GMX MOTORBIKES TRACKER 110cc, Assembly Manual

Page 1: ...TURN 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 TRACKER 110cc QUAD BIKE PH 1300 766 469 CHRISCO SUPPORT www gmxmotorbikes com au chriscosupport ...

Page 2: ...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 pass...

Page 3: ...pstick oil fill point and fill the vehicle with suggested correct amount of oil required Tighten SWING TAG S WARNINGS Swing 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 ...

Page 4: ...ents suspension drive train and brakes fittings 30 Days Parts Replacement Parts Bearings 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 qualified skilled small engine mechanic You may need to provide proof of being assembled by a skilled mechanic if not a report from a sm...

Page 5: ...ions Parents and adult responsibility and supervision are necessary for any off 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 reflect 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...

Page 6: ...or off 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 affect where the item can be used Keep safely away from motor vehicles and traffic at all times and only used where allowed and with caution Watch out for potential obstacles The product is intended for use on f...

Page 7: ...milar 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 influence 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 thro...

Page 8: ...Safety Information 2 Engine Stop Lanyard Cord Remote 4 IWHUPDUNHW FFHVVRULHV 0RGLdžFDWLRQV 5 Description 7 Control Layout 8 Controls Functions 8 Pre ride Safety Checks 14 Getting to know your ATV 20 Maintenance 33 Emission Control System Warranty 39 ...

Page 9: ...orsports dealer THE MUDHAWK 6 ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV NEVER OPERATE THIS ATV WITHOUT PROPER TRAINING OR INSTRUCTION CHILDREN MAY NOT BE ABLE TO OPERATE THIS VEHICLE SAFELY DUE TO PHYSICAL OR MENTAL LIMITATION The ATV you purchased may differ slightly from the illustra...

Page 10: ...e operating this ATV O Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills O Never modify an ATV through improper installation or use of accessories O Never attempt wheelies jumps or other stunts O Always inspect your ATV before you ride Make sure it is in safe operating condition Always follow the inspection and maint...

Page 11: ...light O Never let your child operate an ATV without close adult supervision a child under 6 should not operate this ATV even with adult supervision O Promptly correct your child if he or she begins to ride beyond his or her abilities and if necessary intervene by pulling the cord lanyard to stop the engine O I WKH FKLOG ULGHV EH RQG KLV RU KHU DELOLWLHV RU ULGHV LQ WHUUDLQ WKDW LV WRR GLIdžFXOW KH ...

Page 12: ...ng speed 1 Install the cap on the end of the engine stop switch cord onto the engine shut off switch white button 3XW RXU džQJHUV LQ WKH ORRS DW WKH RWKHU HQG RI WKH FRUG 3 As your child is riding walk behind the ATV closely watching his or her actions as well as the path ahead I WKHUH LV D SRWHQWLDO KD DUG DKHDG RU LI RXU FKLOG LV QRW ULGLQJ FRUUHFWO SXOO džUPO RQ WKH FRUG ODQ DUG WR stop the engin...

Page 13: ...e instructions have been given the adult can restart the engine using the wireless remote switch AFTERMARKET PARTS ACCESSORIES MODIFICATIONS O 0RGLdžFDWLRQV SHUIRUPHG WR RXU YHKLFOH WKDW FKDQJH DQ RI WKH YHKLFOHƪV GHVLJQ RU RSHUDWLRQ FKDUDFWHULVWLFV can put you and others at greater risk of serious injury or death Never install accessories that would impair the performance function of your ATV Care...

Page 14: ...e and unable to save yourself Also deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas If you experience any symptoms of carbon monoxide poisoning leave the area Immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly re...

Page 15: ...PTION LEFT SIDE RIGHT SIDE Front Shock Fuel Cap Rear Cargo Rack 0XILJHU Rear Shock Gear Shifter Fuel On Off Valve Front Bumper Cover Air Filter Fuse 15Amp Spark Arrester Engine Oil Dip Stick Foot Rest Spark Plug ...

Page 16: ...ON All electrical systems are supplied with power and the engine can be started The key cannot be removed Ignition OFF All electrical systems are off The key can be removed Ignition OFF Ignition ON Rear Brake Lever Speed Limiter Front Brake Lever Throttle Lever Main Switch Choke Lever Parking Brake Lock Button ...

Page 17: ...re starting the engine make sure the throttle lever is smooth in operation and will return to the start position If throttle lever is not smooth in operation or will not return to start position do not start engine SPEED LIMITER The MudHawk 6 is equipped vehicle speed limiter adjusting screw Beginning riders should start with the red speed limiter screw for operation below 10 mph slowest setting t...

Page 18: ...speed of the ATV turn the adjustment screw clockwise 3 Tighten the locknut to set adjustment screw in desired position FRONT BRAKE LEVER The front brake lever is located on the right handlebar To apply the front brake pull the brake lever toward the handlebar grip REAR BRAKE LEVER The rear brake lever is located on the left handlebar To apply the rear brake pull the brake lever toward the handleba...

