A Better Built Machine.
Owner’s Manual READ THIS MANUAL CAREFULLY CAREFULLY, IT CONTAINS IMPORTANT SAFETY INFORMATION.
INTERCEPTOR GTR 250/300 MODEL:2861- Differential
This kart is designed for off-road use only and does not comply with Federal Motor Vehi Vehicle cle Safety Standards.
Recommen Reco mmended ded for Ages 16+ 16+ C-GTR-2861-DIFFERENTIAL-US-05-2007
FOREWORD Thank you for purchasing our kart. We hope you will enjoy it. Before you begin operating the kart, please carefully read this Owner’s Owner ’s Manual for the Interceptor GTR 250, as it contains important safety and maintenance information. Failure to follow the warnings contained in this manual could result in serious injury or death. The Interceptor GTR 250 fits the needs of a wide variety of kart users above 16 years old. Beginners should seek instruction from your dealer or qualified instructors before and during intial use of the kart. We also recommend that you practice in a large open area until you become familiar with operations of this kart. Be sure to follow the recommended maintenance schedule and service your kart accordingly. Preventive maintenance is extremely important to the longevity of you r r kart. kart. Those who will will be be servicing this kart should carefullly review this manual before performing any repair or services. All information, illustrations, photographs, and specifications specifications contained in this manual are based on the latest product information, available at the time of publication. Due to improvements, or other changes, there may be some discrepancies in this manual. Therefore, if newer information information is needed in the future, please contact the local distributor distributor.. Distributor reserves the right to make production changes at any time, without notice, and without incurring any obligation to make same or similar changes to vehicles previously built or sold. We hope you will have a pleasant experience with our product. Thanks again for choosing our kart.
Carter Brothers Manufacturing, Co. , Inc.
A Better Built Machine
1871 U.S. Highway 231 South Brundidge, Brundi dge, Alaba Alabama ma 36010 36010 Phone: 800-523-5278 www.carterbro.com
INDEX
Owner’s Manual Warranty About Safety
1 5
Important Safety Information
6
Safety Labels
8
AreYou AreY ou Ready To Drive? Drive?
9
Is Your ourV Vehicle Ready Re ady To Drive?
11
Safe Driving Precautions
13
General Informations
15
Specifications
16
Locations Of Parts
18
Operation
20
Periodic Checks Checks And Services Services
25
Service Instructions
26
Service Information
31
Wiring Diagram
40
Trouble Shooting Charts
41
Set-up Instructions
46
WARRANTY
A Better Built Machine
CARTER KARTS LIMITED WARRANTY REGISTRATION ALL UNITS MUST BE REGISTERED WITHIN 10 DAYS OF PURCHASE OR THE WARRANTY IS VOID
To regis registe terr your your prod produc uct, t, comp comple lete te the the Warrant arranty y Regi Regist strat ratio ion n form form.. Fax Fax or mail mail the the warr warran anty ty regi regist stra rati tion on form form with with a copy copy of the the sale sales s rece receip iptt to Cart Carter er.. A warr warran anty ty regi regist stra rati tion on form form MUST be on file file with with Cart Carter er befo before re a warra arrant nty y clai claim m can can be proc proces esse sed. d.
ARRANTY PERIOD PERIOD WARRANTY The warranty warranty period starts from from the date date that the unit unit is sold sold to the first first retail retail purchaser purchaser for all Cart Carter er prod produc ucts ts Durin During g the warr warran anty ty cove covera rage ge peri period od,, we will will cove coverr warr warran anty ty part parts s and and labo laborr only only.. Parts repaired and replaced under this warranty are covered only for the remainder of the kart’s warranty. WARRA ARRATNY PERIOD PERIODS S FOR ALL KARTS KARTS ARE AS FOLLOWS: FOLLOWS: FRAME FOR 1YEAR
Void if frame is broken or bent due to abuse. se. 1. Unde Undersi rside de scra scrape ped d abusi abusivel vely y. 2. Whe Wheels are bent or bro broken due to to impact. impact. 3. Spin Spindl dles es are are bent bent due due to impa impact ct.. 4. Pain Paintt is worn worn off off of rear rear bump bumper er,, indi indicat catin ing g an extr extra a rider rider.. Axles es are are bent bent out out of ordi ordina nary ry posi positi tion on eith either er hori horizo zont ntal ally ly or vert vertic ical ally ly.. 5. Axl 6. NonNon-fa fact ctor ory y alte alteri ring ng of engi engine ne or fram frame e and and it’ it’s comp compon onen ents ts.. If the the fram rame is foun found d to be defe defect ctiive due due to mat materi erial and/ and/or or work workma mans nshi hip p when hen insp inspec ecte ted d at an auth author oriz ized ed Cart Carter er Serv Servic ice e Cent Center er.. Cart Carter er will will at its its opti option on - repa repair ir or repl replac ace e defe defect ctiive part parts s to the the orig origiinal nal purc purcha hase serr at no char charge ge.. INTERCEPTOR GTR 250 2R PARTS COVERAGE
