Burromax Burromini-Gas TT40 User manual

Owner’s
Manual
Burromini-Gas
TT40
Gas-PoWErED DirT BiKE
R ead and understand this entire manual
before riding!

IMPORTANT!
READ THIS ENTIRE BOOK CAREFULLY BEFORE
OPERATING THIS PRODUCT, THE FIRST TIME.
This vehicle does not conform to Federal Motor Vehicle regulations
and is not intended to be used on public streets, roads or highways.
THE USER ASSUMES ALL RISK INVOLVED IN USING THIS PRODUCT.
Serious injury or death can result from the unsafe operations of this
vehicle. Operator can minimize these risks by using certain safety
equipment such as: safety helmet, goggles, gloves, elbow and knee
pads along with appropriate footwear.
NEVER operate this product in traffic, and always be careful on wet,
frozen, oily or unpaved surfaces. NEVER operate this vehicle while
under the influence of drugs and/or alcohol. Avoid uneven surfaces,
potholes, surface cracks and obstacles that may be in your path.
WARNING:
Never let a child or inexperienced person operate this vehicle.
Never run the engine without proper ventilation as breathing
exhaust fumes can be fatal and carbon monoxide is difficult to detect.
This product should not be used by persons without good vision,
balance, coordination, reflex, muscle and bone strength and good
decision-making capabilities.
Never let a person under the age of 14 operate this vehicle without
proper adult supervision.
The user of this product assumes ALL risks associated with its use.
To minimize these risks, the user must wear safety helmet, goggles,
gloves, elbow and knee pads and appropriate footwear.

INTRODUCTION.................................................................................. 1
IMPORTANT SAFETY INFORMATION.............................................. 2-4
GETTING STARTED............................................................................. 5-6
OPERATING CONTROLS.................................................................... 7
BEFORE RIDING................................................................................... 8-9
BASIC OPERATION .......................................................................... 10-12
Safe Riding Precautions 10
Starting The Engine 10
A Flooded Engine 11
Stopping The Engine 11
Braking Technique 12
Parking and Post -Ride Inspection 12
MAINTAINING YOUR T40................................................................... 13
Important Safety Precautions 13
Maintenance Schedule ...................................................................... 14
Component Locations ....................................................................... 15
Basic Maintenance Procedures.........................................................16-25
Checking and Adding Oil 16
Changing Engine and Jack-Shaft Oil 17
Air Filter 18
Spark Plug Maintenance 19-20
Adjusting The Idle Speed 20
Cleaning The Fuel Tank 21
Drive Chain Maintenance 21
Brakes 22-23
Primary Chain Housing Maintenance 24
Throttle Operation 24
Tires 25
TROUBLESHOOTING........................................................................... 26
PRODUCT WARRANTY........................................................................ 27
EMISSION CONTROL SYSTEM WARRANTY.....................................28-29
contents
NOTE: Manual illustrations are for demonstration purposes only.
Illustrations may not reflect exact appearance of actual product.
Specifications subject to change without notice.

1
INTRODUCTION
Congratulations on choosing your new Burromax TT40 Gas Minibike
Your Burromax Minibike was designed as a recreational vehicle for
off-road use only and by a single rider only. This minibike is easy to use and
is ideal for riders with basic experience.
Before riding, please take your time to get acquainted with your minibike and
how it works. To protect your investment, we urge you to keep it well
maintained. In addition to regular maintenance it is important to observe and
perform all pre-ride and periodic checks outlined in this Owner’s Manual. In
this manual, you will find helpful safety information, instructions and helpful
tips.
As you read through this manual you will find information that is noted with a
NOTICE symbol. This is to point out key bits of information that will help you
avoid damage to your minibike and property around you. This manual covers
basic maintenance procedures as well. For problems with your minibike that
are not covered in this manual, please refer to [email protected].
And from all of us at Burromax, Enjoy your TT40 Minibike!
Contact your dealer or Burromax ([e-mail]) if you have questions.

