Thumpstar ATV 70CC User manual

MANUAL # 3627

Owner’s Manual
This vehicle is designed and manufactured for off-road use only.
It is illegal and unsafe to operate this machine on any public street, road
and highway.
This vehicle complies with all applicable off-road noise level and spark
arrestor laws and regulation in effect at the time of manufacture.
Thumpstar reserves the right to make changes at any time without
notice and without incurring any obligation.
This publication includes the latest production information available
before printing.
No part of this publication may be reproduced without written permission.
Please check your local riding laws and regulations before operating
this machine.
FOR OFF-ROAD USE ONLY
atv 70cc
atv 125cc
atv 250cc

Contents
These pages give an overview of the contents of your owner’s manual
Introduction ............................................................................................ 1
A Few Words About Safety ..................................................................... 2
Safety Information .................................................................................. 3
Safety Labels ............................................................................................ 4
Pre-Operation Checks ........................................................................... 13
Fuel .................................................................................... 15
Engine Oil .......................................................................... 15
Radiator ............................................................................. 15
Front And Rear Brakes ....................................................... 15
Throttle Lever ..................................................................... 16
Drive Chain ........................................................................ 16
Tires ................................................................................... 16
Chassis Fasteners ................................................................ 17
Instrument, Lights And Switches ......................................... 17
Operation - ATV 70 .............................................................................. 18
To Start Out And Accelerate ................................................. 18
To Decelerate ....................................................................... 18
Engine Break-In ................................................................... 19
Operation - ATV 125 ............................................................................ 20
Remote Engine Stop Switch .................................................. 20
Break-In .............................................................................. 22
Inspection Before Riding ...................................................... 23
Starting The Engine ............................................................. 24
Starting Off ......................................................................... 26
Braking ............................................................................... 27
Turning ............................................................................... 27
Skidding .............................................................................. 28
On Hills ............................................................................... 29
Traversing A Slope .............................................................. 31
Riding Through Water ........................................................ 31
Operation - ATV 250 ............................................................................ 32
Starting A Cold Engine ....................................................... 32
Starting A Warm Engine ..................................................... 33
Shifting ............................................................................... 33
To Start Out And Accelerate ................................................ 34
To Decelerate ...................................................................... 35

Contents
Engine Break-In .................................................................. 35
Owner’s Manual And Tool Kit ............................................. 36
ATV 70 ................................................................................................... 37
ATV 70 - Control Functions .................................................................. 37
Main Switch ...................................................................... 38
Throttle ............................................................................. 38
Handlebar Switches ........................................................... 39
Engine Stop Switch ............................................................ 39
Start Switch ........................................................................ 39
Rear Brake Lever ............................................................... 40
Parking Brake .................................................................... 40
Speed Limiter .................................................................... 41
Seat .................................................................................. 41
Fuel Tank Cap ................................................................ 42
Front Brake Lever ........................................................... 42
Front Shock Absorber Adjustment ................................... 43
Rear Shock Absorber Adjustment ..................................... 43
ATV 70 - Periodic Service ..................................................................... 44
ATV 70 - Component Inspection ......................................................... 46
Engine ................................................................................. 46
Engine Oil ........................................................................... 46
Idle Speed Adjustment ......................................................... 47
Throttle Speed Adjustment ................................................... 48
Brake Lever Lubrication ...................................................... 49
Fuse Replacement ................................................................ 49
Battery ................................................................................ 50
Replacing The Headlight Bulb .............................................. 50
ATV 125 ................................................................................................ 51
ATV 125 - Control Functions .............................................................. 52
Left Handlebar .................................................................... 52
Throttle Lever ..................................................................... 53
Choke Lever ........................................................................ 53
ATV 125 - Equipment And Adjustments ............................................ 54
Fuel Tank Cap ..................................................................... 54
Stopping The Engine ........................................................... 55
Parking The Vehicle ............................................................ 55
Important Advice To The Parents ........................................ 55

