ASSEMBLY MANUAL - Go Easy Online

ASSEMBLY MANUALRead and understand this entire manual before riding!

DO NOT RETURN TO STORE!NOTE: Manual illustrations are for demonstration purposes only. Illustrations man not reflect exact appearance of actual procduct.

WWW.GMXMOTORBIKES.COM.AU

ATV OFF ROAD - GMX SHIFT 150cc QUAD BIKE

This assembly guide covers basic step by step instructions to assist you with assembly process. Products are always subject to further improvement, which will cause some di�erence between vechicle and this manual without further notice. W wish you happy riding!

UNPACKINGPlease CAREFULLY remove all external packaging and metal frame packaging.TIP: Metal packaging can be sharp so when unpacking please handle with caution.

CHECK FOR LOOSE PARTSOn most occasions your bike will come 90% assembled (depending on the model). Please go through all lose parts and check packaging that has been taken out, to ensure no parts get thrown out so you can assemble your GMX Product.

- Be careful to follow fuel/oil ratio requirements and not put to much oil in the fuel.- Always use clean fuel - Never use old Fuel.- After your Bike has sat for a period of time the oil in the fuel can settle in the bottom of the carbie bowl so be sure to drain the fuel and follow points in the trouble shooting to remedy.- Do not overload the bike with more that the recommended weight capacity as this can cause undue wear/damage to the clutch.

WEAR SAFE- Always wear a helmet.- Wear protective clothing and gear such as goggles, long sleeves, long pants, boots and gloves/hand protection.

RIDE SAFE- Never let children ride quad bikes that are meant for adults – even as passengers.- Do not carry any passengers on quad bikes that are meant for one person.- Quad bikes are not all-terrain vehicles so they cannot go safely on all types of terrain. Avoid riding on rough terrain or steep slopes.- Ride on familiar tracks and beware of obstacles.- Never ride under the in�uence of alcohol/drugs.- Ensure children are supervised at all times near any quad bike activity.- Always carry a mobile phone or radio device so you can contact help in case of an emergency.

READ MANUALEnsure that you read and go over the manual and UNDERSTAND before assembling this Bike.

PLEASE NOTE: Minor assembly is required, but in the interest of your safety it is recommended that you have this bike assembled by a skilled bike mechanic.

PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS PRIOR TO ASSEMBLY AND OPERATING OF YOUR VEHICLE.WARNING: This product is powered by a 4 stroke engine and comes with transport oil in the engine.

- THE OIL NEEDS TO BE DRAINED AND REPLACED WITH MOTORCYCLE OIL 10W/40 or 10W/50 IS REQUIRED- IF THE OIL CHANGE IS NOT PERFORMED YOU MAY INTERNALLY DAMAGE THE ENGINE AND CLUTCH AND VOID YOUR WARRANTY - DO NOT USE MOTOR CAR OIL - DO NOT USE OIL WITH FRICTION MODIFIERS

OIL WILL NEED TO BE CHANGED EVERY 3 MONTHS IN A HOTTER CLIMATE OR THE NOTHERN HEMISPHERE - There is an oil drain plug located underneath you quad/dirt bike and is highlighted with an oil drain plug sticker. This is a 14mm bolt. - DO NOT remove the other bolt located under the engine.- Place an oil receptacle under the drain hole, undo bolt and let oil drain from the vehicle. Please note: Dispose of oil correctly- Tighten bolt back up, remove dipstick (oil �ll point) and �ll the vehicle with suggested correct amount of oil required. Tighten

SWING TAG’S & WARNINGSSwing tags have been placed on your vehicle for you to identify checks that are located within this manual. Once you have performed the check required remove these swing tags and nylon loops attaching them to the vehicle.

MAKE SURE TO REMOVE THE SWING TAGS AND TAKE SPECIAL NOTICE TO REMOVE THE NYLON LOOP. The tags and loops that need to be removed from this model

ONCE SWING TAGS AND NYLON LOOPS ARE REMOVED YOU ARE ACKNOWLEDGING THAT THESE CHECKS HAVE BEEN PERFORMED There may be a “Spare Parts Package” within the carton so please check all of the packaging and DO NOT THROW OUT

WARNINGPlease use unleaded fuel

90 Octane or above

UNLEADED FUEL ONLY

YOU MUST CHECK THAT THE FRONT STEERING IS ADJUSTED CORRECTLY PRIOR TO RIDING.

CHECK BRAKESARE ADJUSTEDCORRECTLY PRIORTO RIDING.

YOU MUST CHECK THAT THE CHAIN IS ADJUSTED CORRECTLY PRIOR TO RIDING.

BRAKE ADJUSTMENT x3STEERING ADJUSTMENT x2 CHAIN ADJUSTMENT

ALWAYS LEAVE IN THE OFF POSITION WHEN NOT IN USE OR REMOVE KEYS

KEY REMOVAL

GMX Motorbikes WARRANTY

GMX MOTORBIKES WARRANTYOur goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.The manufacturer warrants this product to be free of manufacturing defects for a period of 12 months from date of purchase. This Limited Warranty does not cover normal wear and tear( exclusions apply) or any damage, failure or loss caused by improper assembly, maintenance, or storage or use of the GMX product. Some parts will have a limited warranty period, please see below. This warranty is a part replacement warranty.