2
IMPORTANT SAFETY INFORMATION
Your personal safetyand the safety of those around you is our primary concern.
Operating this Gas minibike safely is
an important responsibility and should not be
taken ligh tly .
Burromax has provided you with safe operating procedures and warning labels on
your minibike and in this manual. This information will alert you to potential hazards
that could harm you or others.
It is understood that it is not practical or possible to warn you about all possible
hazards associated with off-road riding and maintaining your minibike. You must
always use your own best judgement.
Safety information is presented in a variety of forms, including:
• Safety labels and tags on the minibike
• Safety messages proceeded by a safety symbol and one
of these three signal words: DANGER, WARNING and CAUTION.
Any of the above labels can indicate a danger where you or someone around you
can be
KILLED or SERIOUSLY INJURED if the instructions that it accompanies
are not followed carefully.
This manual is filled with important safety information, please read it carefully and
be sure that you understand it.

3
IMPORTANT SAFETY INFORMATION
The Burromax TT40 Minibike can provide many years of service and pleasure,
provided you take responsibility for safety, proper maintenance and understand the
challenges you may encounter while riding it.
Fuel Safety
• Do not mix Oil and Gas.
• Always pour fuel outdoors away from sparks or flames.
• Use only containers that are approved for fuel.
• Never smoke or allow others to smoke near the TT40 while you are
working on the engine, or when refueling.
• Carefully clean up all fuel spills before starting the engine.
• Always move at least 10 feet away from the spot of fueling before starting
up the engine.
• Always kill the engine before removing the fuel cap.
• Burromax recommends that you first empty the fuel tank before shipping
or storage to prevent fuel spills.
• Never store your TT40 near open flames like water heaters, furnaces,
electric motors or switches because fumes may become ignited.
Maintenance Safety
• Maintain your TT40 as recommended in this Owner’s Manual.
• Use only quality replacement parts as recommended by the manufacturer.
• Let the engine cool before making any engine or drive train adjustments.
• Clean your TT40 carefully and store in a cool, dry place.
Safe Riding
• Keep hands and feet away from all moving parts.
• Go over the entire unit looking for loose bolt, fuel leaks or any other
problems each time before you ride it.
• Replace damaged parts as soon as you can.
• Use only parts and accessories that are recommended by Burromax.
• If a situation arises that is not covered in this Owner’s Manual, proceed
with caution and use your own good judgement.
Contact your dealer or Burromax ([e-mail]) if you have questions.

4
IMPORTANT SAFETY INFORMATION
As a parent, your child’s safety is your priority. Riding a minibike is very fun, but just
like riding a bicycle, bad decisions can result in injury or death. As a parent, you
can prevent accidents by making informed decisions about if, when and how your
child will ride. Always supervise your child when he/she is riding.
Before you allow your child to ride you need to determine if he/she is ready. Riding
readiness can vary from one person to another. Age and size are not the only
factors that help to determine riding readiness. There are three other factors that
you should consider before deciding if your child is ready to ride.
First, consider your child’s physical ability. A rider must be able to hold the minibike
up, and be able to reach all handlebar controls and steer the minibike accurately.
Second, consider your child’s athletic ability. It is a good idea if they can operate a
bicycle before operating any motorized vehicle. Determine if your child is a good
judge of speed and distance while riding a bicycle and that they react with proper
foot and hand actions. Any person who does not have good coordination, balance
and agility should not at- tempt to ride this motorized minibike.
Finally, determine their mental maturity. It is imperative that you are honest with
yourself when you answer the following questions: Does your child think through
problems and come to logical conclusions? Does your child obey the rules when
they ride their bicycle? If your child makes bad judgements, takes unnecessary
risks and ignores the rules, they should not ride this motorized minibike.
If you have determined that your child is ready to ride please remember the
following points:
• Never let your child ride without a helmet.
• Your child’s safety is your responsibility. Do not take it lightly.
• Never push your child to try things before they are ready.
• Always supervise your child when they are riding.
• Proper maintenance and upkeep of the minibike is key to safe riding.
Any modifications or improper accessories added to the
minibike, using parts that are not manufactured by Burromax can make it unsafe.
Burromax strongly recommends that you do not remove any of the original
equipment or make any modifications that alter the design and/or operation of the
TT40 minibike.

