UFREE SPORTS VEHICLE www.scooter-manufacturer.com USER MANUAL POCKET BIKE PB-G03 UFREE SCOOTER www.scooter-manufacturer.com MINIBIKE-PMI SERVICE MANUAL FOR USE AND MAINTENANCE AND SPARE PARTS LIST For your own safety and the safety of others Follow these recommendations in order to use your MINIBIKE safely and correctly. Read the instructions CAREFULLY, failure to do so may place yourself and others in extreme and or ultimate DANGER. If you do not understand the instructions and Data then, you are not to attempt to operate this Minibike under any circumstances. It may be used for show purposes only! CONTENTS PAGE INTRODUCTION...........................................................................................2 TECHNICAL DATA....................................................................................2 UNPACKING AND SETTING UP BEFORE RIDING................................................3 SAFETY.................................................................................................. 3 BEFORE STARTING.................................................................................... 3 STARTING THE ENGINE .FIG. 2......................................................................4 CARBURETOR.FIG. 3..................................................................................4 RIDING......................................................................................................4 PERIODIC MAINTENANCE...........................................................................5 CHAIN SETTING AND MAINTENANCE........................................................... 5 CENTRIFUGAL CLUTCH REPAIR OR REPLACEMENT..........................................5 BRAKES ADJUSTING .FIG. 4..........................................................................6 FRONT BRAKES PADS REPLACEMENT .FIG. 7..................................................6 REAR BRAKES PADS REPLACEMENT.FIG. 7......................................................,6 REMOVE AND REFIT THE FRONT WHEEL.FIG. 5..............................................7 REMOVE AND REFIT THE REAR WHEEL . FIG. 5................................................7 REPLACEMENT OF SPROCKET -FK3.9..........................................................7 ENGINE....................................................................................................8 MINIBIKE SQ40A .FJG. 5...........................................................................9,10 PARTS LIST........................................................................................11 12 FRONT AND REAR BRAKES .FIG. 7.............................................................13 REPLACEMENT OF TIRE .FIG. 5...................................................................14 DISMANTCING AND ASSEMBLY OF AIR FFLTER-FIG.3.................................14 WHAT TO DO BEFORE A PERIOD OF IDLENESS...........................................14 1 UFREE SCOOTER www.scooter-manufacturer.com INTRODUCTION The Minibike -SQ40A is designed and built for use on a paved closed circuit track. The track should be clean and without obstacles of any kind. Qualified adults and younger persons can drive the minibike. Children can drive the minibike only under the supervision of a responsible adult person. The minibike is constructed especially for racing competitions on special racing tracks. The minibike uses a single-cylinder two-stroke, Gasoline combustion engine, and has an air filter and exhaust silencer. Transfer of power to the rear wheel is through a drive chain. The overall drive ratio to the rear wheel can be changed by the replacement of chain sprockets. The front and rear wheel is equipped with disk brakes. The rear brake is controlled with the left fever and the front brake is controlled with the right lever on the handlebars. BASIC TECHNICAL DATA ENGINE: MT-A1...................................................TWO-STROKE NUMBER OF CYLINDERS...........................................1 SIZE, CAPACITY...................................................47 cc ENGINE COOLING SYSTEM........................AIR COOLED POWER OUTPUT....................................2.5kW at 8700rpm CARBURETOR.............................................DELL'ORTO FUEL ADMISION......REED VALVE DIRECT TO CRANKCASE IGNITION...................................................ELECTRONIC SPARK PLUG.................................................NGK B9 ES STARTING............................HAND PULL TYPE, MANUAL CLUTCH..................................CENTRIFUGAL, FRICTION FRAME: WELDED..............................HIGH STRESS STEEL TUBES BRAKES: FRONT WHEEL.........................................DISC BRAKES REAR WHEEL.............................MECHANICAL BRAKES WHEELS: FRONT.................................OF LIGHT ALLOY 6, 5" - 63 REAR...................................OF LIGHT ALLOY 6, 5" - 63 TIRE: FRONT..............................................SIZE 90/65 - 6, 5" REAR.......................................110/50 - 6,5", 90/65 - 6,5" FUEL: PETROL (GASOLINE)..........OCTANE 92 +SYNTHETIC OIL MIXING RATIO (after break in period)..........................50:1 TANK CAPACITY...............................................1 Litre SPEED: WITH THE INSTALLED RATIO:...........up to28mph(45km/h) UNLOADED WEIGHT:................................................(41.5lbs.) 19 kg CARRYING CAPACITY:...............................................(240lbs) 110 kg BASIC DIMENSIONS: LENGTH.........................................................950 mm WIDTH............................................................500mm HEIGHT...........................................................565 mm 2 UFREE SCOOTER www.scooter-manufacturer.com UNPACKING AND SETTING UP BEFORE RIDING The minibike is delivered in a cardboard carton and packed with folded handlebars and brake levers. After unpacking, set up the handlebars into the position, that suits the best for driving. The maximum pulled brake lever position should not touch on the handlebar grip. After setting up, tighten the handlebar nuts 1, brake lever bolts 2, and the throttle assy. Bolts. See, Fig. 1. The level of foot rest's can be regulated by loosening the bolt M5 (914.003.01) on the handle of the foot rest (139.001.01). The foot rest can be moved to the front or back position. It is recommended to try and check the position of handlebars and foot rest's individually. While tightening the bolts and nuts, do not use an excessive force as