GMX MOTORBIKES Rumble 150cc Assembly Manual
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GMX MOTORBIKES Rumble 150cc Assembly Manual

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RUMBLE 150cc - 200cc Dune Buggy
ASSEMBLY MANUAL
Read and understand this entire manual before riding!
DO NOT RETURN TO STORE!
NOTE: Manual illustrations are for demonstration purposes only. Illustrations man not reflect exact appearance of actual procduct.
WWW.GMXMOTORBIKES.COM.AU

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  • Page 1 RUMBLE 150cc - 200cc Dune Buggy ASSEMBLY MANUAL Read and understand this entire manual before riding! DO NOT RETURN TO STORE! NOTE: Manual illustrations are for demonstration purposes only. Illustrations man not reflect exact appearance of actual procduct. WWW.GMXMOTORBIKES.COM.AU...
  • Page 2 WEAR SAFE - Always wear a helmet. - Wear protective clothing and gear such as goggles, long sleeves, long pants, boots and gloves/hand protection. RIDE SAFE - 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.
  • Page 3 GMX MOTORBIKES WARRANTY Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
  • Page 4 To emphasize special important information in the manual, please note the following : This is the alert symbol. The symbol means ATTENTION!, BECOME ALERT!, YOUR SAFET Y IS INVOLVED. To emphasize important safety information, the word WARNING, with the alert symbol, has special meaning: Indicates a potential hazard that could result in SEVERE WARNING:...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS AUTHORIZED DEALER LIMITED WARRANTY ..............3 IMPORTANT LABELS WARNING LABELS ................5 SAFETY ............................6 DESCRIPTIONS AND PART LOCATIONS ................7 IGNITION KEY........................8 BRAKE PEDAL ........................8 GAS PEDAL ........................8 PARKING BRAKE LEVER ....................8 FORWARD AND REVERSE LEVER ..................
  • Page 6 CHARGING THE BATTERY ........... Error! Bookmark not defined. MAINTENANCE ........................28 AIR FILTER ........................28 INSPECTION AND CLEANING ..................28 SPARK PLUG ........................29 ENGINE OIL ..............Error! Bookmark not defined. CHECKING THE ENGINE OIL ......... Error! Bookmark not defined. CHANGING THE ENGINE OIL ........

  • Page 7: Authorized Dealer Limited Warranty

    AUTHORIZED DEALER LIMITED WARRANTY This Warranty is NOT the Emissions Control Warranty Please note this is a general Limited Warranty for this product. It IS NOT an Emissions Control Warranty. Please see the Emissions Control Warranty in this manual for warranties covering Emission components.
  • Page 8 behalf of Manufacturers without the approval of Manufacturers. A COPY OF YOUR SALES RECEIPT IS REQUIRED FOR WARRANT Y SERVICE. What this Warranty Does Not Cover This warranty does not cover the following 1. Damage due to lack or improper maintenance as described in this manual. 2.

  • Page 9: Important Labels Warning Labels

    IMPORTANT LABELS WARNING LABELS...

  • Page 10: Safety

    SAFETY 1. Always read and understand the use, make sure all tubes are securely in Owner’s/Operator’s manual and place and bolts are tight. warnings before starting the Go Kart for 11. Never operate Go Kart with long hair, the first time loose jewelry or loose clothing that could 2.

  • Page 11: Descriptions And Part Locations

    DESCRIPTIONS AND PART LOCATIONS Front Wheel Front Shocks Steering Wheel Brush Guard Seat Belts Fuel Tank Seat Rear Shocks Rear wheels 10. Engine 11 Muffler 12. Drive Chain...

  • Page 12: Ignition Key

    Ignition key (1): When the ignition switch is placed in the (ON) position the engine can start when the ignition key is turned to the right. When the ignition switch is placed in the (OFF) position the engine will not start, or will turn off, if running.