Warran arranty ty start starts s from from the the date date of purcha purchase se by by the the first first reta retail il purch purchas aser. er. —> Engi Engine ne:: 2 year year Limi Limite ted d fact factor ory y warr warran anty ty.. * —> A-Arm, Spindles, Axles, Rack & Pinion: 90 day days —> Electroni onics, cs, Carb arburet retor & Muffler: 90 days —> Battery : 30 days —> Radiator: 90 days —> CVT CVT: 60 days days 1
WARRANTY * The second year year of the engine warranty is for the FUNCTION FUNCTION of certain engine parts. parts. Function is described as warranty coverage for parts that are not normally exposed to misuse, abuse, or extreme extreme wear. wear. These engine engine parts are warranted warranted to be free of manufacturing flaws such as stress cracks, cracks, inferior material (metal), casting flaws, flaws, and machining flaws. Upon part failure, only Carter Brothers Manufacturing, Manufacturing, Inc. may determine if it is covered. covered. Any failure or damage to a part that does not influence its function will not not be covered. Normal wear of these parts is not covered. covered. Parts covered under under the second year period would include, but not necessarily be limited to: Head cover Cylinder, and Cylinder Head Left Case Cover Left Crankcase Right Case Cover
Right Crankcase Mission Case Cylinder Head Side Cover Certain Internal Engine Parts Certain Bearings and Gears
PARTS NOT COVERED This warranty does not cover consumable wear and tear items such as, but not limited to: Brake pads Throttle cable Tires Brake cable Oil changes Chains Problem occurring due lack of proper maintenance Seats Problem occurring due to abuse Fasteners Air Filters Modifications to your GTR Modifications GTR 250 that are not Carter approved approved will void the warranty. warranty. Defective parts are subject to recall by Carter upon failure, and are required to be held by the dealer or service center until the warranty claim is settled.
WARRANTY COVERAGE Carter Brothers Manufacturing, Inc. will repair or replace, at its option, any part that is found defective in material or factory workmanship under normal use. Parts used in the “repair or replace” process under this warranty are covered only for the remainder of the GTR warranty.
TO QUALIFY FOR THIS WARRANTY: The GTR must be purchased from a dealer who is an authorized Carter dealer, and Prior to delivery to the purchaser, purchaser, set-up and pre-delivery service must be performed by a dealer who is an authorized Carter dealer. All units must be registered WITHIN WITHIN 10 DAYS DAYS OF PURCHASE or the warranty is void. All warranty work must be performed by an authorized Carter dealer or service center.
2
WARRANTY
OWNER’S WARRANTY RESPONSIBILITIES As the kart owner, you are responsible for presenting your kart to the dealer or service centre as soon as a problem exists. All shipping and transportation charges for any items returned for warranty evaluation and/or replacement are to be provided by the kart owner. Costs from kart owner to dealer or service center are the kart owner’s responsibility.
IMPORTANT NOTICE: We do not charge for parts for authorized warranty repairs. Any defective parts from repairs are required to be returned to Carter upon request. All warranties are voided if the vehicle has been altered for use in racing or competition, rented, used under abnormal conditions, conditi ons, or subject to abuse, misuse, neglect or improper maintenance. maintenance. Carter is not liable for any damage claim or liability claim, personal or otherwise, resulting from operation of this vehicle in any way. way. Carter reserves the right to change product specifications, designs, and standard equipment without notice and without incurring obligation. These vehicles are not designed or manufactured for racing or use on rental tracks, public streets, public roads, highways, paved surfaces or right-of-ways.Always wear an approved helmet and eye protection when riding. Always secure loose clothing and long hair. Always wear seatbelts. Read the operations manual.
3
A Better Built Machine.