Page 19: ...the parking brake before you begin riding The brakes could overheat if you ride the ATV without releasing the parking brake You could lose control or cause an accident CHOKE LEVER Starting a cold engine requires a richer air fuel mixture Move the choke lever to the left when starting a cold engine Once the engine is warmed up return the choke lever all the way to the right in the running position ...

Page 20: ... IXHO H SDQGV ZKHQ LW KHDWV XS KHDW IURP WKH HQJLQH RU WKH sun can cause fuel to spill out of the fuel tank FUEL TANK CAPACITY If any fuel spills during fueling please wipe quickly fuel may deteriorate plastic body Remove the fuel tank cap by turning it counter clockwise Turn the fuel tank cap fully clockwise to make sure it is securely closed Your ATV s engine has been designed to use regular unl...

Page 21: ...e the seat pull the seat lock lever backward and then pull up the seat The seat lock is located under the seat in the back of the ATV TO INSTALL SEAT Insert the tabs on the front of the seat into the seat holders and push down on the seat at the rear Make sure that the seat is securely installed in place and will not move during operation ADJUSTING SUSPENSION SPRING PRELOAD This ATV is equipped wi...

Page 22: ...r ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if necessary 19 91 octane min Add Rival Maxima Fuel Stabilizer if using ethanol fuel Check fuel line for leakage Correct if necessary Engine Oil Check oil level in engine and add recommended oil to 19 5LYDO 0D LPD VSHFLdžHG OHYHO LI QHFHVVDU Check ATV for oil leakage Correct if necessary Transmission Oil Check ATV for o...

Page 23: ...f necessary Control Cables Make sure that operation is smooth Lubricate if necessary 20 Drive Chain Check chain slack and adjust if necessary 20 Check chain condition Lubricate if necessary Wheels Tires Check wheel condition and replace if damaged 20 Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary Brake Levers Make sure that operation is smooth Lub...

Page 24: ...throttle is not operating properly DO NOT START ENGINE Have a Rival Motorsports dealer correct the issue before operating this ATV SWITCHES Check to ensure all switches are working properly before starting the engine DRIVE CHAIN Check the condition of the drive chain and check the drive chain slack Lubricate and adjust the drive chain as necessary TIRES KHFN WLUH SUHVVXUH EHIRUH HDFK ULGH WR PDNH ...

Page 25: ...hrottle lever a small amount to start the engine 6 When engine warms up slowly move the throttle lever to the right Choke lever must be in the off position all the way to the right in order to operate the ATV 7 Release the parking brake STARTING ENGINE WARM 1 Set the parking brake The engine can be started only when the rear front rear brake lever is applied 2 Turn the fuel valve lever to the on p...

Page 26: ...iod Subsequent service work should be performed after every 20 hours of operation HOT MUFFLER ENGINE 7KH PXILJHU DQG RWKHU HQJLQH SDUWV EHFRPH H WUHPHO KRW GXULQJ RSHUDWLRQ DQG UHPDLQ KRW DIWHU WKH HQJLQH KDV VWRSSHG 7R UHGXFH WKH ULVN RI džUH GXULQJ RSHUDWLRQ RU DIWHU OHDYLQJ WKH 79 GR QRW OHW EUXVK JUDVV DQG RWKHU PDWHULDOV FROOHFW XQGHU WKH YHKLFOH QHDU WKH PXILJHU RU H KDXVW SLSH RU QH W WR RWKHU...

Page 27: ... SHUIRUPHG WR your ATV that change any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle REAR CARGO RACK Rear cargo rack can be used to carry many items but make sure cargo is properly secured with tire downs The rear cargo rack s maximum load of 15 lbs should nev...

Page 28: ...20 GETTING TO KNOW YOUR ATV ...

Page 29: ... acquired through practice over a period of time Take the time WR OHDUQ WKH EDVLF WHFKQLTXHV ZHOO EHIRUH DWWHPSWLQJ PRUH GLIdžFXOW PDQHXYHUV W LV HVVHQWLDO WR IDPLOLDUL H yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this manual completely and understand how to operate all of the ATV s controls Pay particu...

Page 30: ...r protective eyewear O Over the ankle boots gloves long sleeved shirt or jacket and long pants O An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident Wear eye protection when operating your ATV to reduce the ris...

Page 31: ...Consuming alcohol or drugs could seriously affect your judgment cause you to react more slowly and affect your balance and perception Never consume alcohol or drugs before or while driving this ATV You increase your chance of an accident 23 1 Protective clothing 2 Protective Goggles 3 Protective Gloves 4 Protective Boots 5 Protective Helmet ...

Page 32: ...tempting wheelies jumps and other stunts increases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off BE CAREFUL WHERE YOU RIDE This ATV is designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driv...

Page 33: ...me to react to hidden rocks bumps or holes Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Do not operate on rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain Failure to use extra...

Page 34: ...QJ PRUH GLIdžFXOW WUDLQ Set the parking brake and follow the instruction on page 14 to start the engine Once it has warmed up you are ready to begin riding your ATV Remember that the engine and exhaust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these components ACCELERATING YOUR ATV With the engine idling release the parking brake Apply the thr...