5
GETTING STARTED
Your Burromax TT40 comes with the following items in the shipping carton. When opening
the carton for the first time, be sure you have the following items:
1. TT40 Gas Minibike
2. Owner’s Manual
3. Engine Oil (110ml)
4. Primary Oil (30ml)
5. Tool Kit
Please read and follow these instructions carefully!
1. Carefully remove the TT40 from the Shipping Box
2. When you first take the TT40 out of the box, the HANDLEBARS are not clamped to the
fork to save space for shipping.
3. Place the handlebars in the handlebar clamps. (fig. A) Make sure cables are not twisted or
kinked
4. Center handlebar in clamps and position to fit the rider height. Tighten the bolts using a
6mm Allen wrench. When properly tightened, you should have a small gap in front and
back of each clamp. The handlebars should not move forward or back.
5. Rotate the front fork from side to side making sure that the wires and cable are free.
Squeeze the brake handle a couple times to loosen up the brake. Turn the throttle a
couple times making sure that it returns to idle position on its own when released
6. Install fork cover using 2- Screws M6x12. Route cables and wires on the left side of
the top mounting screw. Make sure you orientate the cover as shown below and tighten
securely.
Do not pull cables!
(A) (B)
PACKAGE CONTENTS
IINITIAL SETUP

6
GETTING STARTED
The TT40 uses a Four stroke engine
Do not Mix Oil and Gas.
Please read instructions below before fueling.
1. Fuel should be regular 87 octane pump gas only
2.Use only approved fuel container.
Make sure container is clean and dry inside
before filling with fuel.
3. Make sure that the engine is not running.
4. Open the fuel cap slowly, so that possible
pressure build-up can be released.
5. Wipe off the fuel cap area to make sure that it is free of dirt and debris.
6. Pour Gas into the fuel tank being careful not to overfill.
7. After fueling, replace the fuel cap and tighten.
8. Clean any spilled fuel off the tank and engine.
Move at least 10 feet away from where you filled up the tank to
get away from spills and fumes.
1. Set the choke to the
START position.
2. Turn the Kill switch to the
ON position.
3. Press the fuel primer bulb several times until you see fuel in the bulb.
4. Holding the left-hand grip, pull the starter briskly. Note: Do not allow it to snap
back, instead, let it recoil slowly.
3. You may want to give it a little throttle by slightly turning the twist throttle.
4. It may be necessary to pull start the motor several times the first time you start it.
5. Once the engine has started and run for 20 seconds, slowly move the choke
lever to the
RUN position.
6. Let the engine warm up for a minute or two before riding.
7. When operating for the first time a 30-minute break in period is recommended.
Operate the mini bike at moderate speeds during the break in period.
NOTE: Extended running with the choke fully on will cause the engine to run
poorly and can cause damage to the spark plug and cylinder wall.
FUELING
STARTING

7
OPERATING CONTROLS
The operating controls of the TT40 are relatively simple, but a rider must to be able
to operate the throttle, brake and other controls. Please become familiar with the
function and the location of each control.
Before starting your TT40, you must be sure that the kill switch is intheON position, the choke
is
inthe START position and that there isfuel inthe primer butt on. The locationsandoperation
information
of each of thesecontrols in shown belo w .
The Kill S wit ch is loca t ed onHandlebars next to the
throttle control
The minibike will not run
w ithout moving the kill switch
to the
ON position.
The Choke Lever is located on the right side of the engine and
is used to start the engine when it is cold. It is used to restrict
the amount of air in the fuel mixture to start easier and warm up.
Flip the lever to the
START position to start, and then as the
engine warms up move the lever to the
RUN position.
The Fuel Primer Bulb is used to start the flow of fuel to the
carburetor and is located blow the choke lever under the
carburetor. It is made of soft clear neoprene to allow you to see
the fuel in the line. Use your finger to push it a several times
when the engine is cool until you see fuel passing through it.
The Pull Starter is used to start the engine. To start the engine
after you have confirmed the readiness of the above three
components, stand on the left side of the minibike holding the
left-hand grip firmly. Using your right hand, pull up sharply on
the pull start grip to pin the motor.
BEFORE STARTING
KILL SWITCH
CHOKE LEVER
FUEL PRIMER BULB
PULL STARTER

