuster counterclockwise until a slight resistance is felt.

4. From this position, turn the adjuster clockwise 1/8 turn, and tighten

the lock nut.

5. Aer adjustment, test ride the motorcycle to be certain the clutch oper-

ates properly.

If you can’t get proper adjustment, or the clutch does not work properly, see
your Certied Motorcycle Mechanic.

Lock Nut

Clutch Adjuster

Cover

56

Throttle

UPPER ADJUSTMENT

Minor adjustments are generally made with the upper adjuster.

1. Pull the rubber dust cover back.

2. Loosen the upper lock nut on the throttle cable mechanism.

3. Turn the upper adjuster.

4. Tighten the lock nut. Return the dust coverto its normal position.

5. Aer adjustment, check for smooth rotationof the throttle grip from
fully closed to fullyopen in all steering positions.

Locking Nut

Throttle Adjuster

Rubber Dust Cover

57

Throttle

THROTTLE LIMITER

Designed to be able to adjust the throttle for youngsters learning to ride.
e more the adjuster is screwed in, the less the children to be able to turn
the throttle. For full throttle, when throttle limiter is not being used we
recommend installing a smaller screw.

1. Loosen the locking nut.

2. Turn the throttle limiter.

3. Tighten the locking nut.

Locking Nut

Trottle Limiter

58

Throttle

THROTTLE INSPECTION

1. Check that the throttle assembly is positioned properly and the secur­ing bolts are tight.

2. Check for smooth rotation of the throttle from fully open to fully
closed in all steering positions. If there is a problem, see your Certied

Motorcycle Mechanic

3. Inspect the condition of the throttle cables from the throttle grip down
to the carburetor. If the cable is kinked or chafed, have it replaced.

4. Check the cables for tension or stress in all steering positions

5. Lubricate the cables with a commerciallyavailable cable lubricant to
prevent premature rust and corrosion.

Throttle

59

Valve Clearance

Excessive valve clearance will cause noise and eventual engine damage.
Little or no clearance will prevent the valve from closing and cause
valve damage and power loss. Check valve clearance when the engine is
cold at the intervals specied in the Maintenance Schedule.

e checking or adjusting of the clearance should be performed while the
engine is cold. e clearance will change as engine temperature rises.

1. Remove the cylinder head cover by removing the bolts and mount
rubbers.

2. Remove the cylinder head cover gasket.

3. Remove the cranksha hole cap and timing hole cap

4. Rotate the generator ywheel counterclockwise until the T mark on the
ywheel lines up with the index mark on the le crankcase cover. In
this position, the piston may either be on the compression or exhaust
stroke.

e adjustment must be made when the piston is at the top of the com-

pression stroke when both the intake and exhaust valves are closed.

is condition can be determined by moving the rocker arms. If they

are free, it is an indication that the valves are closed and that the piston
is on the compression stroke. If they aretight and the valves are open,
rotate the ywheel 360° and realign the T mark to the index mark.

5. Check the clearance of both valves by inserting a feeler gauge between
the adjusting screw and the valve stem.

Clearance should be:

Intake: 0.003” in

Exhaust: 0.005” in

60

Valve Clearance

6. If it is necessary to make an adjustment, loosen the adjusting screw

lock nut and turn the adjusting screw so there is a slight resistance
when the feeler gauge is inserted.

Aer completing the adjustment, tighten the adjusting screw lock nut

while holding the adjusting screw to prevent it from turning. Finally,
recheck the clearance to make sure that the adjustment has not been
disturbed.

7. Check that the mount rubbers in good condition. Install the mount

rubbers onto the cylinder head cover with the ‘‘UP’’ mark facing up.
Install a new gasket onto cylinder head cover. Install the cylinder head.
Install and tighten the cylinder head cover bolts.

Exhaust Valve

Intake Valve

Cam

Feeler Gauge

61

Engine Idle Speed

e engine must be at normal operating temperature for accurate idle
speed adjustment. Ten minutes of stop-and-go riding is sucient.

Do not attempt to compensate for faults in other systems by adjusting idle
speed. See your Certied Motorcycle Mechanic for regularly scheduled
carburetor adjustments.