  • Page 13: Fuel Tank Cap

    Fuel Tank Cap (1): To open fuel tank cap, Turn cap counter clockwise to remove. To re-install cap, turn cap clockwise until snug. Make sure cap is seated properly Oil Fill plug/Dipstick (2): To open Oil fill plug/Dipstick, turn cap counter clockwise to remove.

  • Page 14: Description And Part Functions

    DESCRIPTION AND PART FUNCTIONS SEAT ADJUSTMENT △ WARNING Failure to have the seat locked in position could be hazardous The seat coming loose could cause the operator to loose control. Never operate the Go Kart without the seat locked in place. Seat Latch (1) The seat latch is located under the driver side seat.

  • Page 15: Fuel And Oil

    FUEL AND OIL FUEL Never use leaded gasoline in this product. △ WARNING It could affect the engine’ s emissions and damage the engine. Fuel and fuel vapor are highly flammable Go Kart requires clean unleaded regular and toxic. You can be burned or poisoned gasoline with a minimum octane rating of while refueling.

  • Page 16: Break - In

    BREAK IN PERIOD components. Be careful not to load the engine too much. The initial 20 hours of operation is most important in the life of your Go Kart. Proper operation during this break in period will help assure maximum life of Allow oil to circulate before operating.

  • Page 17: Pre-Ride Inspection

    PRE-RIDE INSPECTION WHAT TO CHECK FOR Inspecting and checking the condition of CHECK • the Go Kart before each ride is important. Smoothness • Following the pre-ride check list will Steering No restriction of help insure the you do not have movement •...
  • Page 18 △ WARNING Carrying more than one passenger on this △ WARNING Go Kart could be hazardous Carrying more than one passenger could Operating this Go Kart in a irresponsible cause loss of control resulting in severe manner which includes jumping or other injury of death to the operator and/or stunts could be hazardous.

  • Page 19: Helmet, Eye Protection,Protective

    OPERATING THE GO KART HELMET, EYE PROTECTION, PROTECTIVE CLOTHING Always wear a DOT certified motorcycle helmet (1). A helmet helps protect against serious head injuries in the event of an accident. A helmet is the most important safety gear item you can wear.

  • Page 20: Seat Belts

    OPERATING THE GO KART SEAT BELTS △ WARNING Riding in this go kart without the seat belt harness worn and attached properly for both the operator and passenger could be hazardous Operating the go kart without the seat belt harness worn by both the operator and passenger increases the chance of injury or death in the event of an accident Never operate or allow a passenger to...

  • Page 21: Starting Engine

    OPERATING THE GO KART STARTING ENGINE To start the engine 1. Before starting the engine, ALWAYS REVIEW THE PRE RIDE INSPECTION PROCEDURES LISTED IN THIS MANUAL 2. Make sure parking brake lever(1) is set before attempting to start the engine. 5.

  • Page 22: Starting Off

    OPERATING THE GO KART STARTING OFF 1. Once engine has warmed up, release parking brake by moving parking brake lever (1) to the forward position 3. Let off brake pedal (2) and gradually depress gas pedal (3) until kart moves. 4.

  • Page 23: Climbing A Hill

    OPERATING THE GO KART CLIMBING A HILL To operate the Go Kart going down a hill, follow the instructions below. 1. Stop and evaluate the hill before 1. Stop and evaluate the hill before attempting to climb. Make sure the hill is attempting to descend.

  • Page 24: Skidding Or Sliding

    OPERATING THE GO KART SKIDDING OR SLIDING In certain situations you may experience skidding or sliding even though the brakes are not applied. Follow the △ WARNING operating techniques listed below to regain control. Applying the parking brake while operating the Go Kart could be hazardous. Front wheel begins to slide or skid: Applying the parking brake while To regain traction, let off the throttle, do...