Contents
Proper Clothing And Protective Gear ................................... 56
Familiarization With The Vehicle ........................................ 56
Starting Off And Stopping ................................................... 56
Putting It All Together ......................................................... 58
ATV 125 - Inspection And Maintenance ............................................ 58
Maintenance Schedule ......................................................... 58
Periodic Maintenance Chart ................................................ 60
Seat Removal ...................................................................... 61
Air Cleaner ......................................................................... 61
Spark Plug .......................................................................... 62
Idle Speed Adjustment ........................................................ 63
Throttle Cable Adjustment ................................................. 64
Fuel Hose ........................................................................... 64
Engine Oil .......................................................................... 64
Brake ................................................................................. 65
Brake Adjustment .............................................................. 65
Brake Oil ........................................................................... 66
Brake Friction .................................................................... 66
Tires .................................................................................. 67
Tire Pressure ...................................................................... 68
Tire Replacement ............................................................... 68
Tubeless Tire Repair ............................................................ 69
Drive Chain ...................................................................... 69
Front and Rear Wheel Removal ......................................... 71
ATV 250 ................................................................................................. 72
ATV 250 - Control Functions ............................................................... 73
Main Switch ........................................................................ 73
Indicator Light .................................................................... 73
Engine Stop Switch .............................................................. 74
Start Switch ......................................................................... 74
Light Beam Switch ............................................................... 75
Choke Switch ....................................................................... 75
Throttle Lever ...................................................................... 75
Speed Limiter ....................................................................... 76
Clutch Lever ........................................................................ 77
Brake Lever ......................................................................... 77
Brake Pedal ......................................................................... 78

Shift Pedal ........................................................................... 78
Fuel Tank Cap ..................................................................... 79
Fuel .................................................................................... 79
Fuel Tap ............................................................................. 80
Seat .................................................................................... 82
ATV 250 - Periodic Maintenance And Adjustments ........................... 85
Periodic Maintenance Chart For The Emission Control System ........... 86
General Maintenance And Lubrication Chart ..................... 87
Checking The Spark Plug .................................................... 88
Engine Oil And Oil Filter Element ...................................... 91
Cleaning The Air Filter Element .......................................... 93
Adjusting The Carburetor ................................................... 98
Adjusting The Engine Idling Speed ...................................... 98
Adjusting The Throttle Lever Free Play ................................ 99
Valve Clearance ................................................................... 100
Checking The Front And Rear Brake Pads ............................ 100
Checking The Brake Fluid Level ............................................ 100
Checking The Front Brake Level Free Play ........................... 103
Checking The Brake Pedal Height ........................................ 103
Checking The Clutch Lever Free Play .................................... 104
To Check The Drive Chain Slack .......................................... 105
Lubricating The Drive Chain ............................................... 107
Checking And Lubricating Cables ........................................ 108
Checking And Lubricating Brake And Clutch Levers ............ 108
Checking The Shift Pedal ..................................................... 109
Checking And Lubricating The Brake Pedal ......................... 109
Checking The Wheel Hub Bearings ...................................... 109
Lubricating The Swing Arm Pivots ...................................... 110
Lubricating The Upper And Lower Arm Pivots .................... 110
Lubricating The Steering Shaft ............................................ 112
Battery ............................................................................... 112
Replacing A Headlight Bulb ................................................ 118
Adjusting A Headlight Beam ............................................... 120
Replacing The Tail/Brake Light Bulb ................................... 120
Removing A Wheel ............................................................. 120
Troubleshooting ................................................................................. 122
Cleaning Procedure ............................................................................ 127
Contents

Contents
Storage Procedure .............................................................................. 129
Circuit Diagram ................................................................................. 130
Appearance Care ................................................................................ 131
Preparing for a Ride ........................................................................... 133
Transporting your Thumpstar ........................................................... 134
You & the Environment ...................................................................... 135
Taking Care of the Unexpected .......................................................... 136
Technical Information ........................................................................ 140
Specification ....................................................................................... 141
ATV 70 .............................................................................. 141
ATV 125 ............................................................................ 142
ATV 250 ............................................................................ 143
Spare Part Catalogue ......................................................................... 144
ATV 70 .............................................................................. 144
ATV 125 ............................................................................ 153
ATV 250 ............................................................................ 163
Parts Finder ...................................................................................... 171
Warranty ........................................................................................... 172
Disclaimer ........................................................................................ 173
Service Manual ................................................................................. 174
Title Ownership ............................................................................... 175