CUSTOMER SAFETY INFORMA INFORMATION TION AND WARRANTY WARRANTY REGISTRA REGISTRATION TION FORM INTERCEPTOR INTERCEPTOR GTR 250
Warranty registration must be filed with Carter Brothers Manufacturing within 10 days of purchase or warranty will be void. In order to validate the warranty, warranty, purchaser agrees and promises to hold Carter Brothers Manufacturing and the Dealer harmless and indemnify them from all claims and demands or causes of action which may arise or be asserted asserted against them arising or allegedly arising from any claim related to the delivery of the Vehicle or its use by the Purchaser or any third parties, including all attorney fees and legal costs whether or not any claim or assertion is deemed or found to be valid or not. All parties agree and stipulate that any legal proceedings, which relate to or arise out of this transaction, shall be brought only in afederal or state court located in the County of Pike, State of Alabama. This form and Owner’s Manual contains vital safety information. Carter Brothers Manufacturing asks that you review the warnings and verify that you have read and understood each warning by placing your initials on the line beside it. I understand that I must: (please initial beside each number) _____1.Read the Owner’s Manual carefully, follow the operating procedures described in the Owner’s Manual and pay special attention to the warnings contained in the manual and on all labels. _____2.It Is Recommended that no one under the age of 16 operate the Vehicle. _____3.Never allow _____3.Never allow any operation of the Vehicle before reading the Owner’sManual. _____4.Never allow _____4.Never allow more than one operator and one passenger to ride on the Vehicle. _____5.Never operate _____5.Never operate the Vehicle Vehicle after consuming alcohol or drugs. _____6.Never operate _____6.Never operate the Vehicle without wearing your seat belt ( Karts only ), a proper helmet, eye protection, and protective clothing. _____7.Never operate _____7.Never operate the Vehicle on unsafe terrain or at excessive speeds. _____8.Never do _____8.Never do wheelies, jumps, or other stunts. _____9.Never allow _____9.Never allow anyone to ride on the back or the front of the Kart or the handlebars of the Scooter. _____10.Never allow _____10.Never allow the Kart to be driven on a public road of any kind, even a dirt or gravel one because you may not be able to avoid colliding with other vehicles. Operating your Kart on a public road may be against the law. _____11.Never operate _____11.Never operate the Kart on pavement. The Kart is not designed to be used on paved surfaces and may be difficult to control. _____12.Always follow the break-in period as described in the Owner’s Manual or your engine warranty will be voided. _____13.Always clean the air filter as filter as described in the Owner’s Manual or your engine warranty will be voided. Never operate _____14.Never _____14. operate the Kart at night. The attached lights are for ornamental purposes only. only. They will not provide sufficient lighting for night time operation. In signing this document, the Purchaser acknowledges and agrees that he has read the Owner’s Manual and that failure to do so voids all warranties, both implied and expressed. I certify that I understand all of the above warnings, warnings in the Owner ’s Manual, and that failure to obey these warnings could result in death or severe injury.
Date of Purchase(mm/dd/yy)
First Name
Model Number
MI
VIN Number
Last Name
e-mail
Street Addre Address ss
City
Zip Code
State
Website Webs ite Addres Address s
Dealer Name
City
Home Telephone Number Number
Zip Code
State
Purchaser Signature
Please fill out this form and fax or mail it back to :Carter Bronther Manufacturing
Carter Brothers Manufacturing 1871U.S.Hwy.231 Brundidge,AL.36010 Ph:800-523-5278 Fax:334-735-3500 Web: ww w.carterbro.com w.carterbro.com C-GTR-WR-US-03-2007
4
ABOUT SAFETY
In order order to keep keep everyon everyone e safe, safe, you must take respons responsibi ibilit lity y for the safe operat operation ion of your your kart. kart. To help help you make make infor informe med d deci decisi sion ons s about about safety safety,, we have have provid provided ed oper operati ating ng procedu procedures res and other other informat information ion on labels labels and and in this this manual manual.. This This informa information tion aler alerts ts you you to pote potenti ntial al hazar hazards ds that that coul could d hur hurtt you you or othe others. rs. It is not not pract practic ical al or possi possibl ble e to warn warn you you abo about ut all all the the haz hazar ards ds assoc associa iated ted with with oper operati ating ng or main mainta tain inin ing g a kart. kart. You must must use use your your own own good good judg judgme ment. nt. You will will find find impor importan tantt safet safety y info informa rmati tion on in a varie variety ty of forms forms,, inclu includi ding ng:: Safety Safety Labels Labels _ On the the kart kart.. Safety Safety Message Messages s _ Preceded by a safety alert symbol
and one of two signal
word words: s: WARNI ARNING NG,, or CAUT CAUTIO ION. N.
Thes These e sign signal al word word mean: mean:
WARNING Physi Physical cal harm harm may may resul resultt from from fail failur ure e to adhe adhere re to the the instr instruc ucti tion ons s that are are descri describe bed d withi within n the WARNI WARNING NG labe labels. ls. Safety Safety Heading Headings s — such such as impor importan tantt safet safety y remi remind nder ers s or impor importa tant nt safet safety y preca precaut utio ions. ns. Safety Safety Section Section — such such as kart kart safety safety.. Instructions — how how to use use this this kart kart corr correc ectl tly y and and safe safely ly.. This This entire entire manual manual is filled filled with import important ant safety safety inform informatio ation—p n—plea lease se read read it careful carefully ly..