8
BEFORE RIDING
Before you ride you must be certain that you are ready to ride. Below is your
pre-ride checklist. Be sure to review all the topics below and determine your
readiness to ride.
1. Have you completely read, and do you thoroughly understand this owner’s
manual?
2. Have you found all the safety messages on your minibike and do you
understand them?
3. Do you understand the location of, and how all the operating controls on
your minibike work?
4. Are you in good mental and physical condition?
5. Are you drug and alcohol free?
6. Are you wearing a helmet that fits properly?
7. Are you wearing eye protection?
8. Are you wearing sturdy shoes and protective clothing?
9. Is your minibike in good working order?
Additional suggested protective clothing.
1. Gloves to protect your hands.
2. Sturdy riding boots that support your ankles.
3. Knee and elbow pads.
As a reminder:
Never ride without a helmet. Helmets significantly reduce the
number and severity of head injuries. An approved DOT motorcycle helmet is the
most important part of your safety gear. Choose one that fits properly and is snug
on your head. Motorcycle dealers can help in selecting a good quality helmet with
proper fit.
PRE-RIDE CHECKLIST

9
BEFORE RIDING
1. Check tire pressure with a tire gauge. Recommended tire pressure is
30-40PSI for both tires.
2. Check engine oil level to be full.
3. Make sure you have added the proper amount of primary jack-shaft oil (30ML).
4. Check rims to make sure they are not bent or damaged.
5. Inspect the engine for fuel and oil leaks.
6. Check the level of fuel in the gas tank.
7. Check the drive chain to see if it needs to be lubed or tightened.
8. Check the brake to be sure that they are working properly.
9. Look over the entire minibike for loose nuts and bolts.
10. Check the throttle to be sure it moves freely and returns to the idle position on
its own when released.
11. Be sure that the handlebars turn freely.
Failure to properly maintain your TT40 minibike can lead to a
crash in which you can be seriously injured or killed. Always perform a
pre-ride inspection on your minibike and keep it in good condition to get the
most out of your Burromax TT40
The TT40 utilizes a 4 stroke engine.
Never mix the Oil and Gas together it will severely affect the Starting and running
of your TT40 Mini bike.
NOTE: Extended running with the choke fully on will cause the engine to run
poorly and can cause damage to the spark plug and cylinder wall.
PRE-RIDE INSPECTION

10
BASIC OPERATION
The following section of the manual provides some basic information on
how to begin riding your TT40 Gas Minibike. We will cover how to start and stop the
engine, how to use the throttle and brake and what you should do when you finish
riding.
B efore riding this minibike, be sure that you have read and understand this entire
owner’s manual up to this point, including the sections that are titled
Important
Safety Information
and Before Riding. Even if you have ridden other minibike in
the past, take time to become familiar with how this minibike runs and how it
handles. Different minibikes have different handling characteristics. Always
practice in a safe area until you feel comfortable with how this minibike runs and
handles.
For your safety, NEVER run the engine in an enclosed space
with poor ventilation, such as a garage. The exhaust contains poisonous carbon
monoxide which can collect rapidly and cause illness or death.
This minibike is not equipped with lights. Do not ride after dark.
1. Move the kill switch to the
ON position.
3. If the engine is cold, flip the choke lever into the
START position.
If the engine is warm, you may not need to use the choke at all.
4. Press the fuel primer bulb a several times.
5. Stand on the left side of the minibike and hold the left-hand grip.
6. Using your right hand, pull the starter handle upward sharply until it starts,
lowering the handle back to the recoiled position gently.
7. Once the engine starts to run, let it warm up by operating the throttle for
about 20 seconds, slowly move the choke lever to the
RUN position.
8. Let it warm up a little. Once the engine is warm, the idle will smooth out and the
minibike will be ready to ride.
NOTE: Extended running with the choke fully on will cause the engine to run poorly
and can cause damage to the spark plug and cylinder wall.
SAFE RIDING PRECAUTIONS
STARTING THE ENGINE

