Rokon Trail-Breaker Illustrated Owners And Parts Manual
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Rokon Trail-Breaker Illustrated Owners And Parts Manual

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Owners and Parts Manual
©2002-7 Rokon International, Inc. Printed in U.S.A. ROKON
Illustrated
ROKON International Inc.
50 Railroad Avenue
Rochester, NH 03839
Tel: 603 335-3200
Fax: 603 335-4400
e-mail:parts@rokon.com
web site: www.rokon.com
and its logo are registered trademarks.
®
Made In
The USA
Rev. 4

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Summary of Contents for Rokon Trail-Breaker

  • Page 1 Made In The USA ROKON International Inc. 50 Railroad Avenue Rochester, NH 03839 Tel: 603 335-3200 Fax: 603 335-4400 e-mail:parts@rokon.com web site: www.rokon.com ©2002-7 Rokon International, Inc. Printed in U.S.A. ROKON and its logo are registered trademarks. Rev. 4 ®...
  • Page 2 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.

  • Page 3: Table Of Contents

    Carefully read and follow the instructions in the safety section of this manual. 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). Follow the Pre-Operation Checklist.

  • Page 4: Safety Information

    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.
  • Page 5 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. ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...

  • Page 6: Description And Machine Identifi Cation

    The Vehicle Identifi cation Number is on the center frame tube beneath The Engine Number the driver seat. 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...

  • Page 7: Control Functions

    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.
  • Page 8 STARTING THE ENGINE. Stand on the left hand side, put the front brake on with two fi ngers 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...

  • Page 9: Pre-Operation Checks

    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...

  • Page 10: Operating Your Rokon

    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.
  • Page 11 The ROKON is designed with individual disc brakes on the front and rear gear boxes. The right hand front brake will stop both wheels through the gear train. When braking with the front brake, the machine should be in a “straight away”...

  • Page 12: Periodic Maintenance And Adjustment

    Periodic Maintenance Section 6 and Adjustment Routine care of your ROKON vehicle is easily done and is important for rider safety and vehicle longevity. 1. Inspect all fasteners for tightness. 2. The drive chains require adjustment at intervals, depending on the mileage and the care which the operator has given the chains.
  • Page 13 Storing your ROKON Close the gasoline shut-off valve. This will prevent fuel leakage when transporting or storing your ROKON. This is a key item when transporting your ROKON for example on the wheel free carrier. Start the engine and allow it to run until it stops from lack of fuel. This will use up all the fuel in the carburetor and prevent the formation of deposits due to evaporation of fuel.
  • Page 14 Improperly adjusted throttle linkage. Ice in system. Idle set too low. 10. Valve core disappears Tire pressure too low. within wheel. (only tubed tires) Tube not secured by stem kit. ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 15 Incorrect spark plug – gap too wide or too narrow. Incorrect air gap on ignition coil. Worn or stuck piston rings or leaky head gasket. Ice in system. Hi altitude running. (use hi altitude jet) ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 16 Leaking gaskets. Air gap too wide. Exhaust restriction. Low compression. 10. Poor high speed performance. Low compression. Pre-ignition. Improper spark plug or air gap. Belt worn. Brakes dragging. ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 17 Care and Adjustment of ROKON Brakes General: ROKON all wheel drive vehicles have individual front and rear disc brakes. They are hydraulically operated by hand levers on the handlebars. The left lever controls the rear brakes and, in the forward direction, stops the rear wheel. The overrunning clutch in the driveline allows the front wheel to continue rotating.
  • Page 18 Pucks in place. (Note: Screw head will fi t into recessed area of Puck. Be sure only friction material will contact disc when reassembled.) 6. Reassemble caliper and mount as before. ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 19 General Maintenance and Lubrication Section 6 Continued ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...

  • Page 20: Repair Procedures

    Remove brake caliper assembly and brake bracket as a complete unit. (Remove the two 1/2 “ bolts under the brake disc.). Slide brake disc off shaft. Take note the way the caliper and brake disc came off for reassembly. ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 21 Shift ball closest to the transmission.) Pull the assembly straight out of the bore. Reverse procedure for reassembly. ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 22 Replace the key by means of long needle nose pliers or your fi nger and repeat the procedure. When you have the miter box installed properly, reverse procedure 1-5. ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 23 Line up pin hole and replace. If internal transmission damage is suspected, transmission must be removed and repaired as necessary. Contact ROKON for transmission repair. ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...