5
IMPORTANT SAFETY INFORMATION
Your kart kart will will provide provide you you with with many years years of service service and and pleasu pleasure, re, provi providin ding g you take respon responsibi sibilit lity y for your your own own safety safety and and underst understand and the challen challenges ges you may meet meet whil while e driv drivin ing. g. Ther There e is much much that that you can can do to prot protect ect you yours rsel elff while while oper operat atin ing g your your kart. kart. You'l ou'lll find many helpful helpful recommen recommendation dations s through throughout out this manual. manual. The following following are a few few that that we consi conside derr most most impor importa tant. nt. Follow Follow the Age Recommend Recommendatio ation n Experi Experienc enced ed adult adult supervi supervisio sion n should should be present present for all all inexpe inexperie rienced nced operato operators. rs. Always Wear a Helmet It's a proven proven fact: fact: wearin wearing g helme helmets ts signifi significan cantly tly reduces reduces the number number and severit severity y of head head inju injuri ries es.. Alwa Always ys wear wear an appr approv oved ed motor motorcy cycle cle helme helmet. t. We also also reco recomme mmend nd that that you you wear wear eye protect protection ion,, sturdy sturdy boots, boots, gloves, gloves, and other other protecti protective ve gear gear. Drive Off-Road Off-Road Only Your our kart kart is desig designe ned d and and manu manufa factu cture red d for for off-r off-roa oad d use onl only y. Its tires tires are are not made for pavement, pavement, and the kart kart does not have have features features required required for use on public roads. roads. If you you need need to cross cross a pave paved d or pub publi lic c road road,, shut shut the kart’ kart’s s powe powerr off, off, get get off off and and walk walk your your kart kart acro across. ss. Take ake Time Time to Learn Learn & Pract Practice ice Even Even ifif you have driven driven other other karts, karts, take time to beco become me familia familiarr with how this this kart kart works works and and hand handle les. s. Prac Practic tice e in a safe safe are area a until until you buil build d your your ski skill lls s and and get get accus accustom tomed ed to this this kart kart's size and weight. weight. Because Because many accidents accidents involve involve inexperienced inexperienced or untraine untrained d drivers, drivers, we urge urge all all drivers drivers to take take a trai traini ning ng cours course e appr approve oved d by the the Go-K Go-Kar artt Safe Safety ty Insti Institu tute. te. Check Check with with your your dea deale ler r for more information information on training training courses. Be Alert Alert for Off-Road Off-Road Hazar Hazards ds The terrain terrain can can prese present nt a vari variety ety of challen challenges ges when you driv drive e off-r off-road oad.. Continu Continuall ally y "read" "read" the terrain terrain for unexpe unexpected cted turns, turns, drop-o drop-offs ffs,, rocks, rocks, ruts, ruts, and and other other hazar hazards. ds. Always Always keep keep your your speed speed low low enoug enough h to allo allow w time time to see and and react react to haz hazar ards. ds.
6
IMPORTANT SAFETY INFORMATION
Drive Drive within within Your Your Limits Limits Pushin Pushing g limits limits is another another major major cause cause of kart accide accidents. nts. Never Never drive drive beyond beyond your your person personal al abilit abilities ies or faster faster than conditi conditions ons warran warrant. t. Remembe Rememberr that that alcohol alcohol,, drugs, drugs, fatigue fatigue,, and inattention can significantly reduce your ability to make good judgments and drive safely. Alcohol, Alcohol, Drugs, Drugs, and Driving Driving Alcoho Alcohol, l, drugs drugs and drivin driving g don't don't mix. Even Even one one drin drink k can can redu reduce ce your abilit ability y to respond respond to changi changing ng conditi conditions ons,, and and your reactio reaction n time time gets worse worse with with every every additio additional nal drink. drink. So don't don't drink drink and and drive, drive, and don't don't let your friends friends drink drink and drive drive either either.. Do not operat operate e this this kart kart if you you are are takin taking g any any presc prescri ripti ption ons. s. Do Not Not Oper Operat ate e this this Kart Kart at Nig Night ht Lowe Lowerr visib visibil ility ity at at nigh nightt can can greatl greatly y reduc reduce e a driver’ driver’s s judg judgme ment. nt. Drivi Driving ng at nigh nightt is dangerous dangerous and will increase increase the possibility possibility of an accident. accident. Never Run Your Your Kart Indoors Indoors The exhau exhaust st from from the engine engine contai contains ns carbon carbon monoxid monoxide, e, a poisono poisonous us gas which which is tastele tasteless ss & odorless. Carbon monoxide kills. Keep Keep Away Away from from Moving Moving Parts Parts of the Kart Kart Never place your hands or any other body part near any moving part of the the kart. kart. Failure Failure to adhere adhere to this warning warning may cause physical physical harm harm to your body. body. Skidd Skidding ing or Slidin Sliding g The The terra terrain in’s ’s surf surfac ace e can can be a majo majorr fact factor or affe affect ctin ing g turn turns. s. Skid Skiddi ding ng in a turn turn is is more more likel likely y to occu occurr on slipp slipper ery y surfa surfaces ces such such as snow snow,, ice, ice, mud mud,, and and loose loose grav gravel el.. If you skid skid on ice, ice, you may lose lose all direct direction ional al contro control. l. To avoid avoid skiddin skidding g on slippe slippery ry terrai terrain, n, keep your your speed speed low and drive drive carefully carefully..
7
8
ARE AR E YO YOU U READ READY Y TO DRI DRIVE VE ?