  • Page 25: Operating Through Water

    OPERATING THE GO KART OPERATING THROUGH WATER Operating through water hazardous, especially if it is fast moving. △ WARNING Make sure the water your are operating through is shallow and is not more than Operating this Go Kart through fast or 10cm (4in) deep.
  • Page 26 OPERATING THE GO KART OPERATING IN COLD WEATHER PRE cold weather with snow, slush, water or RIDE INSPECTION ice, dry off the Go Kart including brake and throttle linkages. Apply the brakes Brake and throttle linkages: several times making sure that the Cold weather requires additional pre-ride friction has dried off the brake pads and inspection of the Go Kart before...
  • Page 27 OPERATING THE GO KART LOAD GUIDELINES AFTER MARKET PARTS Load guidelines including accessories: After market parts and accessories are Never exceed maximum load available from many manufactures. capability of the Go Kart. This includes Cannot confirm the quality, safety or the weight of the operator and any cargo.
  • Page 28 MAINTENANCE For maintenance, your Go Kart may be maintained by an authorized original manufacturer service dealer or a repair △ WARNING shop of your choosing. Following the proper maintenance Performing maintenance and procedures and time table for inspection while the engine is running maintenance listed in this manual is could be hazardous.
  • Page 29 MAINTENANCE CHART First 5 Before Every20 hours Every Every ITEM hours of each of operation 50 hours 100 hours operation ride or 1 month or 3 months or 6 months Exhaust pipe nuts and muffler bolts Air cleaner element Valve Clearance** Spark Plug Fuel Line Idle speed...
  • Page 30 BATTERY INSTALLATION AND MAINTENANCE △ WARNING Battery electrolyte (Sulfuric Acid) is poisonous , electrolyte can cause severe burns if contacts skin. Avoid contact with skin, eyes or clothing. If sulfuric acid is swallowed or splashed in the eyes, treat immediately. Sulfuric acid in the eyes can cause blindness.
  • Page 31 CHARGING THE BATTERY place. Note: Do not turn the charger on before attaching the charger clips to the battery terminals. The standard charging rate is 0.7A x 5 -10 hours. Maximum charging rate is 3A x 1hour 1. Attach the Charger to the battery terminals.

  • Page 32: Air Filter

    MAINTENANCE AIR FILTER The air cleaner element needs to be CAUTION cleaned or replaced periodically (see chart for cleaning/replacement Clean air filter more frequently if Go intervals). The air filter element will need Kart is driven in wet, muddy or dusty to be cleaned more often if Go Kart is conditions.

  • Page 33: Spark Plug

    MAINTENANCE SPARK PLUG This Go Kart comes equipped with an A7TC spark plug. To inspect the spark plug, remove the plug cap (1) then remove the spark plug (2) from the engine with the spark plug tool provided. Inspect the plug for carbon deposits and clean if necessary with a wire brush.

  • Page 34: Engine Oil

    MAINTENANCE ENGINE OIL allow to run for a few minutes,Re-check The proper amount and grade of engine oil level and fill accordingly. oil will have a great impact on the life of the engine. Checking the oil daily and changing the oil as listed in the maintenance schedule is the most △...

  • Page 35: Cleaning Oil Filter Screen

    MAINTENANCE CLEANING OIL FILTER SCREEN 1. Remove oil drain plug (1) located on hole (approx. 13oz.) with fresh clean bottom left side of engine and drain oil in 85w-90 gear oil. an appropriate container. Once oil is drained, re-install drain plug (1) Note: Always dispose of used oil at an oil reclaim facility.

  • Page 36: Idle Speed Adjustment

    MAINTENANCE IDLE SPEED ADJUSTMENT the shocks in the front are not adjusted to The idle speed should be set at 1700 ± the same settings, or if the shocks in the 100 RPMs back are not adjusted to the same To adjust the idle speed: settings.

  • Page 37: Fuel Hose Inspection

    MAINTENANCE FUEL HOSE INSPECTION Inspect the fuel hose (1) for any cracks or leaks and make sure all clamps are in place. Replace the fuel hose if any defects are found. BRAKES This Go Kart is equipped with rear hydraulic disk brakes △...