11
BASIC OPERATION
If the engine fails to start after repeated attempts, it may mean that it is flooded
with excess fuel. A common indication of a flooded engine is a strong smell of
fuel around the minibike. Follow the steps below to clear a flooded engine.
1. Switch the choke lever to the RUN position.
2. Twist the throttle all the way in to the full open position.
3. Move the kill switch to the OFF position.
4. Using the pull starter, crank the engine over 10 or 15 times.
5. Move the kill switch back to the ON position.
6. Start the minibike using the pull starter and NO
To stop the engine, press the kill switch to the OFF position. The engine will stop.
A FLOODED ENGINE
STOPPING THE ENGINE

12
BASIC OPERATION
This section will cover basic braking technique for your minibike. To slow
or stop, squeeze the brake lever firmly and smoothly. Gradually increase your
braking pressure as you feel it is needed.
Always think ahead and allow yourself enough room to stop safely. Just be careful
to apply braking power carefully to avoid sending the minibike into a skid which will
cause you to lose control.
If you apply the brake too quickly and start to skid, release the brake to regain
control and then apply braking power carefully.
When riding on wet, or loose surface conditions your braking power can be reduced
greatly, and it will be much more likely to put the minibike into a skid and lose
control. If the surface is wet or loose, you must reduce your speed and allow more
room to stop safely.
Avoid jamming on the brake suddenly or accelerating too quickly as either of these
actions can cause you to lose control of the minibike.
With the minibike stopped, turn off the kill switch, flip down the kickstand and lean
the minibike over on it to park. Always park your minibike on a flat surface to avoid
tipping over. Then check over the minibike to make sure there are no fuel leaks, oil
leaks, damaged parts or loose nuts and bolts.
BREAKING TECHNIQUE
PARKING AND POST-RIDE INSPECTION

13
MAINTAINING YOUR TT40
Keeping your minibike in perfect operating condition is essential to your safety. It is
also the best way to protect your investment, get maximum performance, avoid
breakdowns and have more fun. To help keep your minibike well maintained, the
maintenance schedule on the following page will provide you valuable information
that will help you keep your minibike in good and safe operating condition and
avoid injury.
The service intervals in this section are based on average riding conditions. More
frequent service is needed if you subject your minibike to severe use, riding in
unusually wet or dusty conditions.
Improper maintenance of this minibike or failing to correct a
problem before you ride can cause a crash in which you could be seriously injured
or killed. Always follow the inspection and maintenance routines recommended in
this manual.
Remember, proper maintenance of your minibike is the responsibility of the owner
and failure to do so can cause your warranty to be void.
Note to parents: As a parent, it is up to you to make sure the minibike is properly
maintained and in safe operating condition. For youngsters, learning how to take
care of any motorized vehicle and perform basic maintenance can be an important
part of their riding experience. However, if you allow a youngster to
perform or assist in any maintenance task, such as filling the fuel tank, you need to
provide close supervision to make sure the task is performed safely.
Make sure the engine is off before you begin any maintenance or repairs. This will
help eliminate the following hazards:
1.
Carbon monoxide poisoning from engine exhaust. Be sure
you have good ventilation whenever you have the engine running.
2.
Burns from hot engine parts. Let the engine and exhaust cool before you
touch them.
3.
Injury from moving parts. Do not work on the engine while it is running
unless instructed by this manual to do so.
Be sure you have all the tools needed and understand the procedure before
starting. Always be careful around gasoline. Keep flames and sparks away.
IMPORTANT SAFETY PRECAUTIONS

