Rokon Trail-Breaker User manual

Illustrated
Owners and Parts Manual
ROKON International Inc.
50 Railroad Avenue
Rochester, NH 03839
Tel: [phone]
Fax: [phone]
e-mail:[e-mail]
web site: www.rokon.com
Made In
The USA
©2002-7 Rokon International, Inc. Printed in U.S.A. ROKON® and its logo are registered trademarks. Rev. 4

Welcome to the growing group of ROKON owners. All operators must read and familiarize
themselves with this owners manual and the safety information.
The ROKON Warranty Statement is enclosed with this manual. For it to be validated, the
complete ROKON Utility Vehicle Registration Card must be signed and returned to
ROKON within 10 days of the date of purchase.
We congratulate you on your decision to purchase a ROKON Utility Vehicle. By following
the procedures and suggestions outlined in this manual, you will be rewarded with many
hours of reliable, gratifying performance that others have come to expect from ROKON
Utility Vehicles.
ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A. Copyright 2002-7

TABLE OF CONTENTS
SECTION: Page
1. Safety Information 3-4
2. Description and Machine Identification 5
3. Control Functions 6-7
4. Pre-Operation Checks 8
5. Operating Your Rokon 9-10
6. Periodic Maintenance and Adjustment 11-18
7. Repair Procedures 19-22
8. Torque and other specification charts 23
9. Limited Warranty 24
10. Illustrated Parts Manual 25-56
BEFORE YOU OPERATE YOUR NEW ROKON, THE
FOLLOWING IMPORTANT POINTS MUST BE OBSERVED.
1. Children under 16 should not operate a ROKON.
2. Carefully read and follow the instructions in the safety section of this manual.
3. Carefully read and follow the setup procedure on the yellow card
attached to your ROKON (See yellow card instructions, also on page
56 of this manual).
4. Follow the Pre-Operation Checklist.
ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A. Copyright 2002-7

Always wear an approved motorcycle helmet that fits properly, eye protection (goggles
or face shield), gloves, sturdy boots, long sleeve shirt, jacket and pants while operating a
ROKON.
Never consume alcohol or drugs before or while operating a ROKON.
The ROKON is a go slow vehicle. Never operate at speeds too fast for your skills or the
conditions. Always operate at a speed that is appropriate for the terrain, visibility and
operating conditions and your experience.
DANGER-SERIOUS INJURY MAY RESULT! Never attempt wheelies, jumps or other
stunts of any kind while operating a ROKON.
Always keep both hands on the handlebars during operation.
Always go slow and be extra careful when operating on unfamiliar terrain. Always be
alert to changing terrain conditions when operating a ROKON.
Never operate on excessively rough, slippery or loose terrain until you have learned and
practiced the skills necessary to control the ROKON on such terrain.
Never operate on hills too steep for the ROKON or for your abilities. Never exceed a
60% grade (or 31 degrees). Practice on smaller hills before attempting larger hills.
Always follow proper procedures for climbing hills as described in this manual. Check
the terrain carefully before you start up any hill. Never climb hills with excessively slip-
pery or loose surfaces. Shift your weight forward when on an incline.
Always follow proper procedures for going down hills and for braking on hills as de-
scribed in this manual on pages 9 and 10. Check the terrain carefully before you start
down any hill. Shift your weight rearward. Never go down a hill at high speed. Shift into
1st range and keep the torque converter engaged for engine braking as described on
page 9 in this manual. Use the rear brake only in down hill corners. Apply the rear brake
before the front brake when going straight down.
Always maintain proper tire pressure.
Never modify your ROKON. Use only ROKON parts. Follow instructions, and properly
install ROKON parts.
Section 1 Safety Information
3
ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A. Copyright 2002-7

