ATV ATV110-M User manual

110cc Four Stroke ATV
User Manual
Prepared by: Adventure Imports New Zealand
www.adventureimports.co.nz
Thanks for purchasing the ATV from us!
Notes:
1) The exhaust pipe on the right foot side could be hot after a long
time riding, be careful.
2) While use remote start, the ATV may start to move after start up,
if the idle speed is not set properly, be careful.
3) This manual is prepared based on the information provided by the
manufacturer, if any content in this manual is not appropriate,
please consult a qualified mechanic or auto electrician.
1.0 FEATURES OF THIS MODEL
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Proven LONCIN engine.
Four stroke engine for smooth power and reliability.
Easy electric start.
Maximum speed can be restricted for beginners.
The ATV is equipped with an alarm system. The engine can be shut
down remotely for adult supervision.
To ensure a child’s safety, a parent can walk behind the ATV,
holding a cord attached to the cutout at the back of the quad. A
quick tug on the cord will cutout the engine
The ATV has a kill switch on the handle bar.
The size and weight make this model easy for a child to handle
and easy to load into a family car.
The knobby tires, good suspensions and the strong engine will
ensure that riding this little bike be a lot of fun.
The low cost, sturdy design and nice look make this model an
instant hit with children.
The size of the 110cc engine will always excite your rider as
they progress from a beginner to an expert, from tiny to
confident youth.
One brake stops this little quad – no confusion for the little
ones.
2.0 SAFETY PRECAUTIONS
Safety is extremely important when allowing young children to ride a
motor bike. Children of the same age can have different levels of skill
and coordination, so only a parent can understand their child’s
capabilities. If a parent decides to allow a child to ride a motorized
vehicle, it is essential that they realize that the child’s safety
rests entirely on their hands. The child must NEVER be unsupervised.
The quad’s speed must be set to match the child’s capability at all
times. The parent is the only person responsible for the child’s safety.
By allowing the child to ride a quad, the parent accepts that this is
his sole responsibility and risk.
The governor on the quad should be set to allow the child to travel
only at a walking pace while learning to ride. The area in which the
child is allowed to ride must be free of obstacles that could be a
danger to the child and free of people and animals that could be
injured. As the child’s capability increases, the quad’s speed can
gradually be increased but always only to a safe level.
Please read and apply all the safety information in this manual.
Remember: you are responsible for your own safety and the safety of
those in your care. Adventure imports cannot be held liable for
accidents, no matter what the cause. You are responsible for checking
your vehicle thoroughly for faults and for riding safely.
Operating any motorized vehicle carries an element of risk. By choosing
to ride this vehicle, you have accepted this risk. Adventure imports is
not
responsible
for
negligence,
speeding,
component
failure,
inexperience or other unforeseen circumstances that can cause injury or
death.
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To help you ride and operate the quad safely, here is some advice to
increase your safety awareness.
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Ride under the instruction of a competent teacher until you are
an experienced rider.
These vehicles are designed and manufactured for off-road use
only. It is illegal and unsafe to use this machine on any public
street, road or highway, paved, tarred or cement surfaces
Check local riding laws and regulations before operating this
machine.
Check local environmental laws.
Riding an ATV is serious; it can be hazardous to operate. A
collision or rollover can occur quickly, often with serious
consequences. Even in routine maneuvers such as turning, riding
over obstacles and on sloping ground or across water, mud or
loose surfaces, the quad handles differently from other vehicles.
Never
carry
passengers,
as
this
alters
the
handling
characteristics dangerously.
Never exceed the recommended load capacity. Overloading or
improper loading can cause mechanical failure, loss of control
and unnecessary danger.
Always keep both hands and both feet securely on the ATV.
Never attempt stunts, jumps, wheelies or other tricks.
Never ride faster than your skill or conditions permit.
Never ride when tired or after consuming alcohol or drugs or
while experiencing any dangerous medical condition.
