Rokon Motorcycle Manuale utente

Illustrated

Owners and Parts Manual

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

Made In

The USA

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.

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 11-15

7. Repair Procedures 16-21

8. Torque and other specification charts 22

9. Limited Warranty 23

10. Illustrated Parts Manual 24-53

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.

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

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.

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.

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.

Section 3 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 2 fingers of your left hand, throttle

closed, reach over the ROKON and pull the starter handle.

Section 3 Continued Control Functions

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.

Section 4 Pre-operation Checks

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.

Section 5 Operating Your ROKON

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