1. Warm up the engine, shi to neutral and place the motorcycle on its
stand.

2. Connect a tachometer, following the tachometer manufacturer’s in­structions.

3. Adjust idle speed with the throttle stop screw

Idle Speed: 1,400 ± 100 rpm

Throttle Stop Screw

(+)

(-)

62

Spark Plug

SPARK PLUG RECOMMENDATION

e recommended standard spark plug is satisfactory for most riding con­ditions.

Brand / Model Torch A7TC | NGK C7HSA

Use only the recommended type of spark plugs in the recommended heat
range.

NOTICE:

Using spark plugs with an improper heat range can cause engine damage.

1. Clean any dirt from around the spark plug base.

2. Disconnect the spark plug cap.

3. Remove the spark plug with a plug wrench.

4. Inspect the spark plug electrodes for wear. e center electrode should
have square edges. e side electrode should not be eroded. e insula­tor should not be crackedor chipped.

63

Spark Plug

5. Check the spark plug gap, using a wiretype feeler gauge. If

adjustment is necessary, bend the side electrode carefully. e
gap should be: 0.03-0.04 in (0.8-0.9 mm) Make sure the plug washer
is in good condition. If you have to install a new plug, rst check
the gap.

6. With the plug washer attached, thread the spark plug in by hand (to

prevent crossthreading).

7. Tighten the spark plug:

• If the old plug is good: 1/6 turn aer it seats.

• If installing a new plug, tighten it twice to prevent loosening:

a) First, tighten the plug: NGK: 1/4 turn aer it seats.

b) en loosen the plug.

c) Next, tighten the plug again: 1/6 turn aer it seats.

NOTICE:

An improperly tightened spark plug can damage the engine. If a plug is too
loose, a piston may be damaged. If a plug is too tight, the threads may be
damaged.

8. Reinstall the spark plug cap. Take care to avoid pinching any cables or

wires.

Note: An improperly tightened spark plug can damage the engine. If a plug
is too loose, a piston may be damaged. If a plug is too tight, the threads
may be damaged.

64

SPARK PLUG COLORING GUIDELINES

Condition Spark Plug Appearance Mixture
Normal Dark Brown to Light

Tan color with Dry
Electrode

Correct

Overheating (Lean) Light Gray or White

Color

Lean

Wet (Rich) Wet or Sooty Rich

Remember that in addition to improper jetting:

•Aleanconditioncanbecausedbyairleaksintheinlettractorexhaust

system, the passage of too much air because of the use of the wrong air
cleaner, use of a less-restrictive aermarket exhaust system, or a hole or
holes (deliberate or unintentional) in the air box.

•Arichconditioncanbecausedbyapluggedordirtyaircleaner,useofa

more-restrictive aermarket exhaust system, a clogged spark arrester, or
excessive oil on the air cleaner. Excessive smoking will occur.

Spark Plug

Center Electrode

Side Electrode

Insulator

65

Suspension

Loose, worn, or damaged suspension components may adversely aect the
handling and stability of your motorcycle. If any suspension components
appear worn or damaged, see your Certied Motorcycle Mechanic
for further inspection. Your Certied Motorcycle Mechanic is qualied
to determine whether or not replacement parts or repairs are needed.

FRONT SUSPENSION INSPECTION

1. Check fork operation. Pull the front brake lever in, to lock the brake.
en pump up and down on the fork legs several times. e suspen­sion should function smoothly. ere should be no oil leakage.

2. Check the security of all handlebar and fork mounting bolts. If any
front suspension components appear worn or damaged, see your Cer­tied Motorcycle Mechanic for further inspection.

Fork Guard

Axel

Disc

66

Suspension

REAR SUSPENSION INSPECTION

1. Place the motorcycle on a maintenance stand. Push hard against the
side of the rear wheel and feel for any freeplay which indicates worn
swingarm bushings.

2. Check that the fasteners for the shock absorber attachment points are
secure.

3. Check for oil leaks in the shock absorber. If any rear suspension com­ponents appear worn or damaged, see your Certied Motorcycle
Mechanic for further inspection.