Inspect your ATV each time you use it to make sure there are no
mechanical faults or problems with tires, brakes or controls.
Your ATV must be in safe operating condition at all times, with
sufficient oil, gas, and brake fluid and tire pressure.
Never use your ATV in flowing water or in water deeper than 5
inches.
Always use the recommended tire pressure to reduce the risk of
tire failure.
Always turn the engine OFF when refueling.
Don’t run the engine in an enclosed area —THIS CAN BE FATAL.
Always wear an approved helmet that fits snugly as well as eye
protection, gloves, a long sleeved jacket and long pants.
Engine oil from a recently run motor can be very hot. When
draining oil for an oil change, be careful.
Be sure to replace fuses with ONLY the correct ones; using an
incorrect fuse can cause a fire.
Never put your feet on the ground when the vehicle is starting
off or moving.
It is your responsibility to ensure that the ATV is properly and
safely ridden and maintained.
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People should not operate an ATV beyond their physical or mental
limits or capabilities.
While you are learning to ride, use an ATV only on level, open
ground away from people.
If you allow an untrained person to use the ATV, you are
endangering his/her life and the lives of others.
Check that the ATV throttle and throttle cables are free and
working. A jammed throttle can cause an expensive and injurious
accident.
In some other countries ATVs with 110cc or smaller engines cannot
be driven by those aged 6 and under. Recommend that riders under
age 16 should ride only with adult supervision and only after
training.
All riders should take a course of safety instruction.
Never use gasoline (petrol) to clean the ATV. A slight spark
could cause a fatal explosion. Keep a fire extinguisher nearby
when working on the ATV.
Excessive “play” or slippage on a drive chain can cause the chain
to break which could, in turn, cause a serious accident.
“Grabbing,” shuddering or lack of braking ability could mean
there is a serious brake problem. This must be fixed before
riding or serious injury could result.
The high-tension wire from the CDI unit to the sparkplug
generates extremely high voltage and can cause a serious or fatal
shock if touched with the power on.
Don’t touch any part of the engine, exhaust pipe until it has
cooled down.
Don’t siphon toxic liquids such as fuel or brake fluid by mouth
or allow them to remain on your skin.
Wipe up IMMEDIATELY any oil or grease that could cause you to
slip or lose control of the ATV.
Don’t allow animals or children to be around an unattended ATV.
Keep loose clothing and long hair well out of the way of moving
parts.
Remember: MANY PEOPLE HAVE LOST FINGERS OR LIMBS that were pulled
into moving parts, especially chains. DO NOT WORK ON THE ATV WITH
THE ENGINE RUNNING.
If, despite all these precautions, you are injured, seek medical
attention immediately.
3.0 TEACHING TECHNIQUES
Your student’s safety depends on your commitment to take the time
necessary to fully educate him/her on the proper operation of the ATV.
Remember that proper instruction before your student begins to ride is
just as important as proper instruction and supervision while riding.
Following is a step-by-step guide to help make your student’s first use
of the ATV safe and enjoyable. Before you go through the steps, however,
be sure you have reviewed the vehicle features. Be sure to take breaks
as the student becomes tired or his/her attention starts to wander.
Full attention at all times is needed to safely operate any motorized
vehicle.
STEP 1: PROPER CLOTHING & PROTECTIVE GEAR
The first step to safe riding is proper protection of the rider. Your
student should always wear a helmet, eye protection, gloves, long pants,
a long-sleeved shirt or jacket and boots. Make sure your student is not
wearing any loose-fitting clothes.
Loose belts, scarves, etc can get
caught in moving parts and cause personal injury. Even in hot weather,
make sure the student wears long pants and a long-sleeved shirt. These
not only protect against abrasive injuries but also help reduce fatigue
which comes from loss of body heat caused by exposure to the wind.
STEP 2: FAMILIARIZATION WITH THE VEHICLE
Your student should become completely familiar with the names and
functions of all controls. Demonstrate operation of the controls if
necessary. Ask the student to do such things as “Apply the brakes. Turn
off the engine,” etc. Practice this exercise until the student can
operate all of the controls without hesitation.