3 Month Parts Replacement PartsElectrical components, suspension, drive train and brakes/�ttings.

30 Days Parts Replacement PartsBearings, tires, tubes, cables, clutches, brake pads, seats

Minor assembly is required and in the interest of safety and warranty it is recommended that you have this product assembled by a quali�ed, skilled small engine mechanic.You may need to provide proof of being assembled by a skilled mechanic if not a report from a small engine mechanic advising of the issues to process your warranty claims. The warranty is a parts replacement warranty and labor is not included, defective parts may need to be sent back for inspection.

This Limited Warranty will be void if the product is ever;- Used in a manner other than for recreation or transportation- Modi�ed in anyway- Rented or commercial use.The manufacturer is not liable for incidental or consequential loss or damage due directly or indirectly to the use of this product.Always adhere to the maximum load of the product, over loading the product will void the warranty.

How a claim is madeWhen making a claim, you will need to provide proof of purchase, condition photos of the item. This information is required to be submitted via the support center and communication is made through the support center. When the claim is created, the customer will receive the claim number and the customer support team should reply within 48 hours.

Please read these warnings carefully.

PARENTS/SUPERVISING ADULTS MUST TEACH CHILDREN HOW TO RIDE THIS PRODUCT.

If the rider does not use common sense and heed these warnings, there is an increased risk of damage, serious injury or possibly death.

Riding this product presents potential risks.

Like any OFF ROAD riding product, riding this product can be hazardous (e.g., falling o� or riding into a hazardous situation).

These items are meant to move and it is therefore possible for a rider to lose control or otherwise get into dangerous situations.

Persons responsible for supervising the rider must recognize that if such things occur, a rider can be seriously injured or possibly die, even when using safetyequipment and taking other safety precautions.

SAFETY PRECAUTIONS

USE PRODUCTS AT YOUR OWN RISK AND USE COMMON SENSE

Parents and adult responsibility and supervision are necessary for any o� road vehicle.

This product can be hazardous and not always appropriate for every age or size user - age recommendations are found on these items that should re�ect the nature of the hazards and the expected mental or physical ability, or both, of a

rider to be able to handle the hazards. Persons that are supervising need to select themselves the appropriate product for the age of the user that is riding and need to take care to prevent any user who may be too immature or not experienced for a products. characteristics to endanger themselves around it.

Any rider unable to �t comfortable on the product should not attempt to ride it. It’s a parent’s decision to allow the user to ride this o� road vehicle product, which should be based on the user’s maturity, skill and ability to follow rules.

Keep this product away from small children and remember that it is intended for use only by person who are, at the age requirement, completely comfortable and competent while riding.

Persons with any mental or physical conditions that may make them susceptible to injury impair their physical dexterity or mental capabilities to recognise, understand, and follow safety instructions inherent to use of this product, should not use or are permitted to use products inappropriate for their ability.

Persons with heart conditions, head, back or neck ailments (or prior surgeries to these areas of the body), or pregnant women, should be cautioned not to operate such products.

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RIDING PRACTICESThis product is designed for o� road use. Follow all rules applicable in the area of intended use.

Ride defensively to avoid dangers that may enter your path.

Always check and obey local laws or regulations which may a�ect where the item can be used. Keep safely away from motor vehicles and tra�c at all times and only used where allowed and with caution. Watch out for potential obstacles

The product is intended for use on �at, dry surfaces such as concrete or level ground, without loose debris such as sand, leaves, rocks or gravel.

Riding on wet, slick, bumpy uneven or rough surfaces may give less traction and in turn increase the risk of accidents.

Watch out for obstacles that could stop or catch your wheel or make you swerve suddenly or lose control.

Do not ride indoors

Never use near steps or swimming pools.

Do not use the brake and accelerator at the same time as the brake may make the brakes hot and to fail.

Always have your hands on the handlebars and hold them at all times when riding.

Do not touch the motor or brakes whilst riding or directly after riding as they can become hot.

Avoid high speeds on downhill slopes where you might lose control.

Do not ride at night or when visibility is low.

Do not attempt to do stunts or tricks on your item.

It is not strong enough to withstand use such as jumping or any other types of stunts.

Never carry a passenger on an ATV.

Do not allow hands, feet, hair, body parts, clothing or similar articles come in contact with moving parts, wheels or drive train.

Never use headphones or a mobile phone/s whilst riding.

Do not use under the in�uence of drugs and alcohol.

Always wear protective gear, such as an approved safety helmet, gloves, goggles, boots and protective clothing.

A long sleeve shirt, long pants and gloves are recommended.

Never ride barefoot or in thongs.

Never modify an ATV through improper installation or use of accessories.

Never exceed the stated load capacity for an ATV.

Do not tow a trailer, the vehicle is not designed for such use.

Turn o� vehicle after each ride and make sure keys are placed out of reach of children.

