Thumpstar ATV 70, Owner'S Manual

Page 1: ...MANUAL 3627 ...

Page 2: ...ter laws and regulation in effect at the time of manufacture Thumpstar reserves the right to make changes at any time without notice and without incurring any obligation This publication includes the latest production information available before printing No part of this publication may be reproduced without written permission Please check your local riding laws and regulations before operating th...

Page 3: ...tch 7 Rear Brake Lever 8 Parking Brake 8 Speed Limiter 9 Seat 9 Fuel Tank Cap 10 Front Brake Lever 10 Front Shock Absorber Adjustment 11 Rear Shock Absorber Adjustment 11 Pre Operation Checks 12 Front Rear Breaks 12 Fuel 13 Engine Oil 13 Throttle Lever 14 Lights 14 Switches 14 Battery 14 Tires 14 Operation 16 Accelerate 16 Decelerate 16 Engine Break In 17 Periodic Service 18 Component Inspection 2...

Page 4: ...pearance Care 26 Preparing for a Ride 28 Transporting your Thumpstar 29 Storing your Thumpstar 30 Troubleshooting 32 You the Environment 35 Taking Care of the Unexpected 36 Technical Information 40 Oxygenated Fuels 41 Specification 42 Spare Part Catalogue 43 Parts Finder 52 Warranty 53 Disclaimer 54 Service Manual 55 Title Ownership 56 ...

Page 5: ...close attention to the warning and caution labels on the vehicle Never operate an atv without proper training or instruction IMPORTANT MANUAL INFORMATION Failure to follow the warnings contained in this manual can result in serious injury or death Particularly important information is distinguished in this manual by the following notations WARNING Failure to follow WARNING instructions could resul...

Page 6: ...This section presents some of the most important information and recommendations to help you ride your motorcycle safely Please take a few moments to read these pages This section also includes a special message for parents and location information for the safety labels on your motorcycle You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if y...

Page 7: ...nd all of the labels on your Thumpstar ATV They contain important information for safe and proper operation of your ATV Never remove any labels from your quad If a label becomes difficult to read or comes off a replacement label is available from your dealer ...

Page 8: ...ile operating this ATV Never operate at speeds too fast for your skills or the conditions Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe oper ating conditions Always follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footboards of ...

Page 9: ...5 Control Functions 1 2 3 4 5 6 7 8 9 10 1 Rear Bumper 2 Seat Lock 3 Battery 4 Rear Brake Lever 5 Parking Brake 6 Main Switch 7 Handlebar 8 Throttle Lever 9 Speed Limiter 10 Front Brake Lever ...

Page 10: ...HROTTLE Once the engine is running movement of the throttle lever will increase the engine speed Regulate the speed of the engine by varying the throttle position Because the throttle is spring loaded the engine will decelerate and the engine will return to an idle any time your finger is removed from the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soo...

Page 11: ...and can be used at all times to stop the engine especially in an emergency The engine will not start or run when the engine stop switch is turned to START SWITCH The starter motor cranks the engine when this switch is pushed See starting instructions prior to starting engine Lights switch Turn the switch on for front light and taillight option accesory 1 2 3 ...

Page 12: ...erate properly If this should happen remove the battery and recharge it replace if necessary REAR BRAKE LEVER The brake lever is located on the left side of the handle bar Pull down on the lever to apply rear brake PARKING BRAKE Apply the brake lever and then press down the stop button to apply the parking brake Squeeze the rear brake lever to release the parking brake ...

Page 13: ... maximum speed of the ATV For children s safety the ATV has been adjusted to a speed under 15km h 9 3 mph SEAT To remove the seat pull the seat lock lever upward and pull up the seat at the rear Do not turn the speed adjuster out more than 12mm 0 47in Always make sure the throttle lever free play is 3 5mm 0 12 0 20in To install the seat insert the lobe on the seat front into the receptacle on the ...

Page 14: ...ng it counterclockwise Automotive gasoline with octane number of 91 or higher may be used After refueling be sure to tighten the tank cap firmly FRONT BRAKE LEVER The brake lever is located on the right side of the handlebar Pull down the lever to apply the front brake ...

Page 15: ...pring preload turn the adjuster in direction a To deacrease the spring preload turh the adjuster in direction b REAR SHOCK ABSORBER ADJUSTMENT The spring preload can be adjusted to suit the vehicle s load and riding conditions Spring preload adjustment To increase the spring preload turn the adjuster in direction a To deacrease the spring preload turh the adjuster in direction b ...

Page 16: ...tle cable operation Wheels and Tires Check tire pressure wear and damage Fittings and Fasteners Check all fittings and fasteners Lights Check fluid level Battery Fill with distilled water if necessary NOTE Always check each item in the above list prior to operating your ATV FRONT AND REAR BRAKES 1 Check the operation and free play of the lever They should move smoothly and there should be firm fee...