Never exceed the stated load capacity. Cargo should be properly distributed and se-
curely attached. Reduce speed and follow instructions in this manual for carrying cargo
or pulling a trailer. Be careful to allow greater distances for braking when carrying cargo
or operating with a trailer.
Read your engine manual completely and follow all safety instructions.
WARNING:
Potential Hazard- Improper Handling of Gasoline
can catch fire and you could be burned.
Always turn off the engine when refueling. Do not refuel right after the engine has been
running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler
when refueling. Never refuel while smoking, or while in the vicinity of sparks, open
flames or other sources of ignition such as the pilot lights of water heaters and clothes
dryers. When transporting the machine in another vehicle be sure that it is kept upright
and that the fuel cock is in the “OFF” position (see page 6 of manual). Otherwise, fuel
may leak out of the carburetor and flood the engine.
Gasoline is poisonous and can cause injuries. If you should swallow some gasoline
or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor
immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills
on your clothes, change your clothes.
WARNING
Potential Hazard- Starting or running the engine
in a closed area.
Exhaust fumes are poisonous and may cause loss of consciousness and death within
a short time. Always operate your machine in an area with adequate ventilation.
Section 1 Continued Safety Information
WARNING:
Potential bodily injury.
Never operate a ROKON without
the chain guards and side covers
in place and securely attached with
all fasteners properly tightened.
ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A. Copyright 2002-7
4

Record the Vehicle Identification Number and Engine Number in the spaces below to
facilitate ordering spare parts or for reference if the vehicle is stolen.
VIN
Engine Number
Section 2 Description and
Machine identification
The Vehicle Identification Number
is on the center frame tube beneath
the driver seat.
The Engine Number
is on the front of the
engine facing the
front wheel.
ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A. Copyright 2002-7 5

REAR
The Shut Off Switch is black in color and is located on the left hand side of
the handlebar. Pressing the “kill” switch will shut off the engine. This is a
safety feature and will allow the operator to immediately shut off the engine
in an emergency.
The Fuel Petcock located on the right hand side under the fuel tank shuts
off fuel flow to the engine. The down position is for fuel flow. The up position
shuts fuel off. Shut the fuel off when storing or transporting your ROKON.
Throttle. The engine is accelerated by twisting the throttle grip on the right
hand side of the handlebar counterclockwise. The throttle grip is spring
loaded and will automatically close the throttle and slow the engine when
released.
Brakes. The ROKON Utility Vehicle is equipped with separate front and rear disc brakes.
The left brake lever is for the
rear brake. The right brake lever is
for the front brake.
The Choke is used to start a cold engine and should be in the rearward
position to choke. It is located on the right hand side of the engine. As soon
as the engine starts, the choke should gradually be moved forward as
the engine warms up. It should be left fully forward for regular operation.
FRONT
Section 3 Control Functions
ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A. Copyright 2002-7
6

Section 3 Continued Control Functions
Recoil Starter. Firmly grasp the handle and pull slightly until engagement can
be felt. Then pull forcefully, being careful not to pull the rope all the way out.
Return the starter rope gently.
Rider Seat Suspension. The seat suspension spring can be adjusted to suit
the rider’s weight and riding conditions. Adjust the spring per load as follows:
To increase the spring preload, turn the adjuster clockwise. To decrease the
spring preload, turn the adjuster counterclockwise.
Transmission: The three range transmission is a ratio selector and when
coupled with the automatic torque converter, gives the vehicle extremely
broad capabilities, from steep climbing to normal transporting. The torque
converter provides a large overlap of speed and torque between gears.
This makes frequent gear changes unnecessary. Therefore, the trans-
mission has not been designed to shift in motion. STOP THE VEHICLE
BEFORE SHIFTING. Shift only at low idle or when the engine is off. Feel
the gears into engagement, rocking the bike, if necessary, to synchronize
the gears. The shift pattern is from inside out: 3-N-2-N-Low.
Automatic Torque Converter: The torque converter is designed especially
for ROKON and provides smooth automatic clutching and ratio
changing in response to throttle control and terrain requirements. The
front drive pulley tends to shift into high as engine speed is increased.
The rear driven pulley follows this speed change. If torque requirements
increase, the cam in the torque-sensing rear pulley overrides the front
pulley and forces a down shift without a loss of engine revs and power.
WARNING:
Potential Hazard- Starting the engine in gear
could cause the ROKON to move forward unexpectedly.
PUT THE TRANSMISSION IN NEUTRAL BEFORE
STARTING THE ENGINE. Stand on the left hand side,
put the front brake on with two fingers of your left hand, throttle
closed, reach over the ROKON and pull the starter handle.
ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A. Copyright 2002-7 7