Always ware an Australian standard Motorcross helmet when riding an o� road vehicle.

2.

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CONTENTS

VEHICLE CONSTRUCTURE LOCATIONS …………… 2

VEHICLE PARAMETER ……………………… 3

VEHICLE MARK DESCRIPTION ……………………… 4

CONTROL FUNCTIONS …………………………… 7

ATV DRIVING KNOWLEDGE …………………………… 9

INSPECTION AND MAINTENANCE …………………… 16

TROUBLESHOOTING …………………… 23

UNPACKING ASSEMBLY ………………………… 27

YDF SERIES ELECTRICAL CIRCUIT DIAGRAM ……… 29

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VEHICLE CONSTRUCTURE LOCATIONS

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VEHICLE PARAMETER

Vehicle size and weigh

Vehicle length

1535mm（60.43 in）

Vehicle width

920mm （36.22 in）

Vehicle height

950mm （37.4 in）

Seat height

705mm （27.76 in）

Wheelbase

1040mm （40.94 in）

Ground clearance 130mm （5.12 in）

Front wheel track 725mm （28.54 in）

Rear wheel track

705mm （27.76 in）

Vehicle weight 119kg

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Engine parameters

Engine Singe cylinder，four stroke，air cooled

Displacement 124ml

Bore ×Stroke 54×54mm

Compression ratio 8.7 : 1

Max Power 5.8kw/7500rpm

Max Torque 9.2N.m/5000rpm

Minimum Rev

C.D.I

Lgnition electric

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VEHICLE MARK DESCRIPTION

VEHICLE INFORMATION CODE LOCATIONS

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VIN NO .:

Engraved on the frame plate which was mounted on the frame left front tube, please see it as no. "1" position

above.

ENGINE NO .:

Engine name and no. was engraved on the crankcase, please see it as no. "2" position above.

WARNING STICKERS

GENERAL WARNING STICKER

This warning sticker is put on the left

front plastic, same as below picture.

AGE WARNING STICKER

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This warning sticker is put on the left

right plastic, same as below picture.

TYRE PRESSURE AND OVERLOAD

COMBINED WARNING STICKER

PASSENGERS WARNING STICKER

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CONTROL FUNCTIONS

HANDLEBAR&SWITCHES

LEFT HANDLEBAR

With the Engine stop switch in the “Stop”position the engine cannot be started. With the Engine stop with in the 'Run"

position .The engine can be started.

Electric starting button

With the key switch in the 'ON' position, pressing this button will automatically start the engine.

RIGHT HANDLEBAR

Throttle Lever

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Control the engine and ATV speed with the throttle lever. Operate this Iever with your thumb. Push it forward to

increase engine and ATV speed. Release it to decrease engine and ATV speed.

To set parking brake, squeeze front brake lever then depress parking brake pin, set the parking brake lever.

Throttle Adjusting Screw

To limit the throttle, screw in throttle limiter screw.

Use the throttle adjusting screw to restrict maximum speed of the ATV. Adjust this limiter according to the rider’s

skill and experience.

Adjusting procedures:

1. Loosen the Lock nut.

2. Turn the throttle adjusting screw clockwise to restrict maximum speed of the ATV.

3. Turn the throttle adjusting screw counterclockwise to increase the maximum speed of the ATV.

4. After finished, tighten the lock nut

FULE VALVE

There are three positions: “ON","OFF", and "RES".

“ON” position - In this position, fuel will flow to the carburetor when the engine is running or being started.

“OFF” position-No fuel will flow into the carburetor

“RES” position(arrow on valve pointing up)-If fuel level in the fuel tank becomes too low for engine to stay running

while fuel valve is at “ON” position，turn fuel valve to “RESERVE”．Turning fuel valve to “RESERVE” will allow engine

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to begin using reserve fuel supply．You will need to re-fuel as soon as possible．When fuel valve is placed at

“RESERVE”,spare fuel tank can only be maintained for a limited time.

FUEL TANK CAP

To open the fuel tank cap，take the end of the vent tube out from the vehicle body；turn the fuel tank cap

counterclockwise．To close the fuel tank cap，turn in it clockwise and tighten it securely. Be sure that the vent tube

securely connects to the cap as shown．

ATV DRIVING KNOWLEDGE

WHAT YOU SHOULD KNOW BEFORE RIDING

1. Before riding, you should read all the following information carefully. Operating this ATV without proper

instruction could be hazardous.

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2. Beginners and inexperienced operators should complete a certified training course .You should regularly

practice the skills learned in the course and the operating techniques described In this user's manual.

3. Before riding, you should find a good place to practice the skills. Find a flat, open area with enough space to

practice the new skills. Make sure that it is legal to ride in the area you selected. Review the local laws and make

sure you are not trespassing. Protect your riding areas. When you are riding, remember to keep the terrain in

good condition. Don’t destroy plants, trees or other vegetation. Don't litter and don't bother wildlife .With our help,

your riding area can remain open for use in the future.