Page 17: ... use regular gasoline with RON of 91 or higher ENGINE OIL Make sure the engine oil is at the specified level Add oil if necessary Recommend oil Recommended engine oil classification API Service SE SF SG type or higher NOTE Do not add any anti friction modifier to ensure proper clutch function Oil quantity in engine 0 9 L 0 24 gal ...

Page 18: ... check the headlight and taillight to make sure they are in working condition Repair if necessary for proper operation SWITCHES Check the operation of the headlight switch engine stop switch and any other switches Repair if necessary for proper operation BATTERY Check battery power change the battery if electric power is getting poor TIRES 1 Recommend tires for this ATV listed below ATV Front 145 ...

Page 19: ...he minimum specified could cause the tire to dislodge under severe conditions Minimum Tire Pressure Front 0 55 kgf cm 2 Rear 0 55 kgf cm 2 4 Use no more than the following pressures when seating the tire beads Front 2 5 kgf cm 2 Rear 2 5 kgf cm 2 Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst 5 Tire Wear Limit W...

Page 20: ...s Make sure everything is working smoothly before starting TO START OUT AND ACCELERATE 1 Release the parking brake 2 Open the throttle gradually 3 Once the vehicle has attained adequate speed release the throttle lever 4 Open the thorttle gradually TO DECELERATE When showing down or shopping release the throttle and apply the brakes smoothly and evenly ...

Page 21: ...tion 10 20 HOURS Avoid prolonged operation above 3 4 throttle Rev the vehicle freely but do not use full throttle at any time AFTER BREAK IN Avoid prolonged full throttle operation Vary speeds occasionally PARKING When parking stop the engine Turn the fuel cock to OFF and apply the parking brake PARKING ON THE SLOPE Avoid parking on slopes If you must park on an incline apply the parking brake and...

Page 22: ...rs more often if wet or dusty areas Carburetor Check idle speed starter operation Adjust if necesarry O O O O Cylinder Head Cover Breather System Check breather hose for cracks or damage Replace if necessary O O O Exhaust System Check leakage Retighten if necessary Replace gasket if necessary O O O Fuel Line Check fuel hose for cracks or damage Replace if necessary O O O Engine Oil Check oil level...

Page 23: ...pressure and wear Replaced if damaged O O O O O Wheel Bearings Check bearing assembly for looseness or damage Replace if damage O O O O Steering System Check operation replace if damaged Check toe in adjust if necessary O O O O O Battery Check specific gravity Check that the breather hose is positioned properly Never service the engine while still running O ...

Page 24: ... vehicle on a level surface b Warm up the engine for several minutes and stop it c Wait a few minutes until the oil level settles before checking d Remove the dipstick and wipe it off with a clean rag Insert the dipstick in the filler hole without screwing it in e Remove the dipstick and inspect the oil level f The oil level should be between the maximum and minimum marks If the level is low add o...

Page 25: ...nostic tachometer must be used for this procedure 1 Start the engine and warm it up for a few minutes at approximately 1000 to 2000 r min Occasionally rev the engine to 4000 to 5000 r min The engine is warm when it quickly responds to the throttle 2 Connect the tachometer and set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw into increase engine speed a...

Page 26: ...e lever free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut THROTTLE LEVER ADJUSTMENT The rear brake free play should be 20 25 mm 0 80 1 0 in If the free play is incorrect adjust it as follows 1 Raise the rear side of vehicle to make rear tires leave from the ground 2 Turn the rear wheels and turn the bolt and nuts on these 2 positions to adjust the caliper only with a suitable brake condition ...

Page 27: ... REPLACEMENT If the fuse is blown turn off the main switch and install a new fuse of the specified amperage Then turn on the switches If the fuse immediately blows again conult your dealer Specified Fuse A 250V 1 MAIN FUSE Never use an improper fuse An improper fuse can cause damage to the electrical system which could lead to fire To prevent accidental short circuiting turn off the main switch wh...

Page 28: ...ttery asks for no replenishment Just enjoy easy use and sound performance REPLACING THE HEADLIGHT BULB If the headlight bulb is burnt remove the headlight unit assembly take out the defective bulb and replace a new one Air Filter cleaning 1 Remove the set 2 Remove the air filter case cover 3 Remove the air filter element and separate it from the guide 4 Blow the dust on element off with air or rep...

Page 29: ...25 Circuit Diagram ...

Page 30: ...cleaner degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your ATV If your ATV is still warm from recent operation give the engine and exhaust system time to cool off We recommend the use of a garden hose to wash your ATV High pressure washers like those at coin operated car washes can damage certain parts of your...

Page 31: ...ve chain to prevent rusting 7 Start the engine and let it idle for several minutes The engine heat will help dry moist areas 8 As a precaution ride at a slow speed and apply the brakes several times This will help 9 dry the brakes and restore normal braking 10 performance EXHAUST PIPE AND MUFFLER MAINTENANCE When the exhaust pipe and muffler are painted do not use a commercially available abrasive...

