GMX GMXK150WHI, Assembly Manual

Page 1: ...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 ...

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: ...ts 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 small engine mechanic advising of the issues to process your warranty claims The warranty is a parts replacement warranty and labor i...

Page 5: ...azards 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 fit comfor...

Page 6: ...t 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 A...

Page 7: ...STRUCTURE 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 ...

Page 8: ...2 VEHICLE CONSTRUCTURE LOCATIONS ...

Page 9: ... 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 ...

Page 10: ...ne 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 ...

Page 11: ...5 VEHICLE MARK DESCRIPTION VEHICLE INFORMATION CODE LOCATIONS ...

Page 12: ...nt 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 ...

Page 13: ...7 This warning sticker is put on the left right plastic same as below picture TYRE PRESSURE AND OVERLOAD COMBINED WARNING STICKER PASSENGERS WARNING STICKER ...

Page 14: ...8 ...

Page 15: ...itch 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 ...

Page 16: ...xperience 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...

Page 17: ...e 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 instruc...

Page 18: ...ur 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 ...

Page 19: ...y 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 Engin...

Page 20: ...ation 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 ...

Page 21: ...rong 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 ...

Page 22: ...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 ligh...

Page 23: ...ngine 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 ...

Page 24: ...e 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 i...

Page 25: ...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 Avo...

Page 26: ...urn 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 ...

Page 27: ... 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 sharpl...

Page 28: ...ines 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 ...

Page 29: ...ricate 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 ...

Page 30: ... 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 ...

Page 31: ...isfiring 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 electrod...

Page 32: ...ne 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 en...

Page 33: ...0ml 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 Kink...

Page 34: ... 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 w...

Page 35: ...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 specifi...

Page 36: ...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 Recommended lubricant Lithium soap based grease ...

Page 37: ...dote 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 TROU...

Page 38: ...ents 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 exp...

Page 39: ...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 ...

Page 40: ...34 2 Compression Operate the electric starter There is compression Check the ignition There is no compression Please contact dealer ...

Page 41: ...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 ...

Page 42: ...e 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 ...

Page 43: ...n 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 ...

Page 44: ...he 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 ...

Page 45: ...r 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 ...

Page 46: ...40 ...

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...