STEP 3: STARTING OFF AND STOPPING
To help your student develop confidence, she/he should PRACTICE FIRST
WITH THE ENGINE OFF, as follows:
• Have student sit on ATV.
• Instruct student to keep his/her eyes straight ahead while you
slowly push the vehicle from behind. This will give the student
the “feel” of riding a moving vehicle.
• As you push the ATV, instruct your student to steer straight
ahead and perform operations such as stopping the vehicle. Watch
your student closely to make sure she/he is operating the
controls correctly and without looking at them.
• As you approach the end of the practice area, tell your student
to stop the vehicle.
• You should drag the rear end of the ATV around so you can push it
straight ahead in the opposite direction.
• Practice with the engine OFF until your student gets the “feel”
of using the brakes and can stop the vehicle and turn OFF the
engine switch without hesitation and without looking at the
controls.
STEP 4: ADJUST THE SPEED LIMITER TO SLOW
Next, start the ATV’s engine and have the student practice starting off,
riding in a straight line and stopping with the vehicle under power.
Walk alongside the ATV and hold the engine cutout switch cord. Make
sure your student:
• Opens the throttle gently when starting off.
• Releases the throttle and applies the brakes in sequence when
stopping.
• Becomes aware of the distance it takes the vehicle to stop when
the engine switch is turned OFF while the vehicle is moving.
• As you approach the end of the practice session, you should again
tell the rider to stop the vehicle and get off so you can turn it
around for him/her. Practice this exercise until your student can
start off, accelerate, cruise and stop correctly and confidently.
STEP 5: TURNING
After your student has learned to ride the ATV in a straight line and
can stop it at will, you should teach the student how to turn the
vehicle. Explain the proper body movements for turning and let the
student PRACTICE FIRST WITH THE ENGINE OFF as you push the vehicle from
behind.
When turning, watch to make sure your student:
• Shifts his/her weight slightly forward and supports his/her
weight on the outer footrest.
• Leans his/her upper body into the direction of the turn,
pressing down with the opposite leg.
When the rider is able to properly turn the ATV in both directions with
the engine OFF, she/he should practice turning with the vehicle under
power. Again, make sure that the throttle limiter is adjusted to
provide a low maximum speed capability. Watch closely to make sure the
rider is using the proper technique. The rider should practice turning
until s/he can do so correctly and confidently.
STEP 6: PUTTING IT ALL TOGETHER
When your student has mastered the basic riding maneuvers in the
previously listed steps, she/he should practice them all together.
Instruct the student to perform various maneuvers such as turning right,
turning left, stopping, etc. Vary the order of these maneuvers so the
student will not anticipate what s/he will be asked to do next.
Practice this exercise until you are confident that the rider has
mastered all the basic maneuvers. Using this procedure will help the
first-time rider learn the most basic riding techniques. To become a
skilled rider, your student will need a great deal of practice and
continuing instruction in addition to completing these introductory
steps.
After all the riding techniques have been mastered, you can
adjust the throttle limiter to provide higher speed capabilities in
keeping with the rider’s skill and experience.
4.0 SETUP AND ADJUSTMENT
Uncrating the ATV, assemble the handlebar, the front bumper and the
rear cargo bar. The battery is located underneath the seat. The seat
can be removed by pull back the seat lever, which can be accessed from
the back of the ATV. Connect the red wire to the positive terminal of
the battery, and the black wire to the negative terminal of the battery.
You may hear a beep sound once the battery is connected.
CHECK THE ATV BEFORE STARTING ENGINE
The manufacturer has done a basic driving test before packing. However,
we recommend you do the following check before you start the engine.
Check the battery voltage, it should normally be 12V. Charging
the battery if the battery voltage is too low.
Check the brake and fluid, and make sure the brake control is
smooth and adjusted.
Check for smooth rotation of throttle in all steering position.
