CROSSRUNNER 50 ATV Installation instructions

CROSSRUNNER 50
ATV - All Terrain Vehicle
Age Category: Youth Model Y-6
Only riders age 6 years or older and less than 100 lbs may ride this bike
REASSEMBLY MANUAL
Note: This ATV as fully assembled and tested at the CROSSRUNNER factory.
It as partially disassembled before shipping. This manual gives specific
instructions on ho to fully re-assemble and check the unit.
Follo all steps closely to assure a safe and long lasting vehicle!
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CROSSRUNNER 50 ATV
ReAssembly Guide
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CROSSRUNNER 50 ATV
ReAssembly Guide
ATTENTION
:
Always read every hing before doing any hing.
This will help you o know ha you have access
o all he ools, informa ion, and help you may
need o perform all he s eps ou lined in his
manual. Your a en ion o de ail is cri ical in
providing a safe and reliable produc o your
cus omer. There canno be enough emphasis
placed on safe y when assembling or servicing
his ATV. You will be referencing he Owner’s
Manual, he ba ery service ins ruc ions, and he
ire pressure informa ion s icker on he fron
fender as well as he Re-assembly Manual during
his procedure. If you have any ques ions or
concerns per aining o he assembly or he
informa ion found in his bookle , please call
888-520-7222
NOTE: This ATV should be assembled by he
selling dealer only. The end user should never
do he final assembly or inspec ion of his ATV.
© Copyrigh Nor h American Impor s, LLC
This work may no be copied and dis ribu ed wi hou express wri en consen .
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CROSSRUNNER 50 ATV
ReAssembly Guide
1. Unpack. Remove shrink rap, packing straps, and card board
box cover. Remove all bolts attaching metal frame ork to steel base.
Untie ires holding tire and heel assembly to metal frame. See that
bolts are removed that attach handle bar mounting plate and bumpers
to metal frame, if applicable, before attempting to lift metal frame
ork off of base. Carefully lift metal frame ork straight up to remove,
taking care not to scuff fenders or bumpers hile removing. This should
not be attempted by one person alone. T o people, lifting together,
can remove the frame ork ithout causing damage to the ATV or harm
to themselves. Remove small box from shipping frame base containing
all hard are, nuts, bolts, tool kit, battery and acid.
S ep1-Fig1-Unpack
S ep1-Fig2-Included par s
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CROSSRUNNER 50 ATV
ReAssembly Guide
2. Each ATV is shipped ith a desiccant bag that is designed to
absorb moisture during shipping. It is of no further value once the
shipping container is opened and should be discarded immediately to
avoid being played ith by children or pets.
S ep2-Fig1-Desiccan bag
3. Set parking brake for rear heels to prevent ATV from rolling off
packing frame base. Lift and support the front end of the ATV ith a
suitable jack and jack stand that allo s the vehicle to remain stable
hile attaching the front heels. Install the t o front heels using the
lug nuts supplied. Never use any other type lug nut to attach heels
than hat as designed for the specific type heel and ATV.
S ep3-Fig1-Se parking brake
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CROSSRUNNER 50 ATV
ReAssembly Guide
S ep3-Fig2-Jack suppor
4. Evenly snug each lug nut by hand in a star pattern. Install the
heel center caps onto the front hub asher snapping firmly into
place. Final heel torque must be done hen ATV is sitting on flat
ground. DO NOT attempt to perform final heel torque hile ATV is
supported on a jack stand.
S ep4-Fig1-Hand ighened lug nu s
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CROSSRUNNER 50 ATV
ReAssembly Guide
S ep4-Fig2-Ins all cen er cap
5. WARNING! You must use an air gauge that has increments
smaller than 1 PSI to complete this step. Improperly inflated tires can
cause loss of control. Use the valve core tool supplied ith the ATV tool
kit to tighten the valve core in each valve stem before attempting to
add air. Inflate the tires to seat the bead, taking care not to exceed the
tire manufactures recommendation (printed on the tire side all) for
maximum pressure to seat the bead. Release air until the correct
pressure is noted on the air gauge, according to the tire pressure
information label on the front fender of the ATV. Check each valve core
for leaks and install valve stem cap.
S ep5-Fig1-Valve core ool
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CROSSRUNNER 50 ATV
ReAssembly Guide
S ep5-Fig2-Air gage wi h .5 pound incremen s
6. Remove jack or support under front end of ATV and let it rest
on all 4 heels, release parking brake and roll off metal shipping frame
onto flat, level surface.
7. Reset the parking brake and perform the final heel torque
procedure. Torque all lug nuts to 26 Ft/Lbs. using a torque rench
ith the appropriate increments. Proceed in a star or criss-cross
pattern to assure uniform torque results. Install center caps on rear
heels of ATV. Attach front bumper ith bolts provided, if applicable
to your model, taking care to properly snug all bolts adequately and not
over tighten.
