DIRT QUAD
OWNER’S MANUAL
Read and understand this entire manual before using!
For assistance contact Razor. DO NOT RETURN TO STORE.
Item Number:
25117460
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BEFORE YOU BEGIN
Remove contents from box. Remove the foam separators that protect the components from damage during
shipping. Inspect the contents of the box for scratches in the paint, dents or kinked cables that may have
occurred during shipping. Because the Dirt Quad was 95 percent assembled and packed at the factory,
there should not be any problems, even if the box has a few scars or dents.
WARNING:
DO NOT USE NON-RAZOR
PRODUCTS WITH YOUR RAZOR
DIRT QUAD. The Dirt Quad
has been built to certain Razor
design specifications. The
original equipment supplied at
the time of sale was selected
on the basis of its compatibility
with the frame, fork and all
other parts. Certain aftermarket
products may or may not be
compatible.
Estimated Assembly and Set-Up Time
Razor recommends assembly by an adult with experience in bicycle mechanics.
Allow up to 20 minutes for assembly, not including initial charge time.
Allow up to 12 hours for initial charge (see page 3 for charging information).
Charger
Speed Control
Charger
Port
Brake Lever
Charger
Brake Lever
Plug
Adjuster
Drive
Chain
Front Fork
Bolt Assembly
Torque Chart
ft-lb (Standard Metric 8.8
hardware for Razor Products)
The torque values in the
table are based on the use of
lubricated threads. Reduce
15% for dry threads.
Tire
Wheel
Size (mm) Torque in Ft-lb
6
5
9
7
Required Tools
8
17
33
60
Some tools may be supplied; however, we recommend the use of mechanic’s grade tools. Use the supplied
tools only as a last resort.
10
12
N•m (Standard Metric 8.8
hardware for Razor Products)
The torque values in the
table are based on the use of
lubricated threads. Reduce 15%
for dry threads.
or
Size (mm) Torque in N•m
6
9
2.5mm, 5mm and 6mm
hexagonal key wrenches
(included)
10mm wrench
Phillips
screwdriver
Bicycle-style tire pump for
Schrader valve tires, with
pressure gauge
7
8
14
23
45
80
10
12
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2
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ASSEMBLY AND SET-UP
Charging the Battery
WARNING:
Your electric four wheeler may not have a fully charged battery; therefore it is a good idea to charge the
battery prior to use.
Always disconnect your electric
four wheeler from the charger
before cleaning with liquid.
• Initial charge time: 12 hours
• Recharge time: Always remember to turn the
power switch off and recharge for at least 8 hours
after each use. When vehicle is not in regular
use, recharge battery at least once a month until
normal use is resumed. If you have left the power
switch on or your product has not been charged
for a long period of time the battery may reach a
stage at which it will no longer hold a charge.
• Run time: up to 40 minutes
• Average battery life: 250 charge/discharge cycles
Note: If your charger does not
look like the one illustrated,
your unit has been supplied
with an alternative charger.
The specifications and charging
procedure would not change.
The charger has a small window
with one LED or two LEDs to
indicate the charge status. Refer
to the illustration on the charger
unit for the actual “charging” and
“charged” status indications for
your model charger.
Charger
Port
Chargers have built-in over-charge
protection to prevent battery from
being over-charged.
Charger
Plug
Be sure to properly align the
groove on the charger input
port with the corresponding
socket on the Dirt Quad and
tighten threads; otherwise, no
charging action will occur.
1Align the groove on the plug
of the charger port and plug
into the port on the Dirt Quad.
Tighten the threads to secure
the plug. The charger works
with the power switch in either
the on or off position.
2 Plug the charger plug into a
wall outlet.
Attaching the Handlebars
WARNING:
Failing to properly adjust and
tighten the bolts that affix the
handlebars can cause you to
lose control and crash.
3 Insert bolts and tighten
securely. When properly
tightened, the handlebars
should not move forward or
back. Note: The gap between
the upper clamp and lower
clamp should be equal on both
sides of handlebar.
2 Place handlebars in handle-
bar clamp in upright, vertical
position.
1Using the 6mm hexagonal
key wrench, remove bolts
from handlebar clamp.
3
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ASSEMBLY AND SET-UP
Inflating the Tires
Note: The pressurized air
Tires are inflated when shipped, but they invariably lose some pressure between the point of
manufacturing and your purchase. Always inflate the tires to the correct PSI before first time use.
supplies found at gasoline
stations are designed to inflate
high-volume automobile tires.