  • Page 38: Valve Clearance

    MAINTENANCE VALVE CLEARANCE Adjusting the valves should be done by Intake: 0.002 in (0.05mm) authorized service center Exhaust: 0.003 in (0.0762mm) comparable servicing dealer. Proper valve gap will help keep Go Kart running at peak performance. Follow the valve gap adjustment intervals listed in the maintenance chart.

  • Page 39: Chain

    MAINTENANCE CHAIN Lubricating the chain before each ride CHAIN AND SPROCKET will help to ensure maximum life of the INSPECTION chain and sprockets. Inspect drive chain for wear, rust, bound links, proper lubrication and proper Instructions for cleaning and chain tension.

  • Page 40: Tires

    MAINTENANCE TIRES plug type patch kit and air pump with Inspect tires before each ride, this should you. include the following: 1. Inspect for cracks or leaks 2. Inspect tread depth. If tread depth is below 4mm (.16 in.) replace the tire. 3.

  • Page 41: Storage

    MAINTENANCE STORAGE If the Go Kart is left unused for an extended period of time proper storage maintenance is required. 1. Wash Go Kart thoroughly, then wax plastics and painted parts with a non abrasive auto wax. Coat vinyl seat and rubber parts with a vinyl/rubber protectant.

  • Page 42: Washing The Go Kart

    MAINTENANCE WASHING THE GO KART 1.Wash mud and dirt off Go Kart with low water pressure from a hose. 2.Wash Go Kart using a mild detergent or car soap using a sponge, soft rag or brush. Do not use any cleaning materials that could scratch the Go Kart.

  • Page 43: Troubleshooting

    TROUBLESHOOTING Trouble Possible cause Solution Engine will not • Fuse is burned out • Replace fuse start - Starter • Battery terminal is loose • Tighten terminal motor does not • Starter motor not working • Take to a service center turn over Engine will not •...

  • Page 44: Torque Specifications

    TORQUE SPECIFICATIONS FASTNER TORQUE TORQUE THREAD SIZE (ft.lbs.) / (in.lbs.) (nm) 5 mm bolts and nuts 39-52 in.lbs. 4.5 - 6 nm 6mm bolts and nuts 69 - 104 in. lbs. 8 - 12 nm 8mm bolts and nuts 13 - 18 ft.lbs. 18 - 25 nm 10 mm bolts and nuts 22 - 29 ft.lbs.

  • Page 45: Specifications

    SPECIFICATIONS Engine Suspension Displacement 177.3cc Front Type Double A-arm Starting Electric Rear Type Double shock Spark Plug Type A7TC Shock Type Front Hydraulic Cooling Air cooled Type Rear Hydraulic Engine Oil 0.9-1qt.(0.9-1L) Braking Capacity Rear Brakes Hydraulic disk Engine Oil Type SAE 15W-40SF Tires Transmission oil...

  • Page 46: Circuit Diagram

    CIRCUIT DIAGRAM...

  • Page 47: Vehicle And Engine Number Location

    VEHICLE AND ENGINE NUMBER LOCATION The Vehicle identification number and the engine number are needed when calling for parts, service center help or when registering your Go Kart. Locate the numbers and list the numbers below for your reference. The 17 digit Vehicle Identification Number (VIN) is stamped on the right side of the go-kart on the metal frame.
  • Page 48 VEHICLE MAINTENANCE...
  • Page 49 VEHICLE MAINTENANCE - BEFORE YOU RIDE CHECKLIST SAMPLE PRE-OPERATION CHECKLIST Add to or adapt this checklist to suit your quad bike and place photocopies in a sturdy folder where vehicle keys and operator PPE are stored. • Maintain completed forms to provide a record of completed inspection and/or training. •...

This manual is also suitable for:

Rumble 200cc

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