REAR SUSPENSION ADJUSTMENT

1. Use a C Spanner in adjusting the rear shock.

2. Turn the rear shock on the le side to make it harder

3. Turn the rear shock on the right side to make it soer

Shock Absorber Attachment Points

Rear Shock

Swingarm Cover / Bearing

Harder

Softer

67

Brakes

FRONT AND REAR BRAKE LEVER

e front brake is the hydraulic disc type. As the brake pads wear, the
brake uid level will drop. A leak in the system will also cause the level to
drop.

Frequently inspect the system to ensure there are no uid leaks.
Periodically inspect the brake uid level and the brake pads for wear.

If the front brake lever freeplay does not feel within the normal range
while riding, check the brake pads. If they are not worn beyond the
recommended limit, there is probably air in the brake system.
See your Certied Motorcycle Mechanic dealer to have the air bled
from the system.

FLUID LEVEL INSPECTION

With the motorcycle in an upright position, check the uid level. It should
be above the LOWER level mark. If the level is at or below the LOWER
level mark, check the brake pads for wear.

Worn brake pads should be replaced. If the pads are not worn, have your
brake system inspected for leaks.

Sight Glass

68

Brakes

BRAKE PAD WEAR

Brake pad wear depends on the severity of usage, the type of riding, and
riding area conditions. (Generally, the pads will wear faster on wet and
dirty riding terrain.) Inspect the pads at each regular maintenance interval.

Check the cutout in each pad. If either pad is worn to the cutout, replace
both pads as a set. See your Certied Motorcycle Mechanic for this ser-
vice.

Check that the front lever assembly is positioned properly and the securing
bolts are tight.

Brake uid should be added and replaced by your Certied Motorcycle
Mechanic dealer.

Front Brake Caliper

Bleed Screw

69

Brakes

FRONT AND REAR BRAKE LEVER FREEPLAY

Adjust the freeplay of the brake lever with the front wheel pointed straight
ahead.

Front Brake LeverRear Brake Lever

70

Wheels

Keeping the wheels true (round) and maintaining correct spoke tension is
critical to safe motorcycle operation. During the rst 100 miles (150 km),
spokes will loosen more rapidly due to the initial seating of the parts.
Excessively loose spokes may result in instability at high speeds and the
possible loss of control. Loose spokes may also cause rim or spoke damage
(not covered by warranty). It’s also important that the rim locks are secure
to prevent tire slippage.

It is not necessary to remove the wheels to perform the recommended ser­vice in the Maintenance Schedule. However, information for wheel remov­al is provided for emergency situations.

WHEEL RIMS & SPOKES

1. Inspect the wheel rims and spokes for damage.

2. Tighten any loose spokes

3. Rotate the wheel slowly to see if it appears to ‘‘wobble.’’ If it does, the
rim is out of round or not ‘‘true.’’ If the wobble is noticeable, see your
Certied Motorcycle Mechanic for inspection.

Wheel Rim

Spoke

71

Wheels

FRONT WHEEL REMOVAL

1. Raise the front wheel o the ground by placing a maintenance stand or
support block under the engine. Secure the rear of the motorcycle with
tie-down straps.

2. Remove the front axle nut (19mm) and front axle sha.

3. Remove the wheel.

4. Pull the brake assembly out carefully.

Take care to prevent getting grease, oil, or dirt on the brake shoe surfaces.
is can cause poor brake performance or rapid brake shoe wear
aer reassembly.

HubFront Axel Shaft

Front Axle Nut

72

Wheels

INSTALLATION

1. Torque the front axle nut to: 44 lbf· (59 N·m , 6.0 kgf·m)

2. Check front brake adjustment

If a torque wrench was not used to install the wheel, see your Certied
Motorcycle Mechanic as soon as possible to verify proper assembly. Im­proper assembly may lead to loss of braking capacity.

REAR WHEEL REMOVAL

1. Raise the rear wheel o the ground by placing a maintenance stand
or support block under the engine. Secure the front of the motorcycle
with tie-down straps.

2. Remove the rear brake adjusting nut using a 17-19mm ring spanner.

Bleed Screw Rear Axle Shaft

Rear Axle Nut

Chain Adjusters

73

Wheels

3. Loosen the rear axle nut while holding the rear axle sha.

4. Turn both chain adjusters so the rear wheel can be moved all the way

forward for maximum drive chain slack.