4. After you have found a good place to practice, review the control system on your ATV before riding. Learn to find

these controls without looking for them, because you will not have time to look for them when you are riding. The

risk of riding could Increase greatly If you do not know how to operate the ATV properly under different situations

and in different types of terrain.

If you are properly prepared, you will have a more enjoyable ride.

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INSPECT THE ATV BEFORE RIDE：

Falling to inspect the ATV before operating could be hazardous. Failing to perform proper maintenance could also be

hazardous. Failing to inspect and maintain your ATV could increase the chances of an accident or equipment

damage. Always inspect your ATV each time before riding，and make sure it is in a safe operating condition.

ITEM TO CHECK CONTENT

Steering Smoothness; No restriction of movement; No play or looseness

Brakes Proper brake lever free play; enough brake force; Parking brake

effectiveness

Tires Proper air pressure; Enough tread depth; No cracks, rips, or other

damages

Fuel Enough fuel for the intended trip; Fuel hose connected securely; No

damage to fuel tank or cap; Fuel tank cap closed securely

Engine stop switch Proper operation

Engine oil

Proper level - Check the oil by inspecting the Engine Oil indicator

located at the bottom of the engine. The engine oil should completely fill

the view window . Add oil if the window is not completely filled.

Throttle Proper free play of throttle lever; Smooth response; Quick return to idle

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position

Drive chain Proper tension; adequate lubrication; No excessive wear or damage

General condition Bolts and nuts are tight; No rattle from any parts of the engine when

running; No visible evidence of Damage

WARNNING！

1. Overloading could be hazardous. Overloading could cause changes in

vehicle handling and could lead to an accident.

2. Operating this ATV with improper modifications could be hazardous.

Improper installation of accessories or modifications to this

vehicle may cause changes in handling. In some situations, this could

lead to an accident. Never modify this ATV through improper installation

or use of accessories.

3. Operating this ATV with improper tires，or improper tire air pressure.

could be hazardous. If you use improper tires or improper air pressure,

you may lose control of the ATV. This will cause an accident.

Check the condition of the ATV to make sure that the ATV does not have mechanical problems or you could get

stranded when you ride. Before riding the ATV, be sure to check the above items. Be sure your ATV is in good

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condition to ensure the safety of the rider.

SAFETY GEAR

A DOT approved motorcycle helmet is the most important part of you safety gear. A DOT approved motorcycle

helmet can help prevent a serious head Injury. Choose a helmet that fits snugly. Motorcycle dealers can help in

selecting a good quality helmet which fits properly.

You should wear eye protection when you ride. If a rock or a branch hits your eyes, you could be severely injured.

Wear goggles or a face shield.

Wear proper clothing when you ride. The proper clothes can protect you from Injury. Wear a good pair of gloves,

strong boots that are over the ankle, long pants, and a long sleeve shirt

WARNING！

1. Checking maintenance items when the engine is running could be hazardous. You could be severely injured if

your hands or clothing get caught in moving ATV parts. Shut the engine off when performing maintenance checks,

except checking the engine stop switch and throttle.

2. Operating this ATV without wearing an approved DOT motorcycle helmet, eye protection, and protective clothing

could be hazardous. Operating without an approved DOT motorcycle helmet or eye protection. Increases your

chances of a severe head injury or death in an accident. Operating without protective clothing also increases your

chances of severe Injury in an accident. Always wear an approved DOT motorcycle helmet which fits properly.

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Always wear eye protection (goggles or face shield). You should also wear I gloves, boots, long sleeve shirt or jacket,

and long pants.

BREAK-IN

The first month is the most important in the life of your vehicle. Proper operation during this break-in period will be

helpful for assuring maximum life and performance of your new vehicle. The following guidelines explain proper

break-in procedures.

Maximum Throttle Opening Recommendation

During the first 10 hours of operation, you should always use less than 1/2 throttle opening.

Vary the Engine Rotating Speed

Vary the engine rotating speed during the break-in period. This allows the parts to "load" and then “unload” (allowing

the parts to cool). Although it is to place some stress on the engine components during break-in, you munt be careful

not to load the engine too much.

Avoid Constant Low Rotating Speed

Operating the engine at constant low rotating speed (light load) can cause parts to glaze and not seal properly. Allow

the engine to accelerate freely without exceeding the maximum throttle limit.

Allow the Engine Oil to Circulate Before Riding

Allow enough idling time after warm or cold engine starting. This allows the lubricating oil to reach all critical engine

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components.

Observe Your Initial and Most Critical Service

The initial service (break-in maintenance) is the most important service that your vehicle will receive. Observing a

proper break-in operation, will help engine components seal properly. Maintenance required as part of the initial

service includes proper adjustments, tightening of all bolts & nuts, and replacement of dirty oil. Timely performance of

this service will help you get the best service life and performance of the engine.

BRAKE SYSTEM

To stop the ATV, first release the throttle lever, then apply the rear

and front brakes smoothly.

WARNING！

1. Braking while turning the ATV could be hazardous. Use of the brake when turning could cause the ATV to slide or

roll over. Use the brake to slow down before you begin to turn.