S ep7-Fig1-Wheel orque
S ep7-Fig2-Fron bumper moun ing
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CROSSRUNNER 50 ATV
ReAssembly Guide
8. Install handle bars ith the bolts and hard are provided. See
that knurled areas on handle bars are evenly spaced bet een the t o
halves of the pinch mount supports. Lightly snug attaching bolts and
then position handle bars at the desired angle best suited for the
comfort and safety of the rider so that all hand controls are easily
accessed and operated. The angle of the hand controls is adjustable, as
ell, by loosening the scre s on the underside of the control and
pivoting to the desired position, then tightening scre s. Turn heels to
full left and full right positions to assure adequate clearance for the
rider’s legs and to check for binding cables or iring. Finish tightening
handle bar mounting bolts evenly in a criss-cross pattern and torque to
28 Ft/Lbs.
S ep8-Fig1-Torque handle bar bol s
S ep8-Fig2-Adjus hand con rols
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CROSSRUNNER 50 ATV
ReAssembly Guide
9. Install foam protection pads and cover on center bracket
attached to handle bars.
S ep9-Fig1-Ins all handle bar pad
10. All ATV’s are shipped ith the fuel lines unhooked. Connect the
fuel supply line, coming from the fuel tank, to the fuel inlet port on the
carburetor securing it ith the spring clamp provided on the fuel line.
Make sure the fuel line is routed in a manner to avoid kinks and to
allo for the proper gravity feed from the fuel tank. Do not run the fuel
line near any part of the exhaust or hot section of the engine and take
care to tuck it in a ay from the rider’s feet and legs so that it cannot
be snagged.
S ep10-Fig1-Fuel line rou ing
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CROSSRUNNER 50 ATV
ReAssembly Guide
11. Inspect the fuel drain hose connected to the bottom of the
carburetor at the fuel bo l to assure that it is free of kinks and is
clamped or tie rapped into place. This hose should al ays be heading
in a do n ard direction. See that the drain scre in the bottom of the
fuel bo l is seated in the closed position before adding fuel.
S ep11-Fig1-Fuel drain hose rou ing
S ep11-Fig2-Tigh en fuel drain screw
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CROSSRUNNER 50 ATV
ReAssembly Guide
12. Install left engine side panel ith the 3 scre s and threaded
clips provided.
S ep12-Fig1-Side panel a achmen
13. Caution! Battery acid is very caustic. Gloves and protective
clothing should be orn at all times hen orking ith battery acid.
Any contact ith skin or clothing should be flushed ith ater
immediately. Place battery on rubber or ood surface and carefully fill
battery according to instructions provided ith the battery. When the
battery is full, install the cap and flush ith ater any acid that may be
on or around battery and then test for proper voltage. If the battery
meets the voltage specs called for in the battery instructions hen
tested, install in ATV. The RED cables are positive (+) and the GREEN
cables are negative (-). Connect and tighten all battery cable
connections and see that the cables or any iring cannot be pinched
hen the battery cover is bolted into place. The battery has a dry
charge and should meet the 12.5-volt spec hen filled ith electrolyte.
If it does not meet the spec, charge according to the information
packaged ith the battery and retest.
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CROSSRUNNER 50 ATV
ReAssembly Guide
S ep13-Fig1-Ba ery fill
S ep13-Fig2-Ba ery ins alla ion
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CROSSRUNNER 50 ATV
ReAssembly Guide
S ep13-Fig3-Ba ery cover re ainer
14. Remove all plastic protective covering from shocks, seat, lights,
handle bars, etc.
15. Inspect hose and cable routing for emission, brake, and fuel
systems. Make sure that all are secured and not able to bind, kink, or
be pinched. Keep them at least 1” or more a ay from any contact ith
engine or exhaust.
S ep15-Fig1-Example of secured cable
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CROSSRUNNER 50 ATV
ReAssembly Guide
16. Inspect throttle and brake cable free play adjustments. Confirm
that all locking nuts for cables are tight to avoid loss of adjustment.
See Service Manual for adjustment procedure if necessary.
S ep16-Fig1-Thro le cable free-play adjus men
S ep16-Fig2-Fr brake adjus men
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CROSSRUNNER 50 ATV
ReAssembly Guide
S ep16-Fig3-Rear brake cable free-play adjus men
S ep16-Fig4-Rear Brake adjus men
17. Inspect all other critical nuts and bolts to see that they are
secure even if you did not install them. Next, inspect headlight and
brake light operation, here applicable.
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CROSSRUNNER 50 ATV
ReAssembly Guide
18. Add fuel, turn fuel valve to ON position and inspect for leaks.
Install gas cap on fuel tank and run vent hose in front of tank, do n and
a ay from rider to direct vented fumes belo . Inspect oil level in
engine crankcase and brake fluid level in master cylinder reservoir.
S ep18-Fig1-Fuel ven hose
S ep18-Fig2-Oil fill loca ion
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CROSSRUNNER 50 ATV
ReAssembly Guide
S ep18-Fig3-Brake fluid reservoir
19. IMPORTANT! To start ATV, make sure parking brake is set, move
choke lever to closed position, hold front brake lever in, turn ignition
key to on position, flip start s itch to run, push yello start button to
engage starter. If engine does not spin over it may be necessary to push
the “energize button” on the remote kill s itch, atch for the RED
light on the remote, then engage starter button.
S ep19-Fig1-Remo e kill swi ch
20. After ATV is started, closely inspect for any fuel or oil leaks.
Confirm that parking brake holds adequately ith moderate po er
applied.
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CROSSRUNNER 50 ATV
ReAssembly Guide
© Copyrigh Nor h American Impor s, LLC
This work may no be copied and dis ribu ed wi hou express wri en consen .
19

CROSSRUNNER 50 ATV
ReAssembly Guide
Printed in USA
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