Befo Before re each each drive drive,, make make sure sure you and and your your kart kart are are both both read ready y to driv drive. e. This This secti section on discusse discusses s how how to evaluat evaluate e your your drivin driving g readin readiness, ess, what what items items you shou should ld check check on your your kart, kart, and adjustm adjustments ents to make for for your comfort comfort,, convenie convenience nce,, or safety safety.. Before you drive your kart for the the first first time, time, we we urge you to: to: Read Read this this owne owner's r's manual manual and the labels labels on your kart careful carefully ly.. Make sure sure you you unders understan tand d all the safety safety message messages. s. Know Know how to operate operate all the control controls. s. Have an experi experienc enced ed adult adult presen presentt if operat operator or is not experi experienc enced ed in this this kart. kart. Before Before each each drive, drive, be be sure: sure: You wear your your seat seat belt belt at all all times times while while drivin driving g your your kart. kart. You feel feel well well and and are are in good good phys physic ical al and and ment mental al cond condit itio ion. n. You are are wear wearin ing g an appr approv oved ed motor motorcyc cycle le helm helmet et (with (with chin chin strap strap tighte tightene ned d secur securel ely) y),, eye protection, protection, and other protective protective clothing. clothing. You don' don'tt have have any any alco alcoho holl or drug drugs s in your your syst system em.. Protective Apparel For your your safety safety,, we strongly strongly recomm recommend end that that you always always wear wear an approv approved ed motorcy motorcycle cle helmet, helmet, eye protect protection ion,, boots, gloves, gloves, long long pants, pants, and long-s long-slee leeved ved shirt shirt or jacket, jacket, wheneve whenever r you driv drive. e. Altho Althoug ugh h compl complet ete e prote protecti ction on is not not possi possibl ble, e, wear wearin ing g prop proper er gear gear can can redu reduce ce the the chance chance of injur injury y when when you drive. drive. The foll followi owing ng sugges suggestio tions ns will will help help you choose choose the the proper proper drivin driving g gear gear. Helme Helmets ts and and Eye Eye Prot Protec ecti tion on Your helmet helmet is is your your most importa important nt piece piece of drivi driving ng gear gear becaus because e it offer offers s the best best protect protection ion agai agains nstt head inju injuri ries. es. A helm helmet et shoul should d fit your head head comfo comforta rtabl bly y and and secur securel ely y. An open-f open-face ace helmet helmet offer offers s some protect protection ion,, but a full-f full-face ace helmet helmet offer offers s more. more. Regard Regardles less s of the style style,, loo look k for for a DOT (Dep (Depar artme tment nt of Trans ranspo port rtati ation on)) sticke stickerr on any any helme helmett you you buy buy. Alwa Always ys wear wear a fac face e shie shield ld or gogg goggle les s to to prot protec ectt your your eyes eyes and and help help your your visi vision on..
WARNING Operating this go-kart without wearing an approved motorcycle helmet, eye protection, and protective protective clothing clothing could could increase increase your chances chances of head and/or eye injury injury, and the possibili possibility ty of of death death in the event of a severe severe accident. accident. Always Always wear an approved approved motorcycl motorcycle e helmet helmet that fits properl properly y and wear wear eye protecti protection on (goggles or face shield), gloves, boots, boots, long-sleeved long-sleeved shirt or jacket and long long pants.
9
ARE AR E YO YOU U READ READY Y TO DRI DRIVE VE? ?
Additional Additional Driving Gear In addi additio tion n to a helme helmett and and eye prote protecti ction on,, we also also reco recomm mmen end: d: Sturd Sturdy y off-r off-roa oad d motor motorcyc cycle le boot boots s to help help prot protect ect your your feet, feet, ankle ankles, s, and and lowe lowerr legs legs.. Off-road Off-road motorcycle motorcycle gloves to help protect your hands. hands. Drivi Driving ng pants pants with with knee knee and and hip hip pads pads,, a dri drivin ving g jerse jersey y with with pad padde ded d elb elbows ows,, and and a chest chest// shoulder protector. Driver Driver Training Training Devel Develop opin ing g your your drivi driving ng skill skills s is an ong ongoi oing ng proc proces ess. s. Even Even if you you have have drive driven n other other karts, karts, befo before re driv drivin ing g take take time time to beco become me fami famili liar ar with with how how this this kart kart work works s and and hand handle les. s. Prac Practi tice ce driv drivin ing g the the kart kart in a safe safe area area to to buil build d your your skil skills ls.. Do not not dri drive ve in roug rough h terr terrai ain n unti untill you you get get accu accust stom omed ed to the the kart kart's 's cont contro rols ls,, and and feel feel comf comfor orta tabl ble e with with its its size size and and weig weight ht..
WARNING Oper Operat atin ing g this this kart kart with withou outt your your seat seat belt belt coul could d caus cause e you you to be thro thrown wn from from the kart, kart, caus causing ing seriou serious s injury injury or death. death.
Age Recommenda Recommendation tion It is strongl strongly y recom recommen mended ded that that no one under under the age of 16 be permitt permitted ed to operat operate e this go-kar go-kart. t.