2. Braking hard on slippery surfaces could be hazardous. The ATV could skid and go out of control if you brake too

hard. Apply the brakes lightly and carefully on slippery surfaces.

3. Operating the parking brake when the ATV is moving could be hazardous.

The front wheels could lock, and it will cause a skid and an accident.

Use the parking brake only after you stop the ATV.

STEERING SYSTEM

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Turning the ATV improperly could be hazardous. If you turn the ATV improperly, it may cause a collision or overturn.

Always follow proper procedures for turning as described in this section. Practice turning at low speeds before

attempting to turn at faster speeds. Never turn at excessive speeds.

To turn the ATV, the rider must use the proper technique. Because this vehicle has a solid rear axle, both rear wheels

always turn at the same speed. This means that if the rear wheels are getting equal traction, the vehicle will tend to

move straight ahead. This is because the rear wheels will travel the same distance. For the vehicle to turn, the

outside rear wheel must travel a longer distance that the inside rear wheel. To make this happen, the rider must

create less traction for the inside wheel, allowing it to skid. This allows it to travel a shorter distance than the outside

wheel. This happens even though both wheels are still turning at the same speed.

To turn ATV use the following technique：

Move your body weight forward and to the inside of the turn.

Turn the handlebar while looking in the direction of the turn.

Use the same technique that you use when you move your body weight farther toward the inside of the turn to

maintain your balance. Natural turning forces (which can push the vehicle to the outside of the turn) increase as the

speed or the turn sharpness increases. This means you must lean your body farther into the turn as you go faster or

turn more sharply. This prevents the Vehicle from tipping over to the outside of the turn. If your ATV starts to tip while

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turning, lean your body farther into the turn while gradually reducing tho throttle and making the turn wider, if

possible.

SKIDDING OR SLIDING

CAUTION：Skidding or sliding improperly could be hazardous. You may lose control of your ATV when you regain

traction unexpectedly. This may cause the ATV to overturn. Learn to safely control skidding or sliding by practicing at

low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slow and be very cautious,

in order to reduce the chance of skidding or sliding.

You may experience skidding or sliding when you are not braking. You may be able to overcome it by using the

techniques listed below.

If your front wheel skids:

Gain front wheel traction by reducing the throttle opening and leaning your body slightly forward.

If your rear wheel skids:

If space permits, steer in the direction of the skid. Shift your body away from the skid slightly. Avoid using the throttle

or brakes until you regain directional control of the vehicle.

OPERATION ON HILLS

To climb a hill with the ATV, follow the directions below.

1. Speed up and maintain a steady speed before reaching the top of the hill. Remember that you must ride at a

steady speed all the way to the top of the hill.

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2. Shift your body forward by sliding forward on the seat. Lean slightly forward. For steep hills, stand on the

footrests and lean forward.

3. Maintain a steady speed while climbing the hill.

4. Slow down gradually when you reach the top of the hill.

If you climb a hill and are unable to make it to the top, use one of

the correct procedures described below to get back down the hill. Never

attempt to turn an ATV around on a steep hill, doing so could cause the

ATV to overturn.

If you lose forward momentum, or begin to roll backwards, follow these

Instructions.

1. Lean uphill.

2. Never apply rear brake but use front brake.

3. Gradually back down the hill with body weight leaning forward while

applying front brake. Use extreme caution when backing down a hill.

If you still have forward movement and the hill is not steep and there

is enough space to turn around safely, follow these instructions.

1. Turn around on hill before you lose forward momentum. As you turn

on side of hill, lean your body weight uphill.

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2. Once you have turned around, ride down hill as described in the

DESCENDING A HILL section.

CAUTION:

Going down a hill improperly could be hazardous.

Going down a hill improperly could cause loss of control or cause the

ATV to overturn.

To ride down a hill with the ATV, follow the instructions below.

1. Check the terrain carefully for any obstacles before you go down the hill.

2. Point the ATV straight down the hill.

3. Transfer body to the rear by sliding back on the seat.

4. Ride down the hill slowly with the throttle released.

5. Apply the rear brake to control the speed.

6. Avoid going down a hill at an angle that would cause the vehicle to lean

sharply to one side. Go straight down the hill if possible.

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INSPECTION AND MAINTENANCE

MAINTENANCE SCHEDULE

It is very important to inspect and maintain your ATV regularly. Follow the guidelines in the chart. The intervals

between periodic services in months are shown. At the end of each interval be sure to perform the maintenance

listed.

Item

Interval

Initial 1 month Every 3 months Every 6 months

Air Cleaner — C —

^Exhaust pipe bolt

and muffler bolt T T T

*Cylinder head,cyl

inder and muffler — C C

Spark plug — C R

Idle Speed I 1 1

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Throttle cable 1 1 1

*Fuel line 1 1 1

^Brakes 1 1 1

Tires Inspect every month

Drive Chain Clean, lubricate and inspect each time the ATV is

ridden

*Suspension — — 1

*Steering 1 1 1

^Chassis bolts

and nuts T T T

Flexible tube 1 1 1

Brake fluid Replace every 2 years

I=Inspect and clean, adjust, lubricate or replace, if necessary. C=CIean R=Replace T=Tighten L=Lubricate

^Replace very 2 years

*Replace every 4 years

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If you ride your ATV usually, you need to have it serviced more frequently.