  • Page 24: Torque And Other Specifi Cation Charts

    Torque and other Section 8 Specifi cation Charts Torque and Threadlocking Specifi cations For Fasteners On Rokon 2WD Vehicles Fastener Location Thread Locking Torque Size In. lbs. Ft. lbs. 10-32 Foot Rest Tube Lock Washer 5/16 Transmission Loctite 242 + Lock Washer...

  • Page 25: Limited Warranty

    Purchaser must: Complete and return Warranty Registration Card to ROKON International Inc. within ten (10) days of purchase. Notify ROKON of any and all defects made within ten (10) days of malfunction and make machine immediately available for inspection at a place to be determined by ROKON.

  • Page 26: Illustrated Parts Manual

    Torque Converter Driven Pulley Tow Bar Transmission Complete Transmission with Attachments 50 & 51 Transmission in Sequence Miter Box Transmission to Miter Box Aluminum Wheels Steel Wheels Wiring Diagram ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 27 O-Ring, Buna-N 0701-1006 Screw, Flat Head Slotted 0701-1005 Puck 0701-1003 O-Ring, Buna-N 0708-1001 Housing, Pneumatic, Retractable 0701-1007 Washer 0701-1008 Nut, Flexloc 3030-1007 Hex Bolt 0701-1032 Puck, Dead Side ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 28 Master Link 100355 Offset Link as needed 100354 Full Link as needed 108984 Chain Length as needed 101568 Front Chain 107P not shown 101570 Rear Chain 117P not shown ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 29 Decal “ROKON” Oval in Red 108991 Decal “ROKON” Oval in Brown 101626 Decal “Shift Instructions” 108057 Decal Made in USA 108988 Decal Oil Warning 108972 Decal Handlebar “ROKON” ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 30 Brake Light Mounting Plate 100170 Bolt HH Bolt 1/4-28 x 1 1/2 100169 Lock Nut 1/4-28 100448 Cable Tie (Long) As Necessary 100449 Cable Tie (Short) As Necessary ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 31 Honda Engine GX160 100369H Spark Plug HON5247408 Air Filter 101548H Crank Key 108253 E Clip 108254 Screw M4 Size, 6 mm length, .7mm pitch 1 108256 Cable Holder ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 32 Section 10 Kohler Engine Continued ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 33 KOH6385304-S Carburetor Complete not shown separately KOH6375704-S Carburetor Repair Kit not shown KOH Air Box Assy Kohler Air Box Assembly not shown separately 108968 Nylon Snap In Plug ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 34 Air Box Cover KOH6314605-S Air Box Plate KOH6308306-S Kohler Air Filter KOH6308651-S Air Box Screw 109202 Air Box Plug KOHAIRBOXASSY Kohler Air Box Assembly Includes all of the above ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 35 Frame Section 10 Continued ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 36 Lock Washer #10 100034 Screw Pan Head Screw 10-32 x 1/2 100037 Hex Nut Self Lock 10-32 108123 Bolt HHCS gr 5 5/16-24X 1 1/2 ZN 100551 Locknut 5/16-24 Hex ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...

  • Page 37: Front Fork

    101630 Receptacle 100035 Screw Pan Head Screw 10-32 x 1 1/2 100037 Hex Nut Self Lock 10-32 100167 Bolt 1/4-28 x 1/2 HH Bolt 100169 NutLock Nut 1/4-28 ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 38 100281 Washer 1/4” Lock Washer 100170 Screw HH 1/4-28 x 1 1/2 100255 Washer 100169 1/4 x 28 Locking 100892 Front Cargo Rack Kit Includes all items above ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...