14
MAINTENANCE SCHEDULE
To keep your minibike safe and reliable when you ride, regular inspections and service is
required. Below you will find a maintenance schedule that explains when components need
to be inspected or serviced. This information lists items that can be performed with basic
mechanical skills and hand tools. In addition, the maintenance schedule will list items that
are more involved and could require taking it to your local Service Center.
Contact us at i[email protected] for a service center.
Because your minibike is not equipped with an odometer, service intervals are expressed in
terms of riding hours. We suggest that you keep a record of the amount of time you spend
riding your minibike to avoid missing needed maintenance procedures.
Note: Your minibike may require more frequent service if you subject your mini bike
to severe use or ride in particularly wet or dusty conditions.
TT40 Maintenance Chart
Each
use 10Hrs 50 Hrs 100 Hrs 300 Hrs
Check Brakes
x
Check Throttle x
Lube, check/adjust chain
x
Check all nuts and bolts for
tightness x
Engine Oil
110ML
Check
x
Replace x x x
Jack-Shaft Oil
30ML
Check
Replace x x x x
Air Filter
Check
x
 Clean x

Replace
x
Spark Plug
 Clean/Adjust x x

Replace
x
Check/Adjust Idle Speed x
 Check/Adjust Valve
Clearance
x
 Clean Fuel Tank and Filter x
Check Fuel Tube
x
 Can be performed by owner with proper tools and knowledge, otherwise consult a service center.
 Recommended to be performed by service center.
Contact us at i[email protected] for a service center.

15
Component Locations

16
Basic Maintenance Procedures
SAE 10W-30 is recommended for use in most climates. See the oil/air temperature chart to
help you choose the best oil for your climate:
SAE Viscosity Grades
AMBIENT TEMPERATURE
Your mini-bike does not need oil additives. Only use the
recommended oil. Do not use oils with graphite or molybdenum additives or oils
displaying the API circular logo that is labeled “energy conserving”. These engine oils may
adversely affect engine performance
Engine Oil
1. Park the dirt bike on a firm level surface.
2. Clean around the oil fill cap and any nearby
surfaces.
3. Unscrew the oil fill plug and wipe it clean.
4. Hold the minibike upright so that it is not resting
on the kick stand.
5. Insert the oil fill cap back into the engine until it
seats, but do not screw it in.
6. Remove the oil fill cap and check the oil level. If
the oil level is at or near the upper mark (1), you
do need to add oil. If the oil level is below or
near the lower level mark (2), add the
recommended oil until it reaches the upper
level mark (1).
Do not overfill.
7. Insert the oil fill cap and screw it in tightly.
8. Start the engine and check for oil leaks.
Checking and Adding Oil

17
Basic Maintenance Procedures
Adding Jack-Shaft Oil for the first time
1. Park the dirt bike on a firm level surface.
2. Clean around the oil fill cap.
3. Unscrew the oil fill plug using an 8mm hex
wrench and wipe it clean.
4. Hold the minibike upright so that it is not resting
on the kick stand.
5. Fill with the recommended amount of oil.
Do not over fill
6. Insert the oil fill cap back into the jack-shaft
housing and tighten.
1. Park the minibike on a firm level surface.
2. Remove the oil fill cap/dipstick.
3. Place an oil drain pan under the
engine/jack-shaft housing.
4. Unscrew and remove the oil drain bolt.
5. Lean the minibike towards the drain plug to
make sure all oil drains out.
6. Examine the sealing washer for damage and
replace if any damage is present.
7. Install the oil drain bolt and tighten. Be careful
not to over tighten drain plugs.
8. Pour the recommended oil into the engine or
jack-shaft housing and fill until the oil level is
correct. The jack-shaft does not have an oil
level check, you must drain and add the correct
amount. (1oz / 30 ml)
9. Install the oil filler cap/dipstick and tighten
securely.
10. Start the engine and let it run for a minute or
two.
11. Shut off the engine and check the engine oil
level, add oil if needed. Do not overfill.
12. Check for any oil leaks.
13. Dispose of waste oil in an approved manner
Changing Engine and Jack-Shaft Oil
NOTICE
The jack-shaft does not have an oil level check. You must drain out and
refill with the correct amount. (1oz / 30 ml)