◆ Maintenance for hydraulic brake system:

1） Inspect the brake fluid regularly, if necessary, please replace the brake fluid that is specified.

2） Replace the brake fluid per two years.

3） Replace brake soft pipe per four years.

WARNING: Don’t take any chances not to maintain those parts which must be replaced, otherwise, it may

result in injury or death.

◆ Inspecting spark plug

Spark plug is the key electrical parts, and it’s easy to inspect it.

The heat and debris can rust the spark plug slowly, not making it discharge normally and having strong enough spark,

so that it can’t ignite the gas mixture. In order to make the engine work normally, you must maintain it regularly and

replace the spark plug if necessary.

● Removing spark plug

1. Pull up the wire connecting cap of the spark plug;

2. Use the special tool for spark plug in the tool bag, screwing out the

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spark plug anticlockwise.

●Inspecting spark plug：

1. Inspecting whether the spark plug terminal which is wrapped with pottery (connecting with the wire cap) is oxidated

or not.

CAUTION: It would affect conductivity if the terminal is oxidated or rusted, what’s worse, it would make the engine

power lower, fuel consumption rise up, leading to misfiring and cutout, this will result in the engine operation not

stable, affect the normal work seriously. If you’re not able to judge whether the terminal meets the requirement,

please contact Kayo after-service agent for help.

2. Inspect whether the electrode of the spark plug has rust, carbon deposit or other sediment, if necessary, you must

replace it.

3. Measure the clearance of the spark plug electrode, if necessary, adjust the clearance.

● Assemble the spark plug:

Spark plug model：

A7RTC

Spark plug electrode clearance：

0.6-0.7mm（0.024-0.028in）

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1. Wash the spark plug gasket and its matching surface, and wipe up the dirt in the thread of the spark plug.

2. Screw the spark plug in the mounting hole with the special tool, tightening it according to the specified torque.

CAUTION: When assembling the spark plug, if there’s no appropriate wrench, you can estimate whether it is

tightened, after tightening spark plug, using spark plug wrench screw 1/4-1/2 will be fine. Of course, in this way,

someone may not meet the requirement when assembling, you should check it with torque wrench.

3. Tighten wire cap on the terminal spark plug.

◆ ENGINE OIL

Running the engine without an adequate amount of engine oil could cause severe engine damage. Running the

engine without any engine oil could cause engine overheating. Always check the amount of engine oil before

starting the engine.

Changing engine oil

The engine oil should be changed every 20 to 40 hours of operation. It should be changed more often in dirty and

dusty areas.

To change oil:

Spark plug tightening torque：

18Nm（1.8m*kgf，13ft*lbf）

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1. Park the vehicle on level ground.

2. Remove the oil cap.

3. Remove the drain bolt and drain oil into proper container.

4. Reinstall the drain bolt

5. Pour fresh oil of the specified type through the oil fill hole.

NOTE: Approximately 900ml (1 Qt) of oil is required.

6. Tighten the oil cap, and check oil level.

7. Dispose of used oil as per governmental regulations.

◆DRIVE CHAIN/SPROCKETS

The condition and adjustment of the drive chain should be checked before riding. Always follow the guidelines below

for inspecting and servicing the chain.

When Inspecting the chain, look for the following:

. Loose pins

. Damaged rollers

. Dry or rusted links

. Kinked or binding links

. Excessive wear

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If you find anything wrong with the drive chain, solve the problem by repairing or replacing the chain. If necessary,

consult your authorized service center.

If It is determined the drive chain is damaged, check the sprocket also for damage. A worn chain can have an

adverse affect on the front and rear sprockets.

DRIVE CHAIN CLEANING, OILING AND ADJUSTING

Clean and oil the chain as the following:

1. Wash the chain with water.

2. Dry the chain, and then oil the links with Chain lube or equivalent.

Failing to inspect the drive chain slack before each use of the ATV could

be hazardous. Too much chain slack could cause the chain to come off the sprockets, resulting in an accident or

serious damage to the ATV. Inspect the drive chain slack before each use. The drive chain should be adjusted and

make sure there is 20-30 mm(0.8-1.2 inches) of slack

◆ Checking the wheel hub bearings

The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and

lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, please contact the local dealer to

check the wheel hub bearings.

Recommended lubricant：

Lithium-soap-based grease

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◆ Checking swingarm pivots

The swingarm pivots must checked at the intervals specified in the periodic maintenance and lubrication chart, if

there is play in swingarm, or if need lubricated. Please contact the local dealer to check if you found any abnormal

noise or swingarm can not turn smoothly.

◆ Checking the upper and lower arm pivots

The upper and lower arm pivots must be checked at the intervals specified in the periodic maintenance and

lubrication chart. To check if the clearance is within specification, if there is play in arm pivots. It is very important to

lubricate the arm pivots.