Page 32: ...rces Canada only riding clubs and off road magazines are good sources of information WHAT TO TAKE TO THE RIDING AREA Along with your ATV and riding gear you should take along some tools and supplies in case you have a problem We recommend that you always take water food a first aid kit and your owner s manual Other items you should consider loading on your truck or trailer include a tool kit tire ...

Page 33: ...ttach the lower ends of two straps to the tie down hooks on your vehicle Attach the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork WHAT TO TAKE ON THE TRAIL What you take with you during a ride depends on the kind of terrain how long you expect to ride how far you might go from your base camp or help and how experienced you or your companion...

Page 34: ...formance and may be illegal Choose Sensible Cleaners Use a biodegradable detergent when you wash your ATV Avoid aerosol spray cleaners that contain chlorofluoro carbons CFCs which damage the atmosphere s protective ozone layer Don t throw cleaning solvents away see the following guidelines for proper disposal RecycleWastes It s illegal and thoughtless to put used engine oil in the trash down a dra...

Page 35: ...decide what to do If a problem is relatively minor and you have the tools supplies and skills to make a permanent repair you may be able to fix it on the trail and con tinue riding Or you may be able to make a temporary repair that allows you to slowly ride back to your base where you can make a permanent repair or get help When a problem is more serious or you don t have the tools supplies experi...

Page 36: ... Mechanic sooty exhaust rich fuel mixture See or talk to your Thumpstar Certified Motorcycle Mechanic detonates or pings under load If applicable switch to the recommended octane gasoline or change your brand of gasoline If the problem persists see your Certified Motorcycle Mechanic afterfires backfires See or talk to your Thumpstar Certified Motorcycle Mechanic pre ignition runs on after ignition...

Page 37: ...ir doesn t hold the tube must be replaced The tire will also need to be replaced if it is damaged Replacing a tube or tire involves removing and re installing the wheel If you are unable to repair a flat tire on the trail you will need to push the ATV back to your base or send for help We strongly recommend that you do not try to ride with a flat tire The ATV will be hard to handle and if the tire...

Page 38: ...en you get home thoroughly check your ATV and correct any problems you find Also be sure to have your Certified Motorcycle Mechanic check the frame and suspension after any serious crash IF A COMPONENT FAILS The drive chain master link brake lever or pedal control cables and other components can be damaged as you ride in dense brush or over rocky terrain Making a trailside repair depends on how se...

Page 39: ...t Engine size of your Thumpstar Version No To identify which version your model is Thumpstar models are categorized by version number rather than by model year so to find the correct OEM parts you will need the version number Tip if a model is a version 1 1 1 1 2 1 3 they are all in the same version family meaning that 95 of the spare parts will be the same usually a change in color or minor part ...

Page 40: ...der the name Gasohol MTBE Methyl Tertiary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by Volume You may use gasoline containing methanol containing up to 5 methanol by volume as long as it contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause startin...

Page 41: ...ual Shock Length 320mm Suspension Rear Mono shock 270mm Brakes Front Drum Brakes Rear Disc Single Piston Dual Park Brake Wheel Tyre Front Steel Rim Tubeless 145 70 6 Wheel Tyre Rear Steel Rim Tubeless 145 70 6 Wheelbase 830mm 33 Seat Height 620mm 24 Carton Dimentions 1200 760 640mm 60m3 Weight n w g w 85kgs Tank Capacity 4 3 Litres 1 1gallon ENGINE AND TRANSMISSION SUSPENSION BRAKES AND WHEELS DIM...

Page 42: ...38 Spare Part Catalogue ...

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Page 51: ...s www thumpstar com au https www thumpstar co nz Go to our website then copy the part number or ERP CODE in our Spare Part Catalogue and paste it in the search bar then press enter or click the search icon beside it After searching you will see the parts listed below the search bar ...

Page 52: ...ery Purchasing a motorcycle in the crate without setup by a Thumpstar Autho rized Dealer void the limited warranty Limited Warranty is not transferable and if valid for original purchaser only USA Competition models are absence from a manufactures limited war ranty WARRANTY CLAIMS All warranty claims must be accompanied with the following information and attachments Picture of the motorcycle Pictu...

Page 53: ...ty of this bike for any specific purpose or user The products in this manual are designed for competition use for a single rider with proper safety equipment Thumpstar also recommends that any minors only use motorised vehicles under adult supervision and under the guardian s own discretion Purchasers should check with their local authorities for area specific rules and regulations Adult guardian ...

Page 54: ...efore riding check your local states cities motorcycle codes for more information regarding laws This product is for use on closed private tracks only By purchasing you acknowledge that you have read and understood and you agree to the terms and conditions of this Agreement and you represent that you are of legal age age 18 or older to enter this Agreement and become bound by its term While all ca...

Page 55: ...51 Title Ownership NAME BUYER SIGNATURE SELLER SIGNATURE DATE OF PURCHASE by Thumpstar All rights reserved ...