If you decide to use such an
air supply to inflate your tires,
first make sure the pressure
gauge is working, then use very
short bursts to inflate to the
correct PSI. If you inadvertently
over-inflate the tire, release the
excess pressure immediately.
Using a bicycle-style tire pump equipped for a Schrader-type valve, inflate the front tire to the PSI indicated
on the sidewall of the tire.
Testing the Brake
To use the brake, squeeze the lever to increase the pressure on the brake. The brake lever is fitted
with a cable adjuster to compensate for cable stretch and/or to fine-tune the lever movement to brake
engagement. If brake is not engaging properly, follow instructions for adjusting the brakes outlined below.
REPAIR AND MAINTENANCE
Check the Razor web site for any updates on the latest repair and maintenance procedures.
Turn power switch off before conducting any maintenance procedures.
q Adjusting the Brake
Caliper adjuster
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WARNING:
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Rotor
Pads
The brake is capable of causing
the electric four wheeler
to skid the tire throwing an
unsuspecting rider. Practice
in an open area free from
obstacles until you are familiar
with the brake function. Avoid
skidding to a stop as this can
cause you to lose control or
damage the rear tire.
Backside
view of
disk brake
2 Locate the rear brake caliper
and disk brake behind the right
rear wheel. The distance of the
brake wire between the end of
the cable and the anchor bolt
should be between 37 and 44
mm. If the rear brake has too
much slack, loosen the rear
anchor bolt with a hexagonal
wrench and pull the brake wire
tighter (direction indicated with
arrow).
3 If the brake rotor is
1 To adjust the play, thread the
brake lever adjuster in or out
1/4 to 1/2 turn until the desired
brake adjustment is attained.
Most adjustments are complete
at this step. If brake still needs
further adjustment, proceed to
step 2 for rear brake.
dragging on the brake pads
use your fingers to twist the
caliper adjuster in either
direction until rotor is
centered between pads.
4
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REPAIR AND MAINTENANCE
q Replacing the Fuse
WARNING:
To prevent shock or short circuit,
please follow the instructions
accordingly and do not skip or
combine any steps.
1 Make sure the power switch
2 Under the front fender and
through the frame, locate the
fuse cover attached to the top
of the battery casing.
3Open the fuse cover to
is turned off.
expose the fuse.
Amperage
number
4Remove the fuse and replace
with a new one of equal
amperage.
5Close the fuse cover.
Note: Amperage rating is
located on top of fuse. Fuse
must be replaced with one of
equal amperage.
q Replacing the Chain
Tools required: 6mm hexagonal key wrench, 10mm wrench and Phillips screwdriver.
WARNING:
Do not touch motor after use.
Motor is (or can be) very hot.
3Remove the 3 screws from
the top half of the chain guard
and remove from frame.
1 Remove the bolt on the
2 Remove the bolt on the
inside of the rear wheel.
Remove nut and pull bolt out
of axle.
outside of the rear wheel.
6Remove chain from both
sprockets and replace with new
chain.
4 Remove the 2 screws from
the bottom half of the chain
guard and remove from frame.
5 Spread the chain tensioner
apart to loosen chain.
5
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REPAIR AND MAINTENANCE
9Position top half of the chain
guard to align mounting holes
and screw to frame.
7 Reset chain tensioner.
8 Position bottom half of the
chain guard to align mounting
holes and screw to frame.
10 On the inside of the wheel
slide bolt through wheel and
axle and secure with nut.
11 On the outside of the
wheel replace washers and
secure with bolt.
q Chain and Sprocket
WARNING:
The chain will typically have a “loose spot” and “tight spot” corresponding with a particular sprocket
rotational position. This is normal and common to all chain-driven vehicles due to run-out tolerances of the
freewheel and sprocket. Proper chain alignment must be maintained. If the chain is noisy or rough running,
check the lubrication, tension and alignment of the sprockets, in that order. The tensioner arms must be
aligned and free from binding and the tensioner spring(s) must be operating correctly.
To avoid a pinch or injury, keep
fingers away from moving
sprockets and chain.
q Battery Care and Disposal
Do not store the battery in temperatures above 75° F or below -10° F.
CONTAINS SEALED LEAD BATTERY. BATTERY MUST BE RECYCLED.