Please lubricate the grease nipple with special lubricated tools.

◆ Checking and lubricating the steering

The steering must be checked at the intervals specified in the periodic maintenance and lubrication chart.





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◆ BATTERY

WARNING: Do not leave the head light on for more than 3 minutes while engine is off, because the battery may

discharge，causing starting problems.

If this happens，remove the battery and recharge it，Or use PUSH＆BUMP to start the bike. After adding liquid, it

should be used after being placed for one hour at least, or after being charged.



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WARNNING：Battery electrolyte is poisonous and dangerous, as it contains sulfuric acid, which can cause severe

burns. Avoid contact skin, eyes or clothing. Always shield your eyes when working near batteries.

Antidote:

EXTERNAL: Flush with water.

INTERNAL: Drink large quantities of water or milk of magnesia, beaten egg or vegetable oil. Call a physician

immediately.

EYE: Flush with water for 15 minutes and get prompt medical attention.

Battery produce explosive gases. Keep sparks, flame, cigarettes or other sources if ignition away, Ventilate

when charging or using in an enclosed space.

KEEP OUT OF RACH OF CHILDREN.

TROUBLESHOOTING

32

Although Kayo ATV received a thorough inspection before shipment from the factory, trouble may occur during

operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss

power.

The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself.

However, should your ATV require any repair, take it to a Kayo dealer, whose skilled technicians have the necessary

tools, experience, and know -how to service the ATV properly. Use only genuine Kayo replacement parts, Imitation

part may look like Kayo parts, but they are often inferior, have a shorter service life and can lead to expensive repair

bills.

WARNING ：Do not smoke when checking the fuel system.

33

1. Fuel

Check the fuel level in the fuel

tank

Enough fuel

No fuel

Check the

compression

Supply fuel

The engine does not start Check the

compression.

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2. Compression

Operate the electric starter

There is compression

Check the ignition

There is no

compression

Please contact dealer

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3. Ignition

Remove the spark plug and check the electrodes.

Wet

Dry

Wipe off with a dry close and

correct the spark plug gap, or

replace the spark plug.

Please contact dealer.

The engine does not start.

Check the battery.

The engine does not start.

Check the battery.

36

4. Battery

Operate the electric starter.

The engine turns over quickly

The battery is good

The engine turns over slowly

Check the battery lead connections,

and charge the battery if necessary.

The engine does not start, please

contact dealer.

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UNPACKING ASSEMBLY

1.Put the vehicle packing on the flat ground or workbench;

2.Cut out the tighten belt with scissor. Take out of the carton and you will see the packing steel support.

3.Remove all the bolts and nuts from steel support from top to bottom.

Carefully clear out of all the steel support to avoid hurt anyone.

4.Remove all the bolts and nuts, and separate the Vehicle from the

packing support.

5.Before assembly, turn around the ball joint. Tighten slotted nut and cotter pin.

38

6.Assembly front wheel: put the 8pcs locking nut M10 and the plugs on wheels.

7.Assembly rear wheel: First inflate the rear wheel, put washers, slotted

nut, cotter pins one wheel, each of them 8pcs. Also put on the 2pcs plugs.

8. Assembly the handlebar in the right position and make sure the hydraulic brake in a level position.

39

9. Take out of the bolt on handlebar and assembly the cover of indicating light. Put back the bolt on handlebar.

10. Fully fill the battery with liquid and then put the battery into battery box. Cover the battery and then connect the

cables.

Please carefully check and commission the vehicle after the complete assembly. Only after the full commissioning test, you can drive away the vehicle.

YDF SERIES ELECTRICAL CIRCUIT DIAGRAM

40

VEHICLE MAINTENANCE

SAMPLE PRE-OPERATION CHECKLIST

Add to or adapt this checklist to suit your quad bike and place photocopies in a sturdy folder where vehicle keys and operator PPE are stored.

• Maintain completed forms to provide a record of completed inspection and/or training.• The operator’s manual provides information about minimum maintenance activity.• Additional copies of checklists are available at worksafe.vic.gov.au

Pre-operation checklist:

Check the fuel, oil and coolant every time before use with the engine o�.

Visually inspect Check for damaged or loose parts. Check for fuel or oil leaks.

Wheels and TyresCheck tyres for damage. Ensure tyre pressure is correct and even in each tyre. Check wheel nuts.

ThrottleCheck the throttle operates smoothly across its range. Accumulated mud and dirt can restrict cable movement and prevent the throttle from closing.

BrakesCheck brakes operate properly before reaching full speed.

Check it is not choked with dirt. Clean and replace regularly.

Lights and switchesCheck lights and switches work.

VEHICLE MAINTENANCE - BEFORE YOU RIDE CHECKLIST

Drive chain and chassisInspect chain for proper adjustment, wear and lubrication. Check drive shaft for oil leakage. Look and feel for loose parts with the engine o�. Rough terrain will loosen chassis parts.

Steering Check the steering moves freely, but without undue looseness.

Other checks required

Maintenance actions required

into operation.

