Build Information

This Quad Bike you have bought is one of the best available in its price bracket We put every conceivable effort into sourcing and specification in order that you will enjoy your machine to the full.

Your bike will  be supplied in a crate. This is NOT the same as buying a bike fully PDI’d (Pre-Delivery Inspection) bike from a dealer. It is entirely your responsibility to ensure a qualified motorcycle mechanic puts your bike together correctly. Failure to do so will invalidate the warranty supplied with your bike.

GUIDE FOR ASSEMBLY

This document is supplied only as a guide to a professional and may not be exhaustive. Each machine may require individual attention & therefore ONLY qualified persons should only carry out the following:

• Remove Bike & all accessories from crate & inspect to ensure all necessary parts have been supplied correctly
• Mount shock (where applicable)
• Mount front wheels & ensure free rotation – check for potential bearing &/or brake drag Ensure all frame bolts are tight (use thread lock compound where necessary) – Use locking wheel nut (supplied) install locking split pins into each castle nut.
• Pump front brake lever until firm (bleed if necessary). Check front braking system for potential leaks or damage by pulling brake lever very hard several times. Visually inspect all joints for leaks & remedy where necessary. Spin wheel to ensure calliper is releasing from disk
• Check brake fluid levels, top up with DOT4 where necessary
• Fit front footwells using thread locking compound where required
• 2 Stroke mini quads and mini bikes mix fuel at 25:1 Ratio using a quality semi synthetic 2 stoke motorcycle oil. DO NOT USE GARDENING OR MOWER 2 STROK OIL it fouls the plug and causes the bike to misfire, bog out and not start.

• 4 Stroke 110cc and 125cc use straight unleaded fuel and replace engine oil as below 

IMPORTANT! CHAIN ADJUSTMENT

Before First Ride

• Loosen rear axle & adjust chain tension. Find tightest point in chain by spinning rear wheel, there should 15mm up & 15mm down at the longest section of chain with rider sat on bike. Ensure chain runs true & is on top of chain roller if your models has one.
• You can ensure chain runs true by eye then by straightening the front wheels and measuring from wheel rim front to wheel rim rear and repeating on opposite side the measurements should be same both sides. If this measurement is out your axle needs aligning and your chain will come off as its not running true.

When aligning chains its important to loosen off the top and bottom axle bolts before attempting the chain adjusters otherwise you will thread the adjusters as it tries to pull a fixed solid axle. Chain adjusters must be adjusted evenly on both sides to keep the axle square otherwise you risk throwing your chain off and damaging your engine.

Chain tension must be done with the rider on the quad bike as each rider weight will change the chain tension needed.

Nut and Bolt Check

• Working from front to rear, ensure all nuts & bolts are tight. Where no nyloc nuts or spring washers are present, ensure thread-locking compound has been used. If none has been used during factory assembly, remove nut or bolt, apply locking compound & re-tighten. Pay particular attention to the following critical safety areas: Wheel nuts, brake calliper bolts (thread lock), Top & rear engine bolts (frame must be hard tight against the engine, use thread lock), chain tensioners, rear shock bolts, handlebar clamp bolts (yokes), Handlebars, brake/ clutch/throttle, swing-arm, front & rear sprocket, Exhaust Bracket Bolts,
• Check all engine hardware is tight, (including but not exclusive): flywheel, inlet manifold, exhaust bolts,
• Fully ensure nothing is touching the exhaust system including fuel lines are tied away.
• Ensure all cables and pipes & wiring are away from moving components such as the wheels, use cable ties where necessary
• Fuel bike & check for fuel leaks

Fill and Check oil level with quad bike in upright position using dipstick. Top up with Lucus Oil 10W 40 semi synthetic motorcycle oil, if necessary

• Adjust tension for both clutch & throttle cables
• Ensure wheels are tight & wheels run true
• Start engine & warm up (using choke if necessary). Set idle speed so engine ticks over comfortably without stalling or racing

(bearing in mind that the pads will need to bed in prior to optimum performance

1 HOUR SERVICE – EXTREAMLY IMPORTANT

• Remove Transport Oil & replace with Lucus Oil 10w 40 4-stroke engine oil
• Re-Adjust throttle cable & clutch cable if required
• Re-tension chain as this will stretch in the first hours of use. This will need continual monitoring.
• Check wheel bearings for any sign of wear of free-play
• Check Engine Idle Speed and adjust if necessary
• Check brake calliper operation & brake pad wear
• Check tyre pressures 4-6 psi

RIDING TIPS FOR LONG ENGINE LIFE - IMPORTANT

Every 4 hours use.

• Do not use the gears which the bike is in motion.
• Check all nuts & bolts & tighten where necessary as above PDI
• Re-Adjust throttle cable & clutch cable if required
• Re-tension chain as this will stretch in the first hours of use. This will need continual monitoring.
• Check wheel bearings for any sign of wear of free-play
• Check brake calliper operation & brake pad wear
• Check spark plug gap ~0.6mm-0.7mm
• Check tyre pressures 4-6 psi

PROBLEM SOLVING

• No spark – Either poor earth or faulty Rotor Coils/CDI/Coil/Lead/Cap/Plug – use moving coil mustimeter to diagnose
• Fuel leaks from overflow – Floats set incorrectly or blocked by debris or sticking
• Engine runs fine, but then starts to misfire – faulty rotor coils/CDI/Coil/Plu
• Engine will not tick over when warm – readjust the engine idle
• Engine will not return to idle & races – sticking throttle cable or idle incorrectly set on the carb.

STORAGE.

• It is advisable to fully service and lubricate the bike prior to leaving the bike unused/unattended for any length of time.
• It is advisable to fully drain the tank and carb of fuel prior to leaving the bike unused/unattended for any length of time.

BUILT QUAD BIKES

Where quad bikes have been pre-assembled you are still required to

1. Nut and bolt check the quad bike before use.
2. Check chain tension is suitable for the weight of the rider.
3. Follow the 1 hour and 4 Hour service

49cc Mini Dirt Bikes and Mini Quad Bikes

98% of problems are caused by incorrect fuel mixture and incorrect 2 stroke oil used. Mix at 25:1 ratio or debris blockage of the fuel tap.

Use a quality semi synthetic motorcycle 2 stroke oil and not gardening 2 stoke oil as gardening 2 stroke is a completely different compound of oil and clogs the spark plugs up and causes them to be difficult to start

NEVER YANK THE PULL STARTER WITH FORCE - You will snap the pull cord and these are not a warranty item. Small short pulls are all you need as the pull start is spring assisted.
Unfortunately " it was already frayed when it arrived" is an excuse we hear of everybody who snaps them. We build and start 100s of mini bikes a week and never snap pull starts.

They only snap in frustration normally because the oil mix is wrong and your relentlessly yanking at it.