5. Unscrew the rear axle nut. Pull the rear axle sha out. Push the wheel

forward and derail the drive chain from the rear sprocket. Remove the
wheel and side collar.

6. Take care to prevent getting grease, oil, or dirt on the brake shoe sur-

faces. is can cause poor brake performance or rapid brake shoe wear
aer reassembly.

REAR WHEEL INSTALLATION

1. Reverse the removal procedure. Install the side collar into the wheel.

2. Adjust the drive chain.

3. Tighten the rear axle nut to the specied

Torque: 80 lbf· (108 N·m , 11.0 kgf·m)

4. Adjust the rear brake.

5. Apply the rear brake, release it, then spin the wheel and check that it

rotates freely. Repeat this procedure several times.

If a torque wrench was not used to install the wheel, see your Certied
Motorcycle Mechanic dealer as soon as possible to verify proper assembly.
Improper assembly may lead to loss of braking capacity.

74

Tires & Tubes

To safely operate your motorcycle, the tires must be the proper type (o­road) and size, in good condition with adequate tread, and correctly
inated.

e following pages give detailed information on how and when to
check your air pressure, how to inspect your tires for wear and
damage, and our recommendations on tire repair and replacement.

AIR PRESSURE

Properly inated tires provide the best combination of handling, tread
life, and riding comfort. Generally, underinated tires wear unevenly,
adversely aect handling, and are more likely to fail from being
overheated. Underinated tires can also cause wheel damage in rocky
terrain. Overinated tires make your motorcycle ride harshly, are
more prone to damage from surface hazards, and wear unevenly.

Make sure the valve stem caps are secure. If necessary, install new caps.

WARNING

Using tires that are excessively
worn or improperly inflated can
cause a crash in which you can

be seriously hurt or killed.

Follow all instructions in this

owner’s manual regarding tire

inflation and maintenance.

75

Tires & Tubes

Always check air pressure when your tires are ‘‘cold.’’ If you check air
pressure when your tires are ‘‘warm’’ even if your motorcycle has only
been ridden for a few miles the readings will be higher. If you let air
out of warm tires to match the recommended cold pressures, the
tires will be underinated. e correct ‘‘cold’’ tire pressures are:

Front 20 psi (138 kPa , 1.4 kgf/cm )
Rear 20 psi (138 kPa , 1.4 kgf/cm )

If you decide to adjust tire pressures for a particular riding condition, make
changes a little at a time.

INSPECTION

A at tire or blowout is inconvenient and may even cause a crash. Take
time to inspect your tires and wheels before you ride.

Spoke Nut

Tire Thread Depth

76

Tires & Tubes

• Inspect carefully for bumps or bulges in the side of the tire or the tread.
Replace any tire that has a bump or bulge.

• Look closely for cuts, slits, or cracks in the tires. Replace a tire if you
can see fabric or cord.

• Check for rocks or other objects embedded in the tire or tread. Remove
any objects.

• Measure tread depth. Replace the tire before depth at the center reaches

0.12 in (3 mm), or any time you notice a reduction in traction.

• Check the position of both valve stems. A tilted valve stem indicates
the tube is slipping inside the tire or the tire is slipping on the rim. See
your Certied Motorcycle Mechanic.

TUBE REPLACEMENT

If a tube is punctured or damaged, you should replace it as soon as possi­ble. A repaired tube may not have the same reliability as a new one, and it
may fail while you are riding.

Use a replacement tube equivalent to the original.

We recommend that tubes be replaced by your Certied Motorcycle Me-
chanic. Replacing a tube requires removing and reinstalling the wheel. Any
time a tube is replaced, carefully inspect the tire as described on INSPEC­TION.

77

Tires & Tubes

TIRE REPLACEMENT

e tires that came on your motorcycle were designed to provide a good
combination of handling, braking, durability, and comfort across a broad
range of riding conditions.

Front Steel Rim | 2.50-10
Rear Steel Rim | 2.50-10
Type bias-ply, tube

• Use a replacement tire equivalent to the original.

• Replace the tube any time you replace a tire. e old tube will probably

be stretched and, if installed in a new tire, could fail.