No break, crack, or deformation is seen for throttle grip and the
connecting parts.
Check that the fuel line has been plugged into the carburetor,
and there is no crimp with the fuel line.
Check tire pressure.
Check that the chain has a proper slack.
Check lock nuts for the wheels and steering rods, tighten them if
needed.
Check the safety pin for the lock nuts, crimp and secure them if
needed.
Check the steering of the ATV, align the wheels if needed.
Check the engine oil, add oil to a proper level if needed.
Check for any loose parts.
STARTING THE ATV FOR THE FIRST TIME
Add a small amount (half liter or so) of petrol in the gas tank, and
check for any fuel leaks. Don’t try to start the engine if you should
see any fuel leaking.
Add fuel to a proper level. Switch the ignition key to the “on”
position, and flick the kill switch away from you. Hold the brake
lever, the two rear lights will light up. Now press the start button
to start the engine. Refer to picture 1.
The choke is located on the right side of the ATV if you are sitting on
it. It is under the plastic cover. It may not be convenient to access
the choke, and you might have to remove the seat. Refer to picture 2,
the choke is closed when the choke lever is pulled up, and the choke is
open when the choke lever is pressed down.
The choke shall be used if you have trouble to start the ATV. When the
engine is cold: close the choke, and press the start button to start
the engine. Immediately after the engine starts, press the choke lever
halfway down and allow warm up the engine for a few minutes, then push
the choke down to a fully open position. Let the engine run until the
engine sufficiently warms up before a ride.
When the engine is warm: Open the throttle 1/8 to 1 /4, press the
starter button to start the engine. Operation of the choke is usually
not necessary when starting warm engine. The choke should be at open
position (push down fully).
TURN OFF THE ENGINE
Switch the ignition key to “off ”position shuts down the engine.
flick the kill switch towards you shuts down the engine.
Or
ADJUST IDLE SCREW
Once the engine is running it should be warmed up for five to ten
minutes, then adjustment of idle speed can be carried out. Refer to
picture 3 for idle screw.
Leave the throttle off, and turn the idle
screw in or out so that the engine runs at a proper RPM. With a proper
adjustment of the idle screw the engine shall stay running smoothly
after start up. Turning the idle screw clockwise will richen the fuel
and increase the idle speed. Caution: the vehicle may start to move
when turn the idle screw. Hold the brake while carrying out the
adjustment of idle screw.
ADJUST AIR/FUEL MIX SCREW
The mix screw has been properly adjusted at factory, and normally it
does not need further adjustment. However, if you are operating the
ATV a high altitude then you need lean out the air /fuel mixture to
help keep the engine running at peak performance.
If you have a difficulty to start the engine in cold weather, you may
also need to adjust the mix screw to richen the mixture until engine
starts easily in the cold, you may also need to increase the idle speed
in the cold weather. Refer to Picture 3 for air/fuel mix screw.
You may have to balance the air/fuel mix screw and the idle screw.
know they have been adjusted properly when there is only a slight
hesitation when the engine accelerates to a high RPM.
You
The spark plug (picture 4) will let you know if the mixture is running
lean or rich by the color on the tip; the proper color for the tip of
the plug is a beer bottle brown. If the engine is running lean the plug
will be a white or light gray in color. Do not run the engine with it
running lean severe engine damage may result, if it is running rich it
will be black with carbon and maybe wet with fuel. It is better to run
the mixture on the richer side than the leaner side. A new plug will be
needed each time the spark plug is found in any one of these conditions,
and an adjustment is needed. The only way to tell the condition is with
a new plug each time, the plug will still be useable just not good for
this test.
THROTTLE CABLE ADJUSTMENT
The adjustment is to ensure that the throttle cable is pulling full
throttle and to set free play in the thumb throttle lever. There is a
turn buckle assembly, refer to picture 5. The thumb throttle should
have 2-4mm of free play before it tightens up and starts pull the slide
of carburetor up. Loosen the lock nut and turn the adjuster until the
required free play achieved.