WARNING A chil child d driv drivin ing g a kart kart that that is not not reco recomm mmen ende ded d beca becaus use e he/s he/she he coul could d lose lose cont contro roll of the the kart kart resu result ltin ing g in sever severe e inju injury ry or deat death. h.
No Alco Alcoho holl or Drug Drugs s Alcoh Alcohol, ol, drugs drugs and and kart karts s don't don't mix. mix. Even Even a small small amou amount nt of alco alcoho holl can can impa impair ir your your abil ability ity while while oper operat atin ing g a kart. kart. Cons Consul ultt your your docto doctorr to be sure sure it is safe safe to oper operate ate a vehi vehicl cle e after after taking taking medicat medication ion..
WARNING Opera Operatin ting g this this kart kart after after consum consuming ing alcoho alcoholl or drugs drugs can seriou seriously sly affect affect your your judgme judgment, nt, cause cause you to react react more more slowly slowly,, affect affect your balanc balance e and percep perceptio tion, n, and coul could d result result in in seriou serious s injury injury or or death. death. Never Never consum consume e alcoho alcoholl or drugs drugs before before or while while operat operating ing this this kart. kart.
10
IS YO YOUR UR VEHIC VEHICLE LE READ READY Y TO DRIV DRIVE? E?
Before each drive, it is important to inspect your kart and make sure any problems you find are correct corrected. ed. A pre-dr pre-drive ive inspect inspection ion is a must, must, not only only for for safety safety,, but because because having having a brea breakd kdow own, n, or even even a flat flat tire tire,, can can be a major major inco inconv nven enie ienc nce. e. If your your kart kart has has over overtur turne ned d or has has been been invo involve lved d in a coll collisi ision on,, do not not driv drive e it until until your your kart kart has has been been inspe inspecte cted d by your your deal dealer er.. Ther There e may may be dam damag ages es or othe otherr prob proble lems ms you you cann cannot ot see.
WARNING Improperly maintaining this kart or failing to correct a problem before driving may cause a crash in which you can be seriously hurt or killed. Always perform a pre-drive inspection before every drive and correct any problems.
Pre-drive Inspection Check the following items beford you get on the kart: Engi Engine ne Oil Oil Chec Check k the the leve levell and and add add oil oil if need needed ed.. Chec Check k for for leak leaks. s. Fuel Chec Check k the the leve levell and and add add fue fuel if need needed ed.. Also Also make make sure sure the the fuel fuel fill fill cap cap is secu secure rely ly fast fasten ened ed.. Chec Check k for for leak leaks. s. Tires Use Use a gaug gauge e to chec check k the the air air pres pressu sure re.. Adju Adjust st if need needed ed.. Also Also look look for for sig signs ns of dama damage ge or excessiv excessive e wear wear. Nuts Nuts & Bolt Bolts s Chec Check k the the whee wheels ls to see see that that the the axle axle nut nuts s are are tigh tight. t. Use Use a wren wrench ch to to make make sure sure all all accessib accessible le nuts, nuts, bolts, bolts, and fastene fasteners rs are are tight. tight. Underb Underbody ody & Exhaus Exhaustt Syste System m Check Check for and remo remove ve any dirt, dirt, vegetat vegetation ion or or other other debr debris is that that could could be a fire fire hazard hazard or inter interfer fere e with with the the prop proper er oper operat atio ion n of the the kart kart.. Air Air Clean Cleaner er Housi Housing ng Drain Drain Tube ube Chec Check k for depo deposit sits s in the drai drain n tube tube.. If neces necessa sary ry,, cle clean an the the tub tube e and and chec check k the air air cle clean aner er housing.
11
IS YO YOUR UR VEHIC VEHICLE LE READ READY Y TO DRIV DRIVE? E?
Leak Leaks, s, Loos Loose e Parts Parts Walk alk arou around nd your your kar kartt and and look look for anyth anythin ing g that that appe appear ars s unus unusua ual, l, such such as as a leak leak or or loose loose cable. cable. Lights Make sure the headli headlight ghts, s, brake brake light, light, and tail light light are workin working g proper properly ly.. Throttle Check Check the the free freepla play y and and adju adjust st if need needed. ed. Press Press the throttl throttle e to make make sure sure it move moves s smooth smoothly ly without without sticking sticking,, and and snaps snaps back automat automatica ically lly when it is rele released ased.. Brakes Press Press the brake brake pedal pedal severa severall times, times, check check for prop proper er brake brake pedal pedal freep freeplay lay.. Make sure sure ther there e is no brak brake e flui fluid d leak leakag age. e. Engine Stop Button Whil While e engin engine e is runn runnin ing, g, pres press s and hol hold d the the engi engine ne stop stop butto button n for for two sec secon onds ds.. Make Make sure sure engine engine stops. stops. Steering Wheel Check Check that that the whee wheels ls tur turn n prop proper erly ly as you you turn turn the the stee steeri ring ng whee wheel. l. Cable Check Check all cable cable housi housings ngs for wear wear. Check Check the fitting fittings s for loose loosenes ness. s. Replace Replace or tight tighten en as needed.