• Have the wheel balanced aer a new tire is installed.

• We recommend that tires be replaced by your Certied Motorcycle

Mechanic.

WARNING

Installing improper tires on your

motorcycle can affect handling

and stability. This can cause a

crash in which you can be seri-

ously hurt or killed. Always use

the size and type of tires

recommended in this owner’s

manual.

78

Training Wheel

MOUNT

INSTALLATION

Training wheels can be mounted underneath the motorcycle they are
available for learners until they have developed a utilizable sense of
balanceon the motorcycle. e training wheel can be installed by
inserting it in the 4 slot located on the footpeg mounts underneath the
middle of the motorcycle.

Slot

Slot

Training Wheel

79

Drive Chain

LUBRICATION

Lubricate every 300 miles (500 km) or sooner if chain appears dry. Turn
the rear wheel by hand. Saturate each chain link joint so that the lubricant
penetrates between the link plates, pins, bushings, and rollers. Lubricate
with quality chain oil.

CHAIN GUIDE REMOVAL

1. Remove bolt to remove the chain guide and release the chain.

2. Use 8mm spanner in removing the bolt.

BoltBolt

80

Drive Chain

e service life of the chain depends on proper lubrication and adjustment.
Poor maintenance can cause premature wear or damage to the drive chain
or sprockets.

Under severe usage, or when the motorcycle is ridden in unusually dusty
or muddy areas, more frequent maintenance will be necessary.

Before servicing your drive chain, turn the engine OFF, lower the side
stand, and check that your transmission is in neutral.

It is not necessary to remove or replace the drive chain to perform the rec­ommended service in the Maintenance Schedule.

INSPECTION

1. Check slack in the lower drive chain run midway between the sprock-

ets. Drive chain slack should allow the following vertical movement by
hand

2. Check drive chain slack at several points along the chain. e slack

should remain constant. If it isn’t, some links may be kinked and bind­ing. Lubricating the chain will oen eliminate binding and kinking.

Excessive chain slack may allow the drive chain to damage the engine cases.

Drive Chain

81

Drive Chain

3. Inspect the drive chain for:

• damaged rollers

• loose pins

• dry or rusted links

• kinked or binding links

• excessive wear

Replace the drive chain if it has damaged rollers, loose pins, or kinks that
cannot be freed. Lubricate the drive chain if it appears dry or shows signs
of rust. Lubricate any kinked or binding links and work them free. Adjust
chain slack if needed.

4. Check the chain slider for wear. If the ridge in the center of the slider
is worn, have your Certied Motorcycle Mechanic replace the chain
slider.

5. Replace the drive chain if chain slack is excessive when the rear axle
is moved to the farthest limit of adjustment. Excessive slack indicates
the chain is worn beyond its service limit. To check the chain’s service
limit, remove the drive chain . en measure the distance between a
span of 86 pins, from pin center to pin center. If the distance exceeds
the service limit, the drive chain is worn out and should be replaced.

6. Inspect the front and rear sprocket teeth for excessive wear or damage.
If necessary, have your Certied Motorcycle Mechanic replace a worn
sprocket.

NOTICE:

Use of a new chain with worn sprockets will cause rapid chain wear.

82

Drive Chain

ADJUSTMENT

1. Hold the rear axle sha and loosen the rear axle nut.

2. Loosen the lock nuts on both sides of the swingarm.

3. Turn both the right and le chain adjusters equally to increase or de­crease chain slack.

4. Aer adjusting, be sure the same adjuster index marks align with the
adjuster block on both sides of the swingarm.

5. Torque the rear axle nut to: 47 lbf· (64 N·m , 6.5 kgf·m)

6. Recheck drive chain slack.

7. Check rear brake pedal freeplay and adjust as necessary. Freeplay is af­fected when repositioning the rear wheel to adjust\drive chain slack.

If a torque wrench is not used for this installation, see your Certied Motor-
cycle Mechanic as soon as possible to verify proper assembly.

Rear Axle Shaft

Adjuster Block

Index Marks

Rear Axle Nut

Chain Adjusters

83

Drive Chain

REMOVAL, CLEANING & REPLACEMENT

Your motorcycle has an endless type chain. It should only be removed or
replaced by your Certied Motorcycle Mechanic.

