Xtreme XG-499 User manual

Page1

XG-499

Gas Scooter

Product Handbook

PLEASE BE SAFE WHEN RIDING

ALWAYS WEAR A HELMET AND OBEY ALL LAWS!

X-Treme TM Electric Scooters

Page2

THIS IS A 2-CYCLE ENGINE

IT REQUIRES A MIXTURE OF GAS AND 2-STROKE

ENGINE OIL

1. You must always use a gas/oil mixture. FAILURE TO DO SO

WILL VOID YOUR WARRANTY!

2. Use 32:1 Gas/Oil Mixture. 4 oz. of oil for every gallon of High-

Octane gasoline.

3. Tanaka Perfect Mix, or similar quality 2-Cycle Engine Oil is

recommended. Oil can be purchased from your local X-Treme

Dealer, Outdoor Power Equipment Dealer, or a Power Sports

Dealer

4. High-Octane Fuel recommended. (90 octane or higher)

This PRODUCT IS NOT INTENDED FOR EXTREME or

OFF-ROAD Use! Please take care of your XG-499!

DO NOT JUMP or ABUSE THIS PRODUCT!

DO NOT RIDE IN WET/ICY CONDITIONS!

Failure to follow these instructions will

VOID YOUR WARRANTY!

If you have any questions, please contact X-Treme customer

service on the web at www.x-tremescooters.com

IMPORTANT

Failure to follow these INSTRUCTIONS will

VOID YOUR WARRANTY!

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WARNING

This product does not conform to Federal Motor Vehicle Standards and is not

intended for operation on public streets, roads or highways. Serious injury can

result from the unsafe operations of this product. Operator can minimize these

risks by using certain safety equipment such as: safety helmet, goggles, gloves,

elbow and kneepads and appropriate footwear.

DO NOT operate this product in traffic, on wet, frozen, oily or unpaved surfaces or

under the influence of drugs and/or alcohol. Avoid uneven surfaces, potholes,

surface cracks and obstacles.

DO NOT use a water hose to clean this product. See Product Handbook for more

information.

This product is recommended for riders 16 YEARS OFAGE and older.

SAFETY

This product should not be used by persons without excellent vision, balance,

coordination, reflex, muscle and bone strength and good decision-making

capabilities.

This product should not be used by minors without adult supervision.

This product should not be used by persons unwilling or unable to take

responsibility for their own actions.

The user of this product assumes ALL risks associated with its use. To

minimize these RISKS, the user must wear safety helmet, goggles, gloves,

elbow and kneepads and appropriate footwear.

Never start the engine inside a closed room or building. Breathing exhaust

fumes can be fatal.

IMPORTANT

PLEASE READ THIS BEFORE USING THIS PRODUCT

READ THIS FIRST!

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Fuel Safety

Mix and pour fuel outdoors away from sparks or flames.

Only use a container approved for fuel

Do not smoke or allow smoking near the X-Treme XG-499 while working on the

engine, or while the engine is running.

Wipe up and clean all fuel spills before starting the engine.

Move at least 10 feet away from where you fueled before starting engine.

Stop engine before removing the fuel cap.

It is recommended that you empty the fuel tank prior to shipping or storage to

prevent fuel leaks.

Do not store your X-Treme XG-499 near open flames, furnaces, electric motors or

switches.

Maintenance

Maintain your X-Treme XG-499 as recommended in this Product Handbook.

Disconnect the spark plug cap before performing any engine maintenance, except

for carburetor adjustments.

Keep others away while making carburetor adjustments.

Use only quality replacement parts as recommended by the manufacturer.

Transportation and Storage

Allow the engine to cool, empty the fuel tank and fold the X-Treme XG-499

before carrying or storage.

It is recommended that you empty the fuel tank prior to shipping or storage to

prevent fuel leaks.

Clean the X-Treme XG-499 carefully and store in a cool, dry place.

Product Safety

Keep hands and feet away from moving parts.

Inspect the entire product prior to each use. Replace damaged parts. Check for

fuel leaks and make sure all fasteners are in place and securely fastened.

Replace all parts that are cracked, chipped or damaged before use.

Use only parts and accessories that are recommended by the manufacturer.

If a situation arises that is not covered in the manual,

proceed with caution and use good judgment.

Contact your dealer or X-Treme (www.x-tremescooters.com/support/)

if you need further assistance

QUICK REFERENCE

SAFETY GUIDE

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TABLE OF CONTENTS

Important Information…………………………………….…………………………….. 2-3

Quick Reference…………………………………………………………………………. 4

Table Of Contents……………………………….……………......................................5-6

Getting To Know Your X-Treme XG-499………………………………………………. 7

Package Contents……………………………………………………………………….. 8

Getting Started………………..……………………………..…………………………… 8-11

Assembly……………………………………………………………………………. 8

Gas Tank Installation……………………………………………………………….. 8-9

Fueling……………………………………………………………………………….. 9-10

Starting………………………………………………………………………………..10

Riding/Braking.……………………………………………………………………… 11

Transporting and Storage………………………..……………………………………… 11

Operating Procedures…………………………………….……………………………...12

Maintenance……………………………………………………………………………… 13-17

Recommended Tools……………………………………......................................13

Carburetor …………………………….……………………………………………..13-14

Brake System……………………………………………………………………….. 14-15

Tires and Wheels…………………………………………………………………… 15

Adjusting The Head Unit…………….…………………………………………….. 16

Adjusting The Chain…..………..……………….…………………………………. 16-17

Maintenance Schedule………………………………………………………………......17

Other Questions………………………..….…………………………………………….. 17

How To Guide……………………………………………………………………………..18-24

How To Adjust Chain Tension………………………………………………………18

How To Adjust Handle Bars……………………………………………………….. 18

How To Install Front Brake………………………………………………………….18

How To Mount Wheel………………………………………………………………. 18-19

How to Adjust Front Hub Brakes………………………………………………….. 19

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How To Adjust Rear Hub Brakes………………………………………………….. 19