Disposal: Your Razor product uses sealed lead-acid batteries which must be recycled or disposed of in
an environmentally sound manner. Do not dispose of a lead-acid battery in a fire. The battery may explode
or leak. Do not dispose of a lead-acid battery in your regular household trash. The incineration, land filling
or mixing of sealed lead-acid batteries with household trash is prohibited by law in most areas. Return
exhausted batteries to a federal or state approved lead-acid battery recycler or a local seller of automotive
batteries. If you live in Florida or Minnesota, it is prohibited by law to throw away lead-acid batteries in the
municipal waste stream.
WARNING:
If a battery leak develops, avoid
contact with the leaking acid
and place the damaged battery
in a plastic bag. Refer to the
disposal instructions at left. If
acid comes into contact with
skin or eyes, flush with cool
water for at least 15 minutes
and contact a physician.
q Charger
The transformer/charger supplied with the bike should be regularly examined for damage to the cord, plug,
enclosure and other parts, and, in the event of such damage, the Dirt Quad must not be charged until it has
been repaired or replaced.
Use ONLY with the recommended charger.
q Replacement Parts
The most frequently requested replacement parts (wheels, tires, tubes, batteries and chargers) are
contact an authorized Razor repair center.
q Repair Centers
For a list of authorized Razor repair centers:
• Send an e-mail to [email protected] or call 866-467-2967 for the center nearest you.
6
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TROUBLESHOOTING GUIDE
Problem
Possible Cause
Solution
Vehicle does not run.
Vehicle is rolling backwards.
Throttle will not engage if the vehicle is rolling backwards. Come to a
complete stop and then activate the throttle.
Undercharged battery.
Charge the battery. A new battery should have been charged for at
least 12 hours before using the vehicle for the first time and up to 8
hours after each subsequent use.
Check all connectors. Make sure the charger connector is tightly
plugged into the charging port, and that the charger is plugged into
the wall.
Make sure power flow to the wall outlet is on.
Charger is not working.
You may check to see if your charger is working by using a volt meter or
asking your local Razor authorized service center to test your charger
for you.
Vehicle was running but
suddenly stopped.
Loose wires or connectors.
Burned-out fuse.
Check all wires and connectors to make sure they are tight.
The fuse will burn out and automatically shut off the power if the
motor is overloaded.
An excessive overload, such as too heavy a rider or too steep a hill, could
cause the motor to overheat. Refer to replacing the fuse instructions
on page 5 of this manual. Correct the conditions that caused the fuse
to burn out and avoid repeatedly burning out fuse.
Motor or electrical switch damage.
Contact your local Razor authorized service center for diagnosis and
repair.
Short run time (less than Undercharged battery.
30 minutes per charge).
Charge the battery. A new battery should have been charged for at
least 12 hours before using the vehicle for the first time and up to 8
hours after each subsequent use.
Check all wires and connectors. Make sure the battery connector is
tightly plugged into the charger connector, and that the charger is
plugged into the wall.
Make sure power flow to the wall outlet is on.
Battery is old and will not accept full
charge.
Even with proper care, a rechargeable battery does not last forever.
Average battery life is 1 to 2 years depending on vehicle use and
conditions. Replace only with a Razor replacement battery.
Brakes are not adjusted properly
Driving conditions are too stressful.
Refer to brake adjustment instructions on page 4 of this manual.
Use only on solid, flat clean and dry surfaces such as pavement or
level ground.
Vehicle runs sluggishly.
The tires are inflated when shipped, but they invariably will lose some
pressure between the point of manufacturing and your purchase. Refer
to instructions on page 4 of this manual to properly inflate tires.
Tires are not properly inflated.
Vehicle is overloaded.
Make sure you do not overload the vehicle by allowing more than
one rider at one time, exceeding the maximum weight limit, going up
too steep a hill or towing objects behind the vehicle. If the vehicle is
overheated, the temperature circuit protector will slow motor down
and if the condition continues, will shut off power to the motor. Correct
the driving conditions that caused the overheating, wait 5-10 minutes
and then resume riding. Avoid repeatedly overheating the unit.
7
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TROUBLESHOOTING GUIDE
Problem
Possible Cause
Solution
Check all wires around the motors and all connectors to make sure
they are tight.
Sometimes the vehicle
doesn’t run, but other
times it does.
Loose wires or connectors.
Contact your local Razor authorized service center for diagnosis and
repair.
Motor or electrical switch damage.
Normal response to charger use.
No action required. This is normal for some chargers and is no cause
for concern. If your charger does not get warm during use, it does not
mean that it is not working properly.