When the drive chain becomes extremely dirty, it should be removed and
cleaned prior to lubrication.

1. Clean the side surfaces of the chain with a dry cloth.

2. Inspect the drive chain for possible wear or damage. Replace the drive
chain if it has damaged rollers, loose tting links, or otherwise appears
unserviceable.

Replacement chain: 428 Chain and heavy duty brackets

3. Inspect the sprocket teeth for wear or damage. We recommend replacing
the sprocket whenever a new chain is installed.

5. Lubricate the drive chain.

MORE ABOUT: DRIVE CHAIN

• e master link is the most critical element of drive chain security.
Master links are reusable, as long as they remain in excellent condition.
We recommend installing a new master link retaining clip when the
drive chain is reassembled.

• You may nd it easier to install a new chain by connecting it to the old
chain with a master link and pulling the old chain to position the new
chain on the sprockets.

84

Battery

Your motorcycle has a maintenance-free type battery. You do not have to
check the battery electrolyte level or add distilled water as you would with
a conventional-type battery.

Your battery is a maintenance-free type and can be permanently damaged if
the cap strip is removed.

Electrical accessories use current from the battery, even when the
ignition is OFF. Limited operation also allows the battery to discharge.
If you have electrical accessories on your motorcycle or do not ride
frequently, we recommend that you charge the battery frequently

If you do not expect to ride your motorcycle for at least two weeks,
we recommend you remove the battery, or at least disconnect the
battery cables (negative cable rst).

(+)

( - )

WARNING

Battery posts, terminals and

related accessories contain lead

and lead compounds. Wash

hands after handling

85

Battery

BATTERY STORAGE

If you plan to store your motorcycle, we recommend you remove
the battery and store it where it can be charged at least every 30 days
to maintain its service life.

If you do not remove the battery, we recommend disconnecting the battery
cables (negative cable rst).

You will get the best storage results from removing the battery and slow
charging it every 30 days

Before you remove the battery, be sure to read all the information
that follows, as well as the information on the battery label.

e battery is located in the battery compartment behind the le side
cover.

REMOVAL

1. Make sure the ignition switch is OFF.

2. Remove the le side cover

WARNING

The battery gives off explosive

hydrogen gas during normal

operation.

A spark or flame can cause the
battery to explode with enough

force to kill or seriously hurt

you.

Wear protective clothing and

a face shield, or have a skilled

mechanic do the battery

maintenance.

86

Battery

3. Remove the battery holder by removing the bolt.

4. Disconnect the negative (-) terminal lead from the battery rst, then
disconnect the positive (+) terminal lead.

5. Pull the battery out of the battery compartment.

6. Charge the battery (see following section), unless you have been riding
regularly.

7. Store your battery in an easy-to-reach location o the oor, in an area
protected from freezing temperatures and direct sunlight.

8. Clean the battery box aer removing the battery for storage. Dry the
battery box and, if paint is missing, re-paint the area.

9. Slow charge the battery (see following section) once every 30 days.

INSTALLATION

1. Reinstall in the reverse order of removal. Be sure to connect the posi­tive (+) terminal rst, then the negative (-) terminal.

2. Check all bolts and other fasteners are secure.

BATTERY STORAGE

We recommend using a charger designed specically for your umpstar,
which can be purchased from your Certied Motorcycle Mechanic. ese
units can be le connected for long periods without risking damage to the
battery. However, do not intentionally leave the charger connected longer
than the time period recommended in the charger’s instructions. Avoid
using an automotive-type battery charger. An automotive charger can over­heat a motorcycle battery and cause permanent damage.

87

Appearance Care

Frequent cleaning and polishing will keep your umpstar looking newer
longer. Frequent cleaning also identies you as an owner who values your
motorcycle. A clean motorcycle is also easier to inspect and service.

While you’re cleaning, be sure to look for damage, wear, and gasoline or oil
leaks.

GENERAL RECOMMENDATIONS

• To clean your motorcycle, you may use:

-Water

-A mild, neutral detergent and water

-A mild spray and wipe cleaner/polisher

-A mild spray and rinse cleaner/degreaser and water

• Avoid products that contain harsh detergents or chemical solvents that
could damage the metal, paint, and plastic on your motorcycle.