Section 4 Pre-operation Checks
Before using this machine, check the following points.
Front and Rear Brake. Check brake action. Check pucks to see that they are not over
worn. There should be visible brake material on both sides of the brake disc. See
Section 6.
Fuel Tank. Check fuel level. Fill as necessary. Use super unleaded for altitudes above
10,000 ft.
Engine Oil. The engine holds .6 qt. of SAE10W30/40 motor oil. Fill to the dipstick “full”
line.
Miter Box and Transmission. They are filled at the factory and need not be checked at
the start. The miter box should have 2.5 oz. of EP 80W90 gear lube oil. The transmis-
sion takes 6 oz. of EP 80W90 gear lube oil. The transmission has a fill to plug near the
bottom of the transmission( shown on page 46). There is no fill level for the miter box.
Over filling of either the miter box or transmission will result in leakage.
Throttle. Check for proper throttle cable operation. Look for smooth response to twist
action.
Wheels and Tires. Check Tire pressure, wear and damage.
Fittings and Fasteners. Check all fittings and fasteners.
Drive Chains. Check chains for tension and lubrication. Adjust tension for 1/2” - 3/4”
deflection at mid point.
Engine Manual. Read your engine manual completely and follow all instructions.
FAILURE TO INSPECT YOUR ROKON BEFORE OPERATION
INCREASES THE POSSIBILITY OF AN ACCIDENT OR EQUIPMENT
DAMAGE. ALWAYS INSPECT YOUR ROKON EACH TIME YOU USE IT
TO MAKE SURE IT IS IN SAFE OPERATING CONDITION.
ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A. Copyright 2002-7
8

Section 5 Operating Your ROKON
When starting your ROKON, place the range selector in neutral.
Stand on left hand side, put the front brake on with two fingers of
your left hand, throttle closed, reach over the Rokon and pull the
starter handle. For a cold start put the choke on. Once the engine
turns over, set the choke off. Pull on the starter again and the
vehicle will start. Engage the three-range selector in the desired
gear range. Put the ball of the foot, rather than the instep on the footrest. Accelerate and
ride. Use braking as necessary. Pre-plan your route before attempting to negotiate
difficult terrain. Lean into the hill when climbing switch backs. Descend steep slopes at
slow speed in low range. Apply rear brake pressure before front brake application.
WARNING
Potential Hazard - Failure to use extra care when
operating a ROKON on unfamiliar terrain. Go slow
and be extra careful on unfamiliar terrain. You can
come upon hidden rocks, bumps, or holes, without
enough time to react. Always be alert to changing
terrain conditions when operating a ROKON.
Traversing a sloping surface requires you to properly position your weight
to maintain proper balance. As you travel across or up a slope, lean your
body in the uphill direction. It may be necessary to correct the steering when
riding on loose surfaces by pointing the front wheel slightly uphill. When
riding on slopes, be sure not to make sharp turns either up or down hill,
which could cause a ROKON to turn over and cause the rider injury.
When riding downhill, shift your weight as far to the rear and uphill side
as possible. Use low gear and engage the throttle slightly to allow the
engine compression to provide braking. Whenever possible ride straight
downhill. Turn into corners with the rear brake only, so as not to slide the
front wheel and lose steering control.
ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A. Copyright 2002-7 9