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Troubleshooting & Maintenance

• Assembly & PDI

All units received in crate needs to be fully inspected and a full maintenance pdi (post delivery inspection) needs be performed. We do not recommend our customers attempt any of the following themselves. You should always have you bike assembled and maintained by certified mechanic. Megamotormadness cannot be held responsible if any unauthorized individual attempts assembly, PDI, repair, or maintenance on any product.

Inspection Instruction:

1. Check and tighten all bolts ( use locktite where needed)
2. Check all hose clamps
3. Change engine oil(use recommended in user manual)
4. Check all fluids
5. Check head lights
6. Check brake light
7. Check turn signals
8. Check tire pressure
9. Check chain/ belt tension
10. Check brakes
11. Check throttle
12. Check all cables for kinks.

Inspection Instruction:

(Some of the following instructions might not apply to certain models. Please follow the instructions when applicable.)

1. Remove carton box, top and sides of the metal frame.
2. Handle bars may need to be installed on some models.
3. Front and rear fenders need to be installed on most models. Fenders may need to be manipulated to fit by bending and/ or pressing. It is recommended to use lock tight on all bolts and nuts holding on fenders.
4. On units with windshields, pressing the windshield to fit may be necessary.
5. Attach rear rack and trunk with screws provided.
6. Fit wheels and tighten firmly. Use wheel LocTite to secure lug nuts. Check tire pressure (usually 20 PSI, double check what is printed on the tire).
7. Check/charge and connect battery. (use 12V Charger, charge up to 10-14hr for first time only)
8. Double-check all electrical wiring harnesses and connections to ensure all are satisfactory and secure.
9. Make sure to put LocTite around the bolts and nuts to keep them in place. This includes bolts on fender, brake caliper, wheels, muffler, and anywhere there is a bolt.
10. To open seat turn ignition key to the left until seat pops. If you experience trouble, see below in troubleshooting section.
11. Before your first ride, make sure to replace ALL fluids. Dust and other particles get in the fluids that come from the factory and can cause malfunction of your bike. Replace oil (10W30 or 10W40 synthetic), brake fluid (DOT 4), radiator fluid (coolant), gear oil (80 weight).

Starting Instruction

1. Check oil level. Top up with standard 4-stroke oil if needed 10W30 or 10W40.
2. Use only unleaded fuel.
3. Make sure that the battery has been properly charged and connected.
4. Turn ignition key on.
5. Engage brake lever in until it clicks and press start button to turn over the engine.
6. For starting bike normally, give it throttle sparingly (about 5%) and don't overdo it as that will flood the engine. If you flood the engine, you might not be able to start the engine. In that case, let it sit for 15-20min before trying to start the bike again.
7. If after 10 minutes of trying to start and it will not start, get a bottle of quick start (ether) spray directly into the air box while cranking it, that will get it started.
8. Don't go over 30 mph for the first 300 miles to break it in.

BatterySetup Procedure

Correct battery setup is critical

Tools needed: Safety glasses, rubber gloves, floating style battery charger with a low amp (>2amp charge setting).

Step 1: Remove battery and electrolyte from box.
Step 2: Fold down edges of foil covering electrolyte.
Step 3: Flip electrolyte over and align electrolyte bottle up with holes in top of battery and push down to break aluminum seals.
Step 4: Pierce the top of the electrolyte bottle with the provided push pin if battery acid is draining very slowly once acid has completely drained remove bottle and let sit for a minimum of ½ hour.
Step 5: Hook battery up to charger positive to positive, negative to negative. In most cases red = + positive and black =-negative. Let battery charge on >2amps until fully charged.
Step 6: Install battery red wire to positive black to negative and enjoy your ride!

• Trouble –shooting

General Trouble shooting

The following instructions were compiled to assist customers in the basics of maintenance and trouble shooting on Megamotormadness.com vehicles.

1. If bike cuts off, check one of these three
     a) Intake manifold (see if leaking air). If not getting enough gas to engine it will cut out.
     b) If stator is not good, engine might cut out. This could also make the instrument panel cut in and out.
     c) If battery and regulator is good and stator then check cdi
     d) Carburetor might also not be good or clogged.
     e) Check Air filter
     f) Check coil
2. If gas is not going into engine:
     a) Check gas cap. ----Change the gas cap we'll send a new one.
     b) Check petcock
     c) Carburetor should be cleaned and adjusted because it may not be getting enough gas to the engine. If your carburetor is sealed and not able to be adjusted or cleaned, this is a feature on the newer units which is now required by the EPA. Carburetor will need to be replaced.
3. If the bike will not charge:
     a) Take it to have the battery checked to make sure it is holding a charge. If not, replace battery. Batteries are not warranty. ---- New batteries can be purchased at Costco or Sam's club
     b) Check the voltage at the battery while bike is running, anything above 12.5 is good.
4. If it seems like the gas sensor is not working, fish the float. Get a metal hanger, stick it in the tank, and move the sensor around to get it loose. Sometimes it gets stuck from dried up fluid.
5. If seat will not open: Turn the key to left until the seat pops up. You may have to play with it a little. There is a cable that connects the ignition to the lock mechanism on the seat. There is an adjustment on that cable and make sure the cable is tight enough so that when the key is turned, it opens the lock.
6. If no fuel is flowing through:
     a) Check fuel line for flow, make sure there is no kinks
     b) Check fuel cap is on tight
     c) Check fuel filter make sure not blocked
7. No Spark Issue Diagnosis:
Check all electrical connections and make sure all connectors are tight and pins inside connectors are completely seated and locked in check by pulling on wires at the back of all connectors. It is always good to add a little dielectric grease to each connector this helps cut down on corrosion, and prevents condensation fromforming in connector.
*Common issue: Wiresand pins will sometimes pop out of connector at cdi, ignition coil, and brake switches.