• If your motorcycle is still warm from recent operation, give the engine
and exhaust system time to cool o.

• We recommend the use of a garden hose to wash your motorcycle.
High pressure washers (like those at coin-operated car washes) can
damage certain parts of your motorcycle. If you use a high pressure
washer, avoid spraying the following areas:

-air lter

-wheel hubs

-muer outlet

-area under seat

-engine stop switch

-under fuel tank

-carburetor

-drive chain

NOTICE:

High pressure water (or air) can damage certain parts of your motorcycle.

88

Appearance Care

WASHING YOUR MOTORCYCLE WITH A MILD DETERGENT

1. Rinse your motorcycle thoroughly with cool water to remove loose dirt.

2. Fill a bucket with cool water. Mix in a mild, neutral detergent, such as
dish washing liquid or a product made especially for washing motorcy­cles or automobiles.

3. Wash your motorcycle with a sponge or a so towel. As you wash,
check for heavy grime. If necessary, use a mild cleaner/ degreaser to
remove the grime.

4. Aer washing, rinse your motorcycle thoroughly with plenty of clean
water to remove any residue.

5. Dry your motorcycle with a chamois or a so towel. Leaving water on
the surface to air dry can cause dulling and water spots. As you dry,
inspect for chips and scratches.

6. Lubricate the drive chain to prevent rusting.

7. Start the engine and let it idle for several minutes. e engine heat will
help dry moist areas.

8. As a precaution, ride at a slow speed and apply the brakes several times.
is will help

9. dry the brakes and restore normal braking

10. performance.

EXHAUST PIPE AND MUFFLER MAINTENANCE

When the exhaust pipe and muer are painted, do not use a commercially
available abrasive kitchen cleaning compound. Use a neutral detergent to
clean the painted surface on the exhaust pipe and muer. If you are not
sure if your exhaust pipe and muer are painted, contact your dealer.

TIPS

Here’s helpful advice on how to prepare for an o-road adventure, how to
transport and store your umpstar unit, and how to be an environmental­ly responsible motorcycle owner.

Spraying WD40 or similar product on metal parts will help protect the
motorcycle (never spray WD40 near the brakes)

89

Preparing for a Ride

A safe and enjoyable ride begins with good planning and preparation.
Always ride with at least one other person in case you have trouble, and let
someone know where you’re going and when you expect to return.

Before riding in an unfamiliar area, nd out in advance if you need special
permits, get maps so you can study the terrain, and talk to other riders who
know the area. e Forest Service and the Bureau of Land Management
(USA only), the Ministry of Natural Resources (Canada only), riding clubs,
and o-road magazines are good sources of information.

WHAT TO TAKE TO THE RIDING AREA

Along with your motorcycle and riding gear, you should take along some
tools and supplies in case you have a problem.

We recommend that you always take water, food, a rst aid kit, and your
owner’s manual. Other items you should consider loading on your truck or
trailer include:

• a tool kit

• tire repair supplies and tools, tubes, and tires

• extra parts, such as a drive chain and master links, control levers, air

lter, cables, and spark plugs

• wire, duct tape, and rope

• extra gasoline

For safety, all refueling should be done at a gas station on the way to the
riding area or at your base camp.

90

Transporting your Thumpstar

If you use a truck or motorcycle trailer to transport your umpstar, we
recommend that you follow these guidelines:

• Use a loading ramp.

• Make sure the fuel valve is o.

• Secure the motorcycle in an upright position, using

motorcycle tie-down straps. Avoid using rope, which can loosen
and allow the motorcycle to fall over.

To secure your umpstar motorcycle, brace the front wheel against the
front of the truck bed or trailer rail. Attach the lower ends of two straps to
the tie-down hooks on your vehicle. Attach the upper ends of the straps
to the handlebar (one on the right side, the other on the le), close to the
fork.

WHAT TO TAKE ON THE TRAIL

What you take with you during a ride depends on the kind of terrain, how
long you expect to ride, how far you might go from your base camp or
help, and how experienced you or your companions are in making repairs.