THROTTLE SPEED LIMIT SCREW
Check the throttle limit screw on the right handlebar and
is not limiting full throttle. If the child is young and
loosen the jamb nut an turn the screw clockwise all the
top speed,
tighten the jamb nut while hold the screw
driver. Refer to picture 6.
make sure it
inexperienced,
way to limit
with a screw
BRAKE ADJUSTMENT
The hydraulic brake system has normally been adjusted in the factory.
The brake lever should not have more than 20mm travel before applying
the brake. If there is too much travel distance, do the adjustment as
followed: remove the rubber cap, and squeeze the brake lever a few
times, until you feel braking resistance when you pull the brake lever.
You may need to add brake fluid if above adjustment is not successful.
In the case the brake is too tight and drags the disk, do the
adjustment as followed: disconnect the hydraulic line at the brake end,
use screw driver to push the brake pad, and this give more clearance
between the brake pad and the disk. Refer to picture 8.
CHAIN ADJUSTMENT
The chain should not too tight or too loose, the proper slack should be
around half an inch (12mm). There are two studs that will take up the
slack by rotating the rear axle housing. First loosen the axle housing
bolts; then adjust two nuts. Refer to pictures 8 and 9.
After the ATV has been used the chain will stretch as the ATV gets
broken in and the chain will need to be adjusted from time to time.
The chain should be inspected and lubricated by an adult every time the
ATV is going to be rode. If the chain adjuster can not be turned in so
all the slack is removed, then the chain should be replaced.
CLUTCH ADJUSTMENT
With the centrifugal clutch it will need to be adjusted as it wears.
There is an external adjustment screw that will either put more or less
tension on the clutch disk. By holding the stud with a screw driver and
loosening the jamb nut. Slowly turn the stud counter-clockwise until
there is resistance is felt. Then turn the stud 1/8 turn clockwise.
Tighten the locknut. Turning the adjusting stud clockwise will
increase the free play (more slippage), and counter-clockwise will
decrease the clutch free play (less slippage).
usting nut
VALVE CLEARANCE CHECK
After the first 10-20 hours of riding the ATV, the valve clearance
should be checked, as during this period of time the most wear occurs.
Check the clearance for intake valve and the exhaust valve.
The gap
should be adjusted to 0.03-0.05mm, according to the engine manufacturer.
Ask a qualified mechanic for help if you can not carry out these checks.
RUNNING-IN FOR A NEW ENGINE
The table shows the maximum speed
Initial 160km
less than
Up to 800km
less than
Up to 1600km
less than
in running-in period.
25km/h
30km/h
35km/h
The engine speed should be varied and not held at a constant speed.
This allows the mechanic parts to be “loaded” and “unloaded”, and aids
the matching process of the brand new engine. Operating the engine at
constant low speed can cause parts to graze and not seat in.
Allow
the engine to accelerate freely provided that the recommended maximum
limit is not exceeded. Do not, however, use full throttle for the
first 1600km.
Allow sufficient idling time after engine startup before applying the
load and revving the engine. This allows time for the lubricating to
reach all critical engine parts.
The first 1000km service is the most important for your vehicle. During
the running-in, all engine components will have worn in and seated in.
At this time the dirty engine oil should be replaced and adjustments
should be made.
FUEL AND OIL
Petrol: unleaded petrol,
Engine oil: your new ATV already has oil added, but we recommend that
you drain the oil prior to your first use and add high quality SAE10w30
or SAE10w40 engine oil. You should check the oil level every time
before starting engine. You should drain all oil at least once every 3
months.
After each time the ATV is used
Clean the ATV
Make sure the key is in off position
ALARM AND REMOTE CONTROL
The ATV is equipped with an alarm system. Refer to the follows for
functions of key on the remote. There is a control box underneath the
seat. The control electronics may become faulty due to water ingress,
vibration, and excessive heat. If you relay on the remote to stop the
ATV for supervising the young rider, please make sure the control
system works as expected.
