UFREE SPORTS VEHICLE www.scooter-manufacturer.com USER MANUAL Pocket Bike (Mini Moto) PB-G04 With Water-Cooled / Air-Cooled Engine. WATER-COOLED MINI MOTO PB-G04 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 - FIG. 9 ..................................................................... 7 MINI MOTO PB-G04 - FIG. 5 ............................................................................. 8,9 PARTS LIST ..................................................................................................... 10,11 ENGINE - UFREE ........................................................................................... 12 CLUTCH COMPLETE - FIG. 6.............................................................................. 13 FRONT AND REAR BRAKES - FIG. 7 ................................................................. 14 REPLACEMENT OF TIRE ­ FIG. 5 ................................................................................. 15 REMOVE AND REFIT AIR FILTER .................................................................................. 15 CLUTCH ADJUSTMENT ­ FIG. 8 ......................................................................... 15 MAINTENANCE OF COOLING SYSTEM .............................................................. 16 TORQUE SETTINGS ......................................................................................................... 17 STORAGE PROCEEDURES ............................................................................... 18 INTRODUCTION The pocket bike PB-G04 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 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 lever and the front brake is controlled with the right lever on the handlebars. BASIC TECHNICAL DATA ENGINE: UFREE.............................................................TWO-STROKE NUMBER OF CYLINDERS................................................................. 1 CYLINDER CAPACITY ................................... .........39,8 cc ENGINE COOLING SYSTEM.............................LIQUID COOLED POWER OUTPUT ........................................... 10,5 kW at 12 300 rpm TORQUE ....................................................8,1 Nm at 12 000 rpm CARBURETOR ........................................... PHVA 17,5 DELL' ORTO FUEL ADMISION ............REED VALVE DIRECT TO CRANKCASE IGNITION...................................................................CONTACT-LESS SPARK PLUG............................................................. NGK B9ES STARTING ...........................................HAND PULL TYPE, MANUAL CLUTCH............................................... CENTRIFUGAL AUTOMATIC ENHANCED TRELLIS................. SUPPORTING STRUCTURES MADE OF LIGHT ALLOYS FRONT WHEEL ... DISC BRAKE ­ DISC DIAMETER 162mm ( 6,3") REAR WHEEL ........DISC BRAKE-DISC DIAMETER 119 mm ( 4,7") FRONT ............................................OF LIGHT ALLOY 2,1"x 6,5"- 99 REAR ............................................OF LIGHT ALLOY 2,1"x 6,5"- 130 FRONT ......................................................................SIZE 90/65 - 6,5" REAR ..........................................................110/50 - 6,5", 90/65 - 6,5" .........MIXTURE OF PETROL 92 OR HIGHER OCTANE +2 STROKE SYNTHETIC OIL MIXING RATIO (after break in period) .......................................50: 1 TANK CAPACITY ............................................1,7 Liter 0,44 US gal. ) FRAME: BRAKES: WHEELS: TIRE: FUEL: UNLOADED WEIGHT: ..................................................................... 25 kg ( 55 lb. ) CARRYING CAPACITY: ............................................................... 110 kg ( 242 lb. ) BASIC DIMENSIONS: LENGTH.................................................................... 1 100 mm ( 41" ) WIDTH ......................................................................... 560 mm ( 22 " ) HEIGHT ..................................................................... 550 mm ( 21,6" ) 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 sleeve (clip-on) nuts 1; tighten the brake lever bolts and the throttle assembly 3. See, Fig.1. By loosening the nut M8 (P/N 920.010.01) on the foot peg bracket, the rider can adjust the foot peg position in a forward or rear direction. 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 rests 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 cooling system with coolant and vent the system (follow the instructions in chapter MAINTENANCE OF COOLER SYSTEM). Fill the fuel tank with fuel mixture. Failure to use the proper oil mix ratio will result in Engine damage for which you will be responsible. Fig. 1 2 6 7 3 5 Operating controls: 1. Handlebar bolts 2. Brake lever bolts 3. Throttle Assy. bolts 4. Stop switch 5. Front brake lever 6. Rear brake lever 7. Balance tank for coolant 1 Range of adjusting handlebars function position 4 SAFETY 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 mixture of petrol 92 or higher Octane with 2-stroke synthetic oil in the ratio 30:1 and after break-in period a ratio of 50:1. Mix the petrol 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. IMPORTANT NOTICE: If the coolant level rises in the balance tank, switch off the engine immediately! Check the drive of the coolant pump and sealing of the cooling system. After these steps, execute the ventilation of the Radiator. The raised level of coolant is an indicator of a overheated engine, which can result in seizing the piston in the cylinder. STARTING THE ENGINE Engine starting should be done only on the stand - Fig. 2. Fill the fuel tank and close it with the filler cap. Open the Gas petcock. Set the petrol supply cock. Set the choke lever into position "C", Fig. 3. Without turning the accelerating handle, pull gently twice the starting wire and by next guick pull start the engine. It is not allowed to pull the starting wire up to full winding off. The choke lever will turn back to the position "A" automaticaly by turning the accelerating lever after a short engine run . Let the engine run about 1 min. Leave the minibike on the stand with running engine and if necessary adjust the revolutions so the rear wheel is not turning. For adjustment use the adjustment screw No. 3 on the carburetor Fig. 3. Fig. 2 1 2 C A CARBURETOR 1. Air filter 2. Carburetor body 3. Idle speed adjusting screw 4. Float chamber A ­ Cock position for riding C ­ Cock position for cold starting 3 Fig. 3 4 RIDING Remove the minibike from the stand to sit on the seat. When seated, then slowly rotate the throttle grip to start riding. Before braking, rotate the Throttle grip to the off or idle position and lightly depress the rear brake lever with left hand and then the front brake lever with right hand. Beware to not skid the wheels. The minibike engine is switched off by pushing the red button (Engine stop switch) on the handlebars. It is necessary to check the tightness of bolts and nuts, especially of the engine, and the brake settings after the first ride and often during the break in period. 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 adlustment. B. After every 5 hours of riding: Check the tightness of all bolts and nuts. Tighten with a properly adjusted torque wrench only! For torque settings see tables on page 17. 5. Wash the air filter in gas and lubricate it with special oil for an air filters to better catch the dust. 6. Clean carefully the carburetor float chamber. 7. Check the brake pads, the thickness of brake lining cannot be less than 1 mm (.039 in). Review the basic brake adjustment. 8. 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: 9. Check the state of the clutch pads - the thickness cannot be less than 1 mm (.039in). CHAIN SETTING AND MAINTENANCE To ...