12
SAFE DRIVING PRECAUTIONS
Off-R Off-Roa oad d Use Use Only Only Your kart kart and and its tires tires are are design designed ed and manufac manufactur tured ed for for off-ro off-road ad use only only, not not for for pave pavemen ment. t. Drivin Driving g on pavem pavemen entt can affe affect ct handl handlin ing g and and contr control ol.. You shou should ld not not drive drive your your kart kart on pavemen pavement. t.
WARNING Operating Operating this this kart on paved paved surfaces surfaces may seriousl seriously y affect affect handling handling and and contro controll of the kart, kart, and and may may cause cause the vehicl vehicle e to go go out out of contro control. l. Never operate the kart on any paved surfaces, including including sidewalks, sidewalks, driveways, parking lots and streets.
When When driv drivin ing g offoff-ro road ad,, also also reme rememb mber er to to alway always s obey obey loca locall offoff-ro road ad drivi driving ng laws laws and and regu regula latio tions ns.. Obtai Obtain n perm permis issio sion n to driv drive e on priva private te prop proper erty ty.. Avoi Avoid d poste posted d area areas s and and obey obey "no trespassing" signs. You shou should ld neve neverr drive drive you yourr kart kart on publ public ic stre street ets, s, road roads s or high highwa ways, ys, eve even n if they they are are not not paved. paved. Drivers Drivers of street street vehicle vehicles s may have have diffic difficulty ulty seeing seeing and avoidi avoiding ng you, you, which which could could lead lead to a coll collis isio ion. n. In many many sta state tes s it is is ille illega gall to oper operat ate e kart karts s on publ public ic stree streets, ts, road roads s and and high highwa ways. ys.
WARNING Operating Operating this kart on publi public c streets, streets, roads roads or highwa highways ys could could cause a collision with another another vehicle. Never operate this go-kart on any public streets, roads or highways, highways, whether whether dirt, gravel gravel or pavement. pavement.
Keep Keep Hands and Feet Feet on Contr Controls ols When When driv drivin ing g your your kart, kart, alwa always ys keep keep both both hand hands s on the the steer steerin ing g whee wheell and and both both feet feet on the foot contro controls. ls. Removin Removing g hands hands or feet away away from from the contro controls ls can result result in loss loss of bala balanc nce e and and redu reduce ce your your abil ability ity to reac reactt and and contr control ol the the kart kart..
WARNING Removing Removing hands hands from steering steering wheel or feet from foot controls controls during during operation operation can reduc reduce e your your abilit ability y to contro controll the kart kart or could could cause cause you to lose lose your your balance balance and fall fall off off the kart. kart. Always Always keep both both hands hands on the steering steering wheel wheel and both both feet on the the foot controls controls of your your kart kart during during opera operatio tion. n.
13
SAFE DRIVING PRECAUTIONS
Control Speed Drivin Driving g at excessi excessive ve speeds speeds increa increases ses the chance chance of an accide accident. nt. In choosi choosing ng a proper proper speed, speed, you need need to consider consider the the capabili capability ty of your kart, kart, the terra terrain, in, visibi visibility lity and other other operat operating ing conditions, conditions, plus plus your your own skills skills and and experience. experience.
WARNING Operat Operating ing this this kart kart at excess excessive ive speeds speeds incre increase ases s your your chance chances s of losing control control of the kart, which can result in an accident. Always Always driv drive e at a speed speed that that is prope properr for your your kart, kart, the the terrai terrain, n, visib visibili ility ty and other operating conditions, conditions, and your your experience.
Use Use Care Care on Unfa Unfami mili liar ar or Roug Rough h Terra errain in Before Before drivin driving g in a new area, area, alwa always ys check check the the terrai terrain n thoro thorough ughly ly.. Don't Don't driv drive e fast fast on on unfami unfamilia liar r terrai terrain n or when when visibil visibility ity is limited limited (it's (it's some sometime times s diff difficul icultt to to see obstruc obstruction tions s like like hidden hidden rocks, rocks, bumps, bumps, or or holes holes in time time to to react.) react.)
WARNING Failure Failure to use use extra care when operating operating this kart on unfam unfamilia iliarr terrain terrain could result result in the kart overturning overturning or going going out of control. Go slowl slowly y and be extra careful careful when operatin operating g on unfamilia unfamiliarr terrain. terrain. Always Always be alert to changing changing terrain terrain conditi conditions ons when operati operating ng the kart.
Neve Neverr driv drive e past past the the limit limit of vis visib ibil ilit ity y. Maint Maintai ain n a safe safe dista distanc nce e betwe between en you yourr kart kart and and othe other r offoff-ro road ad vehi vehicl cles. es. Alwa Always ys exer exercis cise e caut cautio ion n and and use use extra extra care care on roug rough, h, slip slippe pery ry and and loos loose e terr terrai ain. n.