Page 35: ...turn slip slightly allowing the ATV to make the turn properly This procedure should be practiced at slow speed many times in a large off road area with no obstacles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the procedure again If the riding surface is slippery or loose it may help to position more of your weight ...

Page 36: ...her person an obstacle or a sharp drop off Use common sense and remember that some hills are too steep for you to climb or descend I RX DUH FOLPELQJ D KLOO DQG RX džQG WKDW RX KDYH QRW SURSHUO MXGJHG RXU DELOLW WR PDNH LW WR WKH WRS RX VKRXOG WXUQ the ATV around while you still have forward motion provided you have the room to do so and go down the hill If your ATV has stalled or stopped and you be...

Page 37: ...he ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear RIDING SLOPING SURFACE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance H VXUH WKDW RX KDYH OHDUQHG WKH EDVLF ULGLQJ VNLOOV RQ LJDW JURXQG EHIRUH DWWHPSWLQJ WR FURVV D VORSLQJ VXUIDFH Avoid slopes with ...

Page 38: ...improperly over obstacles could cause loss of control or a collision Before operating in a new area check for obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual Riding over rough terrain should be done with caution Look out for obstacles which could cause damage to th...

Page 39: ... the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide CARBURETOR ENGINE IDLE RPM ADJUSTMENT If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted as follows 1 DUP XS WKH HQJLQH E UXQQLQJ WKH YHKLFOH DSSUR LPDWHO džYH PLQXWHV 2 Place the transmission in neutral with the parkin...

Page 40: ... Weight 231 5 lbs 105kg DIMENSIONS Overall Length 52 8 in 1340mm Overall Width 31 1 in 790mm Overall Height 35 4 in 900mm Seat Height 23 6 in 600mm ENGINE Type Single Cylinder Four Stroke Air Cooled Automatic Centrifugal Clutch Displacement 107CC Bore X Stroke 52 4 mm x 49 5 mm Idle Speed 1500 150 RPM Start Mode Electric start Ignition Method CDI Spark Plug Gap 0 06 0 085mm Transfer Method Chain D...

Page 41: ...d lubrication intervals of important components are explained in the following chart on the following pages Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adjust or replace p...

Page 42: ... CONTROL SYSTEM CHECK OR MAINTENANCE JOB WHICHEVER COMES FIRST INITIAL EVERY Month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 No ITEM Hours 20 80 160 160 320 1 Fuel Filter Check or replace if necessary 2 Fuel Line Check fuel hoses for cracks or other damage and replace if necessary 3 Spark Plug Check condition and clean regap or replace if necessary 4 Valves Check valve cleara...

Page 43: ...U Replace brake pads Whenever worn to the limit 3 Rear Brake Check operation and correct if necessary Check brake pedal free play and adjust if necessary KHFN LJXLG OHYHO DQG 79 IRU LJXLG OHDNDJH DQG FRUUHFW LI QHFHVVDU Replace brake pads Whenever worn to the limit 4 Brake Hoses Check for cracks or other damage and replace if necessary Replace Every 2 years 5 Rear Brake Hose Protectors Check for wea...

Page 44: ...necessary Check for oil leakage and replace if necessary 11 Stabilizer Bushings Check for cracks or other damage and replace if necessary 12 Rear Knuckle Pivots Lubricate with lithium soap based grease 13 Steering Shaft Lubricate with lithium soap based grease 14 Steering System Check operation and repair or replace if damaged Check toe in and adjust if necessary 15 Engine Mount Check for cracks o...

Page 45: ...ubricate 18 Throttle Lever Housing and Cable Check operation and correct if necessary Check throttle cable free play and adjust if necessary Lubricate throttle lever housing and cable 19 Front and Rear Brake Switches Check operation and correct if necessary 20 Lights and Switches Check operation and correct if necessary Adjust headlight beams GENERAL MAINTENANCE AND LUBRICATION CHART CONTINUED ...

Page 46: ...38 PERIODIC MAINTENANCE RECORD MAINTENANCE INTERVAL PERFORMED SERVICING DATE SERVICING DEALER OR PERSON REMARK ...

Page 47: ...VEHICLE MAINTENANCE ...

Page 48: ...ck the fuel oil and coolant every time before use with the engine off Visually inspect Check for damaged or loose parts Check for fuel or oil leaks Wheels and Tyres Check 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 ...

Page 49: ... oil leakage Look and feel for loose parts with the engine off 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 BEFORE YOU RIDE CHECKLIST ...

Page 50: ... 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 g...

Page 51: ...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 Additional routine maintenance checks required On the back of this sheet list 1 Maintenance acti...

Page 52: ...VEHICLE MAINTENANCE ...

Page 53: ...ck the fuel oil and coolant every time before use with the engine off Visually inspect Check for damaged or loose parts Check for fuel or oil leaks Wheels and Tyres Check 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 ...

Page 54: ... oil leakage Look and feel for loose parts with the engine off 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 BEFORE YOU RIDE CHECKLIST ...

Page 55: ... 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 g...

Page 56: ...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 Additional routine maintenance checks required On the back of this sheet list 1 Maintenance acti...

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