If you decide to take some tools, spare parts, or other supplies on the trail,
be sure you can carry them safely and know how to use them. Also, be sure
to follow the loading guidelines and weight limit.

91

Storing your Thumpstar

Check that the tie-down straps do not contact any control cables or electri­cal wiring.

Tighten both straps until the front suspension is compressed about half­way. Too much pressure is unnecessary and could damage the
fork seals.

Use another tie-down strap to keep the rear of the motorcycle from mov­ing.

We recommend that you do not transport your motorcycle on its side. is
can damage the motorcycle, and leaking gasoline could be a hazard.

STORING YOUR THUMPSTAR MOTORCYCLE

If you won’t be riding for an extended period, such as during the winter,
thoroughly inspect your motorcycle and correct any problem before stor­ing it. at way, needed repairs won’t be forgotten and it will be easier to
get your motorcycle running again.

PREPARATION FOR STORAGE

1. Change the engine oil

2. Fill the fuel tank. Make sure the fuel ll cap

is properly installed.

3. Check that the fuel valve is OFF.

4. Drain the carburetor into an approved gasoline container and dispose

of it in an approved manner. If storage will last longer than one month,
carburetor draining is important, to assure proper performance aer
storage.

92

Storing your Thumpstar

5. Store it in an area protected from freezing temperatures and direct sun-

light.

6. Wash and dry your motorcycle.

7. Lubricate the drive chain.

8. Inate the tires to their recommended pressures

9. Store your motorcycle in an unheated area, free of dampness, away

from sunlight, with a minimum of daily temperature variation.

10. Cover your motorcycle with a porous material. Avoid using plastic or

similar nonbreathing, coated materials that restrict air ow and allow
heat and moisture to accumulate.

REMOVAL FROM STORAGE

1. Uncover and clean your motorcycle.

2. If your motorcycle has been stored for more than four months change

the engine oil

3. If your motorcycle has been stored for more than two months drain

and replace the fuel.

4. Lubricate the drive chain

5. Perform a pre-ride inspection, then test-ride your motorcycle at low

speeds.

93

Troubleshooting

e items that are serviceable using this Manual are followed by the page
number reference in parenthesis. e items that require use of the
umpstar Manual are followed by an asterisk.

POOR PERFORMANCE AT LOW AND UNSTABLE IDLE SPEED

CHECK POSSIBLE CAUSES

BLOCKED

NOT BLOCKED

94

POOR PERFORMANCE AT LOW AND UNSTABLE IDLE SPEED
CHECK POSSIBLE CAUSES

Troubleshooting

95

Troubleshooting

BLOCKED

NOT BLOCKED

96

You & the Environment

Owning and riding a motorcycle can be enjoyable, but you must do your
part to protect nature. When you show respect for the land, wildlife, and
other people, you also help preserve the sport of o-road riding.

Following are tips on how you can be an environmentally responsible
motorcycle owner.

Tread Lightly - Stay on existing roads and trails, avoid surfaces that are
easily damaged, and ride only in areas approved for o-road
vehicles

Keep the Noise Down - Loud motorcycles can be oensive. Ride as quietly
as possible, don’t remove your spark arrester, and don’t modify the muer
or any other part of your air intake and exhaust systems. Such modica
tions not only increase noise, they also reduce engine performance and
may be illegal.

Choose Sensible Cleaners - Use a biodegradable detergent when you wash
your motorcycle. Avoid aerosol spray cleaners that contain chlorouoro
carbons (CFCs) which damage the atmosphere’s protective ozone layer.
Don’t throw cleaning solvents away; see the following guidelines
for proper disposal.

RecycleWastes - It’s illegal and thoughtless to put used engine oil in the
trash, down a drain, or on the ground. Used oil, gasoline, and cleaning
solvents contain poisons that can hurt refuse workers and contaminate our
drinking water, lakes, rivers, and oceans. Before changing your oil, make
sure you have the proper containers. Put oil and other toxic wastes in sepa
rate sealed containers and take them to a recycling center. Call your local
or state oce of public works or environmental services to nd a recycling
center in your area and get instructions on how to dispose of non-recycla
ble wastes.