  • Page 39: Fuel Tank

    101970 Bolt HH 1/2-20 x 3/4 102589 Flat Washer 103120-RED Fuel Tank Red not shown 103120-OD Fuel Tank Olive Drab not shown 103120-BLK Fuel Tank Black not shown ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 40 Name Description 108236 Muffl er Kohler 108150 Muffl er Honda not shown 108998 Sandwich Mount 108997 1/4-20 Jam Nut Nylock 100255 Washer KOH6331402-S Muffl er Guard not shown ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 41 Section 10 Handle Bar Continued ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 42 3/8-16 x 1 1/2 108986 Handlebar Clamp Bolt Long 3/8-24 x 2 1/4 108115 Handlebar Clamp Upper 108116 Handlebar Clamp Lower 108972 ROKON Decal 100191 Shut Off Switch ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 43 Starter, retractable includes 3-9 KOH6308105-S Housing Assembly KOH6316601-S Starter, handle KOH6308921-S Recoil Spring 15585 Pull Rope KOH6309302-S Pulley KOH6375706-S Kit, pawl repair includes 9 KOH6308652-S Screw KOH6310902-S Starter Cup ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...

  • Page 44: Front Seat

    Bolt 101181 Bolt HH Bolt 3/8-24 x 1 3/4 100212 Lock Nut 3/8-24 100168 Bolt Not Pictured for Lower Shock Mount 100169 Not Pictured for Lower Shock Mount ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...

  • Page 45: Rear Seat

    Part Number Name Description 100340 Rear Seat 100343 Passenger Foot Peg Set 100281 Locking Washer Lock Washer 1/4 Spring 105037 Hex Head Bolt HH Bolt 1/4-20 x 1 3/8 ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 46 703116 Bearing Idler Bearing 703127 Washer 703129 Retractor 703151 Plate 703211 Washer Ramp Plate Retaining 108123 Clutch Bolt 108983 Locking Clip 100885 Torque Converter Drive Complete Includes 1-10 ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 47 703110 Bearing 703109 Movable Face 703111 Spring 703305 Button Shoe Ramp 601406 Torque Bracket Includes Items 5 & 7 901709 Set Screw 100884 Driven Pulley Rear Includes 1-7 ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 48 HHCS 5/16-24 x 3/4 100208 Washer Flat Washer 3/8 100551 Locknut 5/16-24 Hex 100893 Tow Bar Kit Includes all except 3 100170 Bolt HH 1/4-28 x 1 1/2 ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 49 Section 10 Transmission Continued Complete Fill Plug Fill Level Drain Plug ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 50 Continued with Attachments Item Part Number Name Description 101680 Transmission Assembly 100884 Rear Driven Clutch 100610 Brake Disc 100040 11 Tooth Sprocket 100270 Roll Pin 100043 Woodruff Key ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 51 Transmission Section 10 Continued in Sequence ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 52 100163 Plug 101525 Screw 1/4”-20 X 1” 101524 Screw 1/4”-20 X 1 3/4” 101939 Dowel Pin 105082-1 End Cap 108987 Pressure Relief Valve 101615 Shim .005 100163 Plug ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 53 101616 Shim ID 3/4” OD 1 1/8” .010 more as needed 100043 Woodruff Key Connects to Brake Disc 101505 Snap Ring 100108 Spacer 100853 Spacer 100100 Miter Box ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 54 3/16 x 1 101655 Drive Line Boss 101656 Retaining Pin 100002 Override Spring 101529 Screw HH Bolt 5/16-18 x 2 1/4 100045 Roll Pin 101640 Drive Line Assembly ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 55 100756 Spacer Dead Side 100758 Spacer Sprocket Side 101181 Bolt 3/8-24 x 1 3/4” 100288 Lockwasher 3/8” Lock 108112 Sprocket 100036 Jam Nut 100523 Plug 100516 O Ring ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...
  • Page 56 Axle 105030 Valve Stem Kit 15” only (not shown) 100772 Bearing 100522 Axle Spacer 100208 Washer 101181 Bolt 3/8-24 x 1 3/4” 100853 Shim 100288 Lockwasher 3/8” Lock ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...

  • Page 57: Wiring Diagram

    Section 10 Wiring Diagram Continued ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A Copyright 2002-7...

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