Rokon Trail-Breaker Scout Ranger
Rokon Trail-Breaker Scout Ranger
National Sports Center
National Sports Center

ROKON - Manuals and Resources


Control Functions


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 fl ow to the engine. The down position is for fuel fl ow. 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.

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 transmission 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.


Safety Information


Always wear an approved motorcycle helmet that fi ts 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 slippery 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 described 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.

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.

Never exceed the stated load capacity. Cargo should be properly distributed and securely 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 fi re 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/muffl er when refueling. Never refuel while smoking, or while in the vicinity of sparks, open fl ames 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 fl ood 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.



Pre-operation Checks


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 transmission 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.



Operating Your ROKON


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.

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.

The ROKON can be used to cross slow moving shallow water of up to a maximum of 24 inches in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ROKON. Drive slowly and carefully. Never change your course in the middle of a stream or you will find that slippery rocks and currents might throw you out of balance.

If the water is over 24” in depth, always float your machine across (hollow wheels only). Keep the air intake out of the water to avoid flooding the engine compartment.

Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ROKON or lead to an upset or an accident. Avoid jumping the ROKON, as loss of control and damage may result.

The real secret to riding perfection is throttle control. Remember that gradual acceleration will take you anywhere you desire with the proper gear selection. Your throttle is designed to retract upon release of the hand as a safety measure for the rider. Always grasp your throttle with ease, and never with full force.

The ROKON is designed with individual disc brakes on the front and rear gear boxes. The right hand front brake will stop both wheels through the gear train. When braking with the front brake, the machine should be in a “straight away” position. Hard braking, with a turned front wheel, can cause loss of steering which can result in loss of control. The left hand rear brake should be used more often for going down steep slopes.



Periodic Maintenance and Adjustment


Routine care of your ROKON vehicle is easily done and is important for rider safety and vehicle longevity.

  1. Inspect all fasteners for tightness.
  2. The drive chains require adjustment at intervals, depending on the mileage and the care which the operator has given the chains. Initial wear must be taken up by adjustment after the first few hours of use. Total deflection should be 1/2” to 3/4” when measured midway between the two sprockets of the most loose position. To adjust the chains, loosen the axle bolts and the adjusting bolt lock nuts, and turn the adjusting bolts equally in or out as required to give the chain the proper setting. After adjusting the chain, rotate the wheel and check to make sure the chain is aligned properly. Periodically, the chains should be removed from the machine and cleaned in solvent and re-lubricated. They should be lubricated with one of the chain lubricants on the market which can be applied to the chain in a liquid form and will penetrate to the inner parts of the rollers.
  3. Clean the air filter based on use. See Engine Manual.
  4. Use normal repair procedures for tires and tubes. Re-seat the tire beads with 40 PSI , then deflate to the 3 -5 PSI operating pressure.
  5. The miter box and transmission should not require service other than checking the oil level or replacing oil seals. The miter box should be removed and oil changed yearly. The miter box is assembled with special tooling to determine the correct tooth engagement and backlash. It is not advisable to attempt to dismantle the unit, unless necessary. The transmission should be drained and refi lled on the same yearly schedule. There is a drain plug on the bottom of the transmission, a fill level plug partway up, and a fi ll plug on the top. The miter box takes 2.5 fluid oz. of EP 80W90 gear lube oil. The transmission takes 6 fluid oz. of EP 80W90 gear lube oil.
  6. Check belt for wear. Belts last at least a year and generally average 4-5 years.
  7. Check the throttle for full return and feel.



Trouble Shooting

Twist grip sticks.
Twist grip end rubbing on handlebar. Deposit buildup under twist grip. Worn or broken twist grip or throttle cable. Throttle linkage improperly adjusted. Moisture under grip freezing in cold temp.
Chains loosen frequently.
Improperly seated chain adjustment bolts. Loose axle bolts. Improper chain alignment. Chains need lubrication. Twisted or distorted chains.
Excessive end play in wheel.
Loose axle bolts. Improper axle or wheel spacer thickness. Defective wheel bearings. Distorted bearing retainer housing in wheel.
Chain scoring tire sidewall.
Improper chain alignment. Improper axle spacer thickness. Defective wheel bearings.


Storing your ROKON


Close the gasoline shut-off valve. This will prevent fuel leakage when transporting or storing your ROKON. This is a key item when transporting your ROKON for example on the wheel free carrier.

Start the engine and allow it to run until it stops from lack of fuel. This will use up all the fuel in the carburetor and prevent the formation of deposits due to evaporation of fuel.

Disconnect fuel line and permit all fuel to drain from the gasoline tank. Replace the fuel line.




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