Done

Checked by: Date


VEHICLE MAINTENANCE - MONTHLY CHECKLIST

ROUTINE MAINTENANCE CHECKLIST

Brakes

Auxiliary brake

Foot and hand levers adjusted – as per the operator’s manualCheck disc wear

Wheels

Axle bearings and wheel nuts are tight Rims not dented or buckled Tyres are roadworthy, with adequate tread depth Tyre type and pressure as per the operator’s manual Use low-pressure tyre gauge. High-pressure gauges

are not accurate for quad bike tyres

Chassis and suspension

Shock absorbers – for leaks and wear Suspension operation Safety guards – for looseness Handlebars, foot decks and major fasteners

– use tension wrench

Steering

Smooth movement from lock to lock Linkages – for wear

Throttle operation

Test while moving handlebars fully to the left and fully to the right

Gear selectors

Gear levers – for damage and excessive slack Splines on gear shaft

Fluid levels

Fluid levels as recommended in the operator’s manual Engine oil

Cooling systems

Fluid levels (if liquid cooled) Thermostatic fan Leaks and damage

Additional routine maintenance checks required:


ROUTINE MAINTENANCE CHECKLIST (CONT.)

4WD system

Constant velocity joints Drive line and shafts Check for split boots on drive shafts

Check, clean and regularly replace

Signals

Lights Horn Indicators

Exhaust Holes and corrosion Excessive noise Looseness

For quad bikes with chain drive

Chain adjustment as per the operator’s manual Sprockets not worn

Battery Battery terminals – for corrosion and tightness Electrolyte levels Damaged casing

Lever controls

Check smoothness of operation Check for broken, sharp or bent levers

Other

Check for attachment and condition of: Load carriers Foot decks Seat


On the back of this sheet list:1. Maintenance actions required 2. Items that require attention from an authorised repair person

Maintenance check performed by: Date: Next service at:

VEHICLE MAINTENANCE

SAMPLE PRE-OPERATION CHECKLIST

Add to or adapt this checklist to suit your quad bike and place photocopies in a sturdy folder where vehicle keys and operator PPE are stored.

• Maintain completed forms to provide a record of completed inspection and/or training.• The operator’s manual provides information about minimum maintenance activity.• Additional copies of checklists are available at worksafe.vic.gov.au

Pre-operation checklist:

Check the fuel, oil and coolant every time before use with the engine o�.

Visually inspect Check for damaged or loose parts. Check for fuel or oil leaks.

Wheels and TyresCheck tyres for damage. Ensure tyre pressure is correct and even in each tyre. Check wheel nuts.

Throttle

Check the throttle operates smoothly across its range. Accumulated mud and dirt can restrict cable movement and prevent the throttle from closing.

BrakesCheck brakes operate properly before reaching full speed.

Check it is not choked with dirt. Clean and replace regularly.

Lights and switchesCheck lights and switches work.


Drive chain and chassisInspect chain for proper adjustment, wear and lubrication. Check drive shaft for oil leakage. Look and feel for loose parts with the engine o�. Rough terrain will loosen chassis parts.

Steering Check the steering moves freely, but without undue looseness.

Other checks required

Maintenance actions required

into operation.

Done

Checked by: Date



ROUTINE MAINTENANCE CHECKLIST

Brakes

Auxiliary brake

Foot and hand levers adjusted – as per the operator’s manualCheck disc wear

Wheels

Axle bearings and wheel nuts are tight Rims not dented or buckled Tyres are roadworthy, with adequate tread depth Tyre type and pressure as per the operator’s manual Use low-pressure tyre gauge. High-pressure gauges

are not accurate for quad bike tyres

Chassis and suspension

Shock absorbers – for leaks and wear Suspension operation Safety guards – for looseness Handlebars, foot decks and major fasteners

– use tension wrench

Steering

Smooth movement from lock to lock Linkages – for wear

Throttle operation

Test while moving handlebars fully to the left and fully to the right

Gear selectors

Gear levers – for damage and excessive slack Splines on gear shaft

Fluid levels

Fluid levels as recommended in the operator’s manual Engine oil

Cooling systems

Fluid levels (if liquid cooled) Thermostatic fan Leaks and damage


VECHICLE MAINTENANCE - MONTHLY CHECKLIST

ROUTINE MAINTENANCE CHECKLIST (CONT.)

4WD system

Constant velocity joints Drive line and shafts Check for split boots on drive shafts

Check, clean and regularly replace

Signals

Lights Horn Indicators

Exhaust Holes and corrosion Excessive noise Looseness

For quad bikes with chain drive

Chain adjustment as per the operator’s manual Sprockets not worn

Battery Battery terminals – for corrosion and tightness Electrolyte levels Damaged casing

Lever controls

Check smoothness of operation Check for broken, sharp or bent levers

Other

Check for attachment and condition of: Load carriers Foot decks Seat


On the back of this sheet list:1. Maintenance actions required 2. Items that require attention from an authorised repair person

Maintenance check performed by: Date: Next service at:

Documents

ASSEMBLY MANUAL - Go Easy Online