1
Introduction
Thank you for your purchase Thumpstar ATV 70 / 125 / 250
This manual will provide you with a clear understanding of the details and
operation of this vehicle. This manual includes all of the necessary safety
information. It provides information necessary to ride your vehicle and also
includes basic service and inspection procedures.
For complete manuals on your particular ATV please visit our website and
view your ATV product to find the Downloadable manual.
AN IMPORTANT SAFETY MESSAGE
• Read this manual carefully and completely before operating your
vehicle. Make sure you understand all instructions.
• Pay close attention to the warning and caution labels on the vehicle.
• Never operate an ATV without proper training or instruction.
IMPORTANT MANUAL INFORMATION
Failure to follow the warnings contained in this manual can result in serious
injury or death.
Particularly important information is distinguished in this manual by the
following notations:
WARNING Failure to follow WARNING instructions could result in
severe injury or death to the vehicle operator a bystander
or a person inspecting or repairing the vehicle
CAUTION A CAUTION indicates special precautions that must be
taken to avoid damage to the vehicle
NOTE A NOTE provides key information to make procedures
easier or clearer

2
A Few Words About Safety
Your safety, and the safety of others, is very important. And operating
this ATV safely is an important responsibility.
WARNING
Always use an
approved helmet &
protective gear
Never carry
passengers
Never use
public roads
Never use with
drugs or alcohol
This section presents some of the most important information and
recommendations to help you ride your motorcycle safely. Please take a few
moments to read these pages. This section also includes a special message for
parents and location information for the safety labels on your motorcycle.
You WILL be KILLED or SERIOUSLY
HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY
HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow
instructions.
Risk of rollover
even on flat terrain

3
Safety Information
To drive an ATV is a serious matter and can be hazardous to operate. An
ATV handles differently from other vehicles including motorcycles and
cars. A collision or rollover can occur quickly, even during routine
maneuvers such as turning and riding on hills or over obstacles, if you
fail to take proper precautions
SEVERE INJURY OR DEATH can result if you do not follow these
instructions:
• Never carry a passenger on an ATV
• Always avoid operating an ATV on any paved surfaces, including sidewalks,
driveways, parking lots and streets.
• Never operate an ATV on any public street, road or highway nor a dirt or
gravel one.
• Never operate an ATV without wearing an approved motorcycle helmet
that fits properly. You should also wear eye protection (goggles or face shield),
gloves, boots, long-sleeved shirt, or jacket, and long pants.
• Never consume alcohol or drugs before or while operating this ATV.
• Never operate at speeds too fast for your skills or the conditions.
• Never attempt wheelies, jumps, or other stunts.
• Always inspect your ATV each time you use it to make sure it is in safe oper-
ating conditions.
• Always follow the inspection and maintenance procedures and schedules
described in this manual.
• Always keep both hands on the handlebars and both feet on the foot boards
of the ATV during operation.
• Never operate the ATV in fast flowing water or in water deeper than 25cm
(10in)
• Always use the size and type tires specified in this manual. Always maintain
proper tire pressure as described in this manual.
• Never modify the ATV through improper installation or use of accesso-
ries
• Never exceed the stated load capacity for an ATV. Cargo should be properly
distributed and securely attached. Reduce speed and follow instructions in
this manual for carrying cargo or pulling a trailer. Allow greater distance for
braking while transporting cargo
Always turn off the engine when refueling.
Don’t start or run the engine in a closed area to avoid
potential hazard.