to not damage the threads, or distort the tubes and other parts. Verify the smooth and perfect function of the Bowden cables to throttle and both brakes. Fill the fuel tank with fuel. (Gas-oil mix) Failure to use the proper oil mix ratio will result in Engine damage for which you will be responsible. Operating controls: 1. Handlebar nut 2. Brake lever bolts 3. Throttle Assy. bolts 4. Stop switch 5. Front brake lever 6. Rear brake lever SAFETY Range of adjusting handlebars function position Fig. 1 The minibike is unsuitable for public road use. It does not comply with valid Safety Standards. Unsafe and careless use of a minibike can result in serious injuries. The driver can minimize the potential risks by wearing the Safety Equipment The driver must wear safety helmet, goggles, gloves, elbow pads, kneepads, and firm footwear. The minibike cannot be used on wet, icy or oily surfaces. Avoid uneven surfaces and obstacles. Drive with two hands on the handlebars. BEFORE STARTING It is strongly recommended to follow all the instructions about the break-in period to promote engine reliability and long life. Break-in period of the minibike is complete after the consumption of five full fuel tanks. It Is important to use petrol 91 or 92 Octane fuel with synthetic oil in the ratio 25:1 and after break-in period a ratio of 50:1. Mix the gas and oil completely before putting it into the fuel tank. During the break-in period do not run the engine at maximum RPM and do not allow the engine to overheat Check the tire inflation - 200 kPa (2 bars) or (28 to 30psi) to be commensurate with the driver's weight The Tyre pressure should never exceed 2,5 bars, (38psi) in either the front or rear wheel. 3 UFREE SCOOTER www.scooter-manufacturer.com STARTING THE ENGINE To be done only on the starting stand - Fig. 2. After opening the tank filling hole, fill the lank with fuel and close it by screwing-in cap. Open the petrol supply cock by turning the small lever into position "ON", Fig. 3. Set the choke lever into position "C',Fig. 3. Without turning the accelerating handle, pull gently twice the starting wire and by next quick pull start the engine. It is not allowed to pull the starting wire up to full winding off. After a short engine run, put the choke lever back to position "A" and let the engine run about 1 min. Let the Minibike on the larking stand and, if need be, adjust the no-load speed to such a rate lest coupling should take along the no-load speed to such a rate lest coupling should take along the rear wheel. For adjustment use the adjustment screw N° 4 on the carburetor, Fig. 3. Fig. 2 Fig. 3 CARBURETOR OFF 1. Suction chamber 2. Sleeve screw 3. Carburetor body 4. Adjusting screw of no-load run 5. Float chamber 6. Fuel cock RIDE After mounting the Minibike and slow turning the acceleration handle, you are starting your ride. Before braking, turn back the acceleration handle and depress slightly the front brake lever and then the rear brake lever. Beware of the wheels not to get them in skid. The Minibike engine will be switched off by pushing the red push-button of the stop switch on handlerods. After the first half-hour ride it is necessary to check the tightening of screws and nuts, especially of the engine. Check also the brake setting. 4 4 UFREE SCOOTER www.scooter-manufacturer.com PERIODIC MAINTENANCE Periodic maintenance is the best way to help the machine perform well, give longevity and provide safety and low cost operation. In addition, you will be spared from many-worries from self caused problems, resulting from poor maintinence or no maintinence. A - Before every ride: 1. Check the Cables and efficiency of brakes. 2. Check the lubrication and chain tension settings. The chain free play should be (5 mm) (.200in) After every ride clean the minibike carefully and keep it clean. Do not use aggressive cleaning detergents. 3. After 1-hour of use, wash the air filter In air drying spirits and lubricate it with special oil for air filters. 4. After 1- hour of use, check the state of the clutch pads. Review the clutch adjustment. B. After every 5 hours of riding: 5. Check the tightness of all bolts and nuts. Tighten carefully to prevent damage to other parts. 6. Wash the air filter in gas and lubricate it with special oil for an air filters to better catch the dust. 7. Clean carefully the carburetor float chamber. 8. Check the brake pads, the thickness of brake lining cannot be less than 1 mm (.039 in). Review the basic brake adjustment 9. Check the state of the clutch pads. - the thickness cannot be less than 1 mm (.039in). Review the clutch adjustment. C. Every time after 10 hours of riding; 10. Check the state of the clutch pads - the thickness cannot be less than 1 mm (.039in). CHAIN SETTING AND MAINTENANCE To set the chain tension, loosen the Nut (920.011.01) of the axel thru the rear wheel and the nut (914.021.01) of the rear Caliper anchor plate. The required chain tension (chain free play ) is (5 mm) (.200in) and is performed by equal movement of the Axel adjustor plate (920.009.01) on the both sides of the rear wheel. When the adjustment is correct, tighten the Axel nuts and the Caliper holding nut Tighten the adjustor plate nuts both sides an extra nip, just to set them firmly. It is important to lubricate the chain regularly, to avoid excess wear and prolong effective lifetime. The lubrication is important after every ride on a wet surface. It is recommended to lubricate the minibike with special chain spray. If chain replacement is necessary, check both chain Sprockets and if there is a need to change them do it together with the chain. CENTRIFUGAL CLUTCH PARTS REPLACEMENT Remove the chain guard by loosing two bolts M6 (916.020.01), Fig. 5. Loosen the chain and remove it from the sprocket. Next, loosen three bolts holding the aluminum clutch housing. Remove it together with steel clutch basket, and dismantle it Loosen the bolt from the carrier and remove the clutch from the engine. Loosen and remove the adjustable bolts and springs. Then dismantle the safety rings from pins. When all this is done, replace with new clutch slipper shoes and springs (if required) at this time. During the reassembly process follow these steps: 1. put the plate with the springs on the slipper shoes. 2. Put the plate against the carrier and mount it on the fixed pins. Fit it with the safety rings and install the adjustable bolts. 5 UFREE SCOOTER www.scooter-manufacturer.com ADJUS ...