The alarm system can be bypassed, and the
ATV can still be operated without the control box. Note that with the
alarm unplugged, the ignition key can not turn off engine, and you have
to use the kill switch to shut down the engine.
There are 4 press buttons in each remote, as shown in the picture 11
above. These 4 press buttons are referred to LOCK, UNLOCK, STARTER,
and SEARCH buttons for description of operation followed.
1) After the ATV stops and the ignition key being removed from the
ATV, press the LOCK button, the beeper of the alarm system will
sound “Bee” once, and the alarm system will be active within 3
seconds, i.e. the ATV is armed within 3 seconds.
When the ATV
is armed and the ATV is being pushed, the beeper will sound “Bee”
4 times; the beeper will sound continuously if the ATV is being
pushed again within 5 seconds.
2) When the alarm system is active and the beeper is beeping; press
the LOCK button will stop beeping. The alarm system remains
active, however.
3) Press UNLOCK button, the beeper will sound “Bee” twice, and the
alarm system will be inactive, i.e. the ATV is disarmed.
4) Remotely starting ATV, press STARTER button twice, the engine
will be started, regardless the position of ignition key and
brake. Note that the ATV may run after remoter starting if the
idle speed is adjusted too high, as the remote starting does not
need to hold the brake.
5) Remotely stopping ATV, press UNLOCK button will stop engine
6) Press SEARCH button, the beeper will sound “Bee” 5 times, which
will tell you where the ATV is.
Note that the remote is dedicated for the alarm system installed
with your ATV, and it shall not trigger other vehicles or other
electronic devices nearby. However, we recommend the users check
this if there are multiple ATVs of same model in the same field.
5.0 STORING YOUR ATV
If the ATV is going to be stored for more than 60 days then there are
some preventive things to guard against deterioration. After a good
cleaning; the fuel tank, fuel line and carburetor float bowl need to be
drained of all fuel. Remove the spark plug, pour about one teaspoon of
SAE 10W30 motor oil in the spark plug hole and reinstall the spark plug.
Turn the engine over several times slowly by hand not with the starter
with out the plug wire hooked up, and this will coat the cylinder wall
with oil to prevent rust and pitting. Block up the frame to raise all
wheels off the ground with an approved jack stand or solid blocks and
keep the wheels from flat spotting. Tie a plastic bag over the exhaust
pipe with a rubber band to prevent moister from entering. If the ATV is
going to be stored in a humid or sea air atmosphere, coat all exposed
metal surfaces with a light oil film. Do not apply oil to any rubber
parts or the seat cover, use an approved vinyl upholstery cleaner to
keep the seat cover pliable and glossy. Remove the battery and apply a
full charge. Store the battery in a dry place and recharge it once a
month. Do not store the battery in an excessively warm or cold place.
Make any necessary repairs before storing the machine this will be less
trouble for when the ATV will be used again.
6.0 WIRING DIAGRAM
Ignition key
green
grey/white
red
black
grey/white
black
red
green
Battery positive to control circuit
red
starter motor
Fuse
Relay
red
12V Battery
handlebar kill & headlight switches
green
black/white
orange
black
blue
green
yellow/red
black
orange
blue
black/white
black
CDI
Coil
blue/white
green
black/white
handlebar starter button
yellow/red
yellow/green
yellow/red
yellow/green
blue/white
black/yellow
red/black
black/yellow
green
red/black
Rectifier
brake switch
black
yellow/green
yellow
yellow/green
black
grey/white
headlights
blue
orange
green
green
Siren
orange
blue
black/white
yellow/red
black
red
green
red
black/white
white
red
white
yellow /red
grey/white
black
Alarm/remote control
green
black/white
110cc Four-stroke ATV Wiring Diagram
Prepared by Adventure Imports
brake lights
blue
yellow/green
green
Engine
green
green
rear cutout
black/white
green
Antena
blue
green
yellow/green
yellow
green
red
green