There are 4 main components to the ignition system
1. Stator(the wrapped winding usually on the 6th pole)
2. CDI
3. Ignitioncoil
4. Sparkplug

Checking for spark
If all connections are good and tight
-Test for ac voltage coming out of blue/white wire and red/black wires
-Spec for blue/white=.05vac *supplies signal to cdi which tell the ignition coil and spark plug when to spark
-Spec for red/black=20vac *supplies power to cdi

To do this test, multi-meter must be set at AC voltage
-Disconnect blue/white wire and red/black wire at stator
-Connect red lead from multi-meter to red/black wire and black lead to ground
-Turn key on, hold brake, and push start button

As the engine turns over, the voltage will fluctuate but there should be a general reading of around 20vac this is the power supply to the cdi.
If voltage is lower that 17vac the stator will need to be replaced.
Repeat this test on the blue and white wire the reading should be .05vac if voltage is less than .03vac stator will need to be replaced.
Next step is to check AC voltage at the cdi to rule out broken wires.
Follow this diagram and do the same AC voltage test on the #1 and #2 pins on the cdi

If voltage is still present wires going to cdi are still good if not there is a break in a wire, or bad connection somewhere.

Next step check if kill switches are faulty
-Remove pin from number 5 position on cdi connector
-Run a wire from number 4 position to a good ground. (Strip a wire and insert into #4 and clamp or screw to a good ground on engine or frame
-Reconnect blue/white and red/black wires and turn engine over checking for spark if spark is present kill switches (right side combination switch, and or ignition/key switch) will need to be replaced.

If still no spark cdi, spark plug and or coil may be faulty and may need to be replaced.

8. If you feel excessive vibration from the bike,
     a) Pop the bead. Lube it soap, and re-bead it. The beads need to be flush all the way around the rim.
     b) Check the tires and make sure they are not out of round.
     c) Check the wheels and make sure they are balanced.

24 point Trike system check:

a. Fuel System
     1) Check carburetor for proper operation
     2) Check for proper operation of fuel pet-cock (some models may not have this)
     3) Make sure fuel switch is on
     4) Check for proper operation of fuel drain line
     5) Check and adjust idle set screw
b. Electrical
     6) Install and check battery - fill with electrolyte if not sealed
     7) Check fuses
     8) Check all lights
     9) Check ignition
     10) Check wiring to make sure wires are connected properly
c. Engine
     11) Check oil for proper level and quality
     12) Check cooling system for anti-freeze (only on water cooled units)
     13) Check radiator hose to assure fluid is flowing through properly
d. Suspension
     14) Check wheel bearings
     15) Check and adjust suspension
     16) Check and adjust tire pressure
     17) Check and adjust brakes
     18) Check beads to make sure they are flush with the wheel
     19) Check wheels to make sure they are balanced
e. Other
     20) Check and adjust throttle cable
     21) Check foot-rests
     22) Test all hand and foot controls for proper operation (some models)
     23) Check transaxle fluid level to keep gears lubricated (some models)

Maintenance

Oil Change General Guidelines

Materials needed:
17mm wrench or socket with ratchet (50cc,150cc, ATVs and go carts)
19mm wrench or socket with ratchet (250ccand 300cc scooters/trikes)
Oil drain pan
Rags or paper towels
Gloves
Funnel
1 quart of high quality oil /2 quarts for UTV650

Find oil drain plug usually found at the bottom of engine toward the right side on scooters and trikes.
50cc 150cc have a 17mm drain plug. 300cc have a 19mm plug.
ATVs, go carts usually will have the 17mm as well.

Place oil drain pan below drain plug and remove plug.
There will be a spring and a screen filter on the scooters and trikes that may fall out.
If there is a screen wipes clean or blows out with compressed air.

Once oil slows to a drip, turn engine over with kick start if equipped or with electric start button a few times to clearany excess oil.

Once all oil is out replace drain plug with spring and screen filter.

Remove oil dipstick usually found on the right side of the engine place funnel in dipstick hole and fill with the recommended amount of oil from the manufacturer.
Replace oil dipstick and verify oil is at the proper level once this is done wipe any excess oil from engine and enjoy your ride.

Oil change is recommended immediately when unit is received then at 300 miles and every 1000 miles after that.

First Service Interval – 300 Miles
     a. Check all nuts/bolts for tightness and security.
     b. Check all Engine/Vehicle fluid levels and ensure there are no leaks.
     c. Check and adjust chain tension- some models (due to "chain stretch").
     d. Check tire pressure.
     e. Check all cables/controls for proper operation.
3 Month Service Interval / 1000 miles
     a. Check all nuts/bolts for tightness and security.
     b. Change Engine Oil.
     c. Check and adjust chain tension if necessary.
     d. Check tire pressure/condition.
     e. Check all cables/controls for proper operation.
     f. Lube all fittings/chain as necessary.
6 Month Service Interval / 2000 miles
     a. Check all nuts/bolts for tightness and security.
     b. Change Engine Oil.
     c. Check and adjust chain tension if necessary.
     d. Check tire pressure/condition.
     e. Check all cables/controls for proper operation.
     f. Lube all fittings/chain as necessary.
     g. Check all Vehicle fluid levels (coolant, brake fluid, etc.)
12 Month Service Interval / 3000 miles
     a. Check all nuts/bolts for tightness and security.
     b. Change Engine Oil and Filter.
     c. Check and adjust chain tension if necessary.
     d. Check tire pressure/condition.
     e. Check all cables/controls for proper operation.
     f. Lube all fittings/chain as necessary.
     g. Flush and replace brake fluid.
     h. On water-cooled vehicles – Flush and replace coolant.