Charger gets warm
during use.
Refer to instructions on page 4 of this manual to properly adjust
brakes.
Vehicle does not stop
Brakes are not adjusted properly.
Chain is too dry.
when applying the brake.
Apply a lubricant such as 3 in 1TM or Tri-FlowTM to the chain.
Vehicle makes loud
noises or grinding
sounds.
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8:00 AM - 5:00 PM Pacific Time.
8
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DIRT QUAD PARTs
Keep your Dirt Quad running for years with genuine Razor parts. Visit our web site or e-mail us for more information on spare part
availability. (Specifications subject to change without notice.)
01 Handlebar grip (right/left)
02 Speed controller w/ LEDs
02-1 Sleeve
17 Brake caliper assembly
18 Brake Disc
19 Chain
03 Handlebar
20 Sprocket
04 Brake lever assemble complete
05 Handlebar clamp complete
06 Frame
21 Chain guard (upper)
22 Chain guard (lower)
23 Plastic body assembly
23-1 Plastic body
07 Shock
08 Front wheel complete
09 Steering mechanism
10 Control module
23-2 On/ Off switch
23-3 Charger port w/ wires
23-4 Seat
11 Battery (2 - 12V/7Ah)
12 Motor (24V 350W)
13 Chain tension assembly
14 Battery cover (right)
15 Battery cover (left)
16 Rear wheel complete
23-5 Footrest platform (left)
23-6 Footrest platform (right)
Items Not shown
24 Charger
25 Tool Kit
9
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SB 1918 (CALIFORNIA) DECLARATION
YOUR INSURANCE POLICIES MAY NOT PROVIDE COVERAGE FOR ACCIDENTS INVOLVING
THE USE OF THIS SCOOTER/ELECTRIC VEHICLE. TO DETERMINE IF COVERAGE IS
PROVIDED, YOU SHOULD CONTACT YOUR INSURANCE COMPANY OR AGENT.
10
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Safety RemindeRS
PRE-RIDE CHECKLIST
Loose Parts
Tire Inflation
Check and secure all fasteners before every ride. Make
Periodically inspect the tires for excess wear, and regularly
q check the tire pressure and re-inflate as necessary. If you
q sure steering stem clamp bolts are locked properly in place.
There should not be any unusual rattles or sounds from
loose parts or broken components. If you are not sure, ask
an experienced mechanic to check.
get a flat tire, the inner tube can be patched or a new tube
can be purchased from Razor or an authorized repair center.
Safety Gear
Brake
Always wear proper protective equipment such as an
q approved safety helmet, elbow pads and kneepads. Always
Check the brake for proper function. When you squeeze
q the lever, the brake should provide positive braking action.
wear shoes (lace-up shoes with rubber soles), never drive
barefooted or in sandals, and keep shoelaces tied and out
of the way of the wheels, motor and drive system.
When you apply the brake with the speed control on, the
brake cut-off switch will stop the motor.
Frame, Fork and Handlebars
Check for cracks or broken connections. Although broken
q frames are rare, it is possible for an aggressive driver to
bash into a curb or wall and wreck and bend or break a
frame. Get in the habit of inspecting yours regularly.
dO nOt RetURn tO StORe
do not use this vehicle for the first time until you
have inflated the tires to the correct PSi and
charged the battery for at least 12 hours.
failure to follow these instructions may damage
your vehicle and void your warranty.
WaRRanty
Razor Limited Warranty
For your records, save your original sales receipt with this manual and
write the serial number below.
The manufacturer warranties this product to be free of manufacturing
defects for a period of 90 days from date of purchase. This Limited
Warranty does not cover normal wear and tear, tires, tubes or
cables, or any damage, failure or loss caused by improper assembly,
maintenance, or storage or use of the Razor Dirt Quad.
__________________________________________
Item Number:
25117460
This Limited Warranty will be void if the product is ever:
• used in a manner other than for recreation;
• modified in any way;
• rented.
The manufacturer is not liable for incidental or consequential loss or
damage due directly or indirectly to the use of this product.
Razor does not offer an extended warranty. If you have purchased an
extended warranty, it must be honored by the store at which it was
purchased.
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8:00 AM - 5:00 PM Pacific Time.
Printed in China for:
Razor USA LLC
PO Box 3610
Cerritos, CA 90703
© Copyright 2006 Razor USA. All rights reserved.
120607
11
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