How To Adjust Throttle Cable………………………………………………………19-20

How To Install Fuel Lines………………………………………………………….. 20

How To Install Ignition Coil………………………………………………………….20

How To Install Engager…………………………………………………………….. 20-21

How To Install Pull Starter…………………………………………………………..21

How To Remove and Install Transmission………………………………………. 21

How To Remove Engine…………………………………………………………… 21

How To Check Restricted Fuel Lines…………………………………………….. 22

How To Remove and Replace Transmission Bell Housing……………………. 22

How To Install Bearings……………………………………………………………. 22

How To Check For Spark………………………………………………………….. 22-23

How To Adjust Air/Fuel Mixture……………………………………………………. 23

How To Change Charger Socket…………………………………………………. 23-24

How To Change Fuse Holder……………………………………………………… 24

Troubleshooting………………………………………………………………………….. 24-25

Getting Broken Bolts Out………………………………………………………….. 24

Scooter Won’t Move…………………………………………………………………25

Diagrams………………………………………………………………………………….. 26-27

Rear Wheel Assembly……………………………………………………………… 26

Engine Diagram…………………………………………………………………….. 27

General Information/Tech Support……………………………….…………………….. 28

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GETTING TO KNOW YOUR X-TREME XG-499

DO NOT RETURN TO STORE!

Do not use this vehicle for the first time until you have inflated the tires to the correct PSI.

Failure to follow these instructions may damage your vehicle and void your warranty.

CALL CUSTOMER SUPPORT OR GO ONLINE

1-253-777-0690

WWW.X-TREMESCOOTERS.COM/SUPPORT

For General Information or Parts Visit WWW.X-TREMESCOOTERS.COM

Page8

PACKAGE CONTENTS

Your X-Treme XG-499 comes with the following items in the box. Please locate

all of the following:

1. The X-Treme XG-499 Gas Scooter

2. Allen Wrench

3. Spark Plug Wrench

4. Product Handbook

5. Fuel Tank and lines

6. Tool Kit

GETTING STARTED

Please read and understand these instructions and the OPERATING

PROCEDURES section, prior to starting or riding your XG-499

Installing the fuel tank

The fuel tank on the XG-499 does not come fully installed from the factory, so it is

necessary to install it before initial use.

The fuel system consists of the carburetor; fuel tank, fuel supply line and the fuel return

line.

To install the tank:

Assembly

1. Carefully remove the XG-499 from the box.

2. Insert the handlebar down tube over the

front fork completely until the gold pin

snaps into place. Slide the clamp down to

the base of the tube and tighten the two

bolts securely. (Fig.1)

3. Attach the handlebars by first attaching the

large handlebar clamp to the top of the

handlebar down tube. Then attach the

handlebars to the clamp. Tighten all bolts

after adjusting the handlebars to the

desired tilted position. (Fig. 2)

4. The BRAKE LEVER is in the down position

for shipping. Using the provided Allen

Wrench, loosen the tension bolt, and adjust

the levers to a comfortable position.

*BE CAREFUL NOT TO PULL ON THE

CABLES!

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1. Using an adjustable wrench, turn the screw counter-clockwise to loosen. (Fig1.).

2. Install the fuel tank and tank shield onto the mounting bracket. Turn screws

clockwise to firmly attach the tank. (Fig.2).

3. Run the fuel lines directly behind the tube with the slot. (Fig.3).

4. Make sure the two fuel lines connect to the engine correctly.

Fueling

This is a two-stroke engine.

Only run the engine using a mixture of gasoline and 2-cycle engine oil.

PLEASE READ OPERATING PROCEDURES BEFORE FUELING!

1. Mix fuel (minimum 90 octane) and 2-cycle engine oil in separate container. Use

Tanaka Perfect Mix or a quality 32:1 2-cycle oil. Make sure the fuel is well mixed by

shaking the container

2. Make sure that the engine is off!

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3. Slowly open the GAS CAP, so that

possible over-pressure disappears.

4. Clean the tank cap area to make sure

that it is free from excess dirt and

debris.

5. *Make sure that no dirt falls into the gas

tank.

6. Pour pre-mixed Gas/Oil mixture into the

GAS TANK. *Do not overfill.

7. After fueling, replace the GAS CAP and

tighten.

Starting

Move at least 10 feet away from where

you filled up the gas.

1. Set the CHOKE LEVER to the

CHOKED (UP) position. (Fig.5)

2. Pull the RECOIL STARTER briskly,

making sure to hold the handle in your

grasp.(Fig.6) *Note: Do not allow it to

snap back, let it back slowly. You may

want to give it a little throttle by gently

squeezing the GAS LEVER.

It may be necessary to repeat step 2

several times until the motor starts.

When starting the XG-499 for the first

time, it may be necessary to pull the

starter handle multiple times until it

starts.

*This is because the gas needs to be drawn

into the carburetor.

3. Once the engine has started, quickly

move the CHOKE LEVER into the RUN

(DOWN) position. (Fig.5)

4. After engine is started, let it warm up for

2-3 minutes before riding.

IF THE MOTOR KEEPS STALLING AT

IDLE SPEED, IT MAY BE NECESSARY

TO ADJUST THE IDLE SPEED ON THE

CARBURETOR.

Please refer to Carburetor Adjustment in

the maintenance section on page 13 for

instructions on how to adjust idle speed.

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