4
Safety Labels
RISK OF ROLLOVER
Quad bikes are dangerous and could roll over causing injury or death to
the operator.
The risk of a rollover increases if the quad bike is travelling on uneven
ground or slopes, travelling at high speed, towing an attachment or carry-
ing a heavy or unstable load.
Risks of a serious incident are also increased when operators:
*are inexperienced
*carry passengers
*do not have the physical strength to ride actively
*are under the influence of alcohol or drugs
*are not wearing suitable personal protective equipment such as a helmet.
*Children are at greater risk of serious injury and death while operating
quads. Adult sized quad bikes should not be operated by children. Even the
smaller youth quads have been involved in fatal incidents in Australia.
Quad bike accidents are common and can happen very easily, so always
take the necessary precautions to protect yourself and children.
RIDE SAFE
*Always wear a helmet.
*Wear protective clothing and gear such as goggles, long sleeves, long
pants, boots and gloves/hand protection.
*Never let children ride quad bikes that are meant for adults — even as
passengers.
*Do not carry any passengers on quad bikes that are meant for one person.
*Ride on familiar tracks and beware of obstacles.
*Ensure children are supervised at all times near any quad bike activity.
*Always carry a mobile phone or radio device so you can contact for help
in case of an emergency.

5
Safety Labels
ATV 70
Read and understand all of the labels on your quad.
They contain information for safe proper operation of your quad.
Never remove any labels from your quad. If a label becomes difficult to
read or comes off, a replacement label is available from your dealer.

6
Safety Labels
Rear Brake Lever
Parking Brake
Main Switch
Handle Bar
Throttle Lever
Speed Limiter
Front Brake Lever
LOCATION OF PARTS
Rear Bumper
Seat Lock
Battery

7
Safety Labels
ATV 125

8
LOCATION OF PARTS
Bumper
Headlight
Rear Shock
Parking Brake
Stop Switch
Thumb Throttle Lever
Fuel Tank Cover
Indicator Switch
Electric Start
Headlight Switch
Safety Labels

9
Thumb Throttle Lever
Safety Labels
ATV 250
Read and understand all of the labels on your ATV. These labels contain
important information for safe and proper operation. Never remove any
labels from your ATV. If a label become difficult to read or comes off,
request a replacement label from your dealer.

10
Safety Labels
6.

11
LOCATION OF PARTS
1. Front Shock Absorber
2. Fuel Tap
3. Rear Shock Absorber
4. Owner’s Tool Kit
5. Air Filter
2
34
5
Safety Labels

12
Safety Labels
1. Spark Plug
2. Fuse
3. Battery
1. Clutch Lever
2. Handlebar Switches
3. Main Switch
4. Front Brake Fluid Reservoir
4. Fuel Tank Cap
5. Brake Pedal
5. Throttle Lever
6. Brake Lever
2,3 1
5
4

13
Pre-Operation Checks
Inspect your vehicle each time you use it to make sure the vehicle is in
safe operating condition. Always follow the inspection and maintenance
procedures and schedules described in the owner’s Manual.
WARNING!
Failure to inspect or maintain the vehicle properly increases the possibility
of an accident or equipment damage. Do not operate the vehicle if you find
any problem. If a problem cannot be corrected by the procedures provided
in this manual, have the vehicle inspected by your dealer.
ITEM ROUTINE
Fuel • Check fuel level in fuel tank, and add recommended
fuel if necessary.
• Check fuel line for leakage. Correct if necessary.
Engine Oil • Check oil level in engine, and add recommended oil to
specified level if necessary.
• Check ATV for oil leakage. Correct if necessary.
Radiator • Check colling liquid in radiator, and add colling liquid
to the full.
• Check colling liquid for leakage. Correct if necessary.
Front Brake • Check operation. If soft or spongy, have a dealer bleed
hydraulic system.
• Check brake pads for wear,and replace if necessary.
• Check brake fluid level in reservoir, and add specified
brake fluid to specified level if necessary.
• Check hydraulic system for leakage. Correct if neces-
sary.
Rear Brake • Check operation. If soft or spongy, have a dealer bleed
hydraulic system.
• Check brake pads for water, and replace if necessary.
• Check brake fluid level in reservoir, and add specified
brake fluid to specified level if necessary.
• Check hydraulic system for leakage. Correct if neces-
sary.