WARNING Failure Failure to use extra care when when operating operating on excessi excessively vely rough, rough, slippery slippery or loose loose terrain terrain could could cause loss loss of traction traction or vehicle vehicle control, control, which which could result result in an accident, including an overturn. Do not operate operate on excessively rough, slippery, slippery, or loose loose terrain until you you have learned learned and practiced practiced the the skills skills necessary necessary to control control the kart on such terrai terrain. n. Always Always be especi especiall ally y cautio cautious us on these these kinds kinds of terrai terrain. n.
Do Not Not Perfo Perform rm Stunts Stunts You shoul should d alwa always ys oper operate ate your your kart kart in a safe safe and and reas reason onab able le mann manner er.. When When driv drivin ing, g, alwa always ys keep keep all all four four whee wheels ls on the the grou ground nd..
WARNING Attemptin Attempting g wheelies, wheelies, jumps, jumps, and and other other stunts stunts increases increases the chance chance of an accident, including an overturn. Never attempt attempt stunts, stunts, such such as wheelies wheelies or or jumps. jumps. Don't Don't try to show show off.
14
GENERAL INFORMA INFORMATION TION
MODEL IDENTIFICATION
FRAME NUMBER The frame number or VIN is stamped on the upper firewall of the frame behind the seat. VIN NUMBER LOCATION
ENGINE NUMBER The engine number is located on the lower front left side of the engine case.
FUEL RECOMMENDATIONS
FUEL Gasoline should be 92 octane or higher. Unleaded gasoline is recommended. Engine oil should be SAE 10W-30.
BREAK-IN PROCEDURE For the first 2 hours of riding, do not exceed 2/3 throttle. Vary Engine speed for the first 5 hours. Never hold engine at full throttle for long periods of time.
VIN NUMBER LOCATION
15
SPECIFICATIONS
DIMENSIONS Overall Overall Length ------------------------------------------------------------------------------------------------------------------------------------------- 92 in. (2340mm) (2340mm) Overall Width ------------------------------------------------------------------------------------------------------------------------------------------------------ 64 in. (1620mm) Overall Height -------------------------------------------------------------------------------------------------------------------------------------------------------- 61 in. (1541mm) Wheelbase ------------------------------------------------------------------------------------------------------------------------------------------------------------------ 68 in. (1727mm) Front Track Track ----------------------------------------------------------------------------------------------------------------------------------------------- 47.1 in. (1060mm) (1060mm) Rear Track ------------------------------------------------------------------------------------------------------------------------------------------------------------ 39.4 in. (1000mm) Ground Clearance ------------------------------------------------------------------------------------------------------------------------------------------------------ 8 in. (205mm)
ENGINE Type -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 4-Stroke Engine Capacity ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 250cc Bore / Stroke ---------------------------------------------------------------------------------------------------------------------------------------------------------------- 71mm / 63mm Displacement ----------------------------------------------------------------------------------------- 294.4cc Corrected Compression Ratio ------------------------------------------------------------------------------------------------------------------------------------------ 10.5:1 Carburetor -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 22mm Output Power ---------------------------------------------------------------------------------------------------------------------------------------------------------- 13.2kw/7000rpm Maximum Torque --------------------------------------------------------------------------------------------------------------------------------------------20.6Nm/5500rpm -----20.6Nm/5500rpm Starting -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- Electric Ignition -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- C.D.I. Lubrication -------------------------------------------------------------------------------------------------------------------------------------------------------------------- Force & Splash Transmission ------------------------------------------------------------------------------------------------------------------------------------- Automatic (C.V.T (C.V.T system) Spark Plug ------------------------------------------------------------------------------------------------ CR8E Plug Gap -----------------------------------------------------------------------------------------------------------------------------------------------------------0.8mm ----------------------------------------0.8mm Fuel Type Type ----------------------------------------------------------------------------------------------------------------------------------------------Ab ----Above ove 92 (unleaded) (unleaded) Engine Oil ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ SAE-10W/30 _ Idling Speed------------------------------------------------------------------------------------1700+100 rpm
CAPACITIES Maximum Load------------------------------------------------------------------Load------------------------------------------------------------------- 2 riders or 180kg/400lbs Fuel Tank ----------------------------------------------------------------------------------------------1 ----------------------------------------------------------------------------------------------18 8L/4Gal Engine Oil -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 1200cc Starting ------------------------------------------------------------------------------------------------------------------------------------------------------------------------5s ---------------------------------5sec. ec.
Climbing ------------------------------------------------------------------------------------------------- 20 -25
Battery ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 12V 12Ah Head Lights ---------------------------------------------------------------------------------------------------------------------------------------------------12V --------------------12V 35W/35W Tail Light -------------------------------------------------------------------------------------------------------------------------------------------------------12V --------------------------12V 21W/5W Gear Oil-----------------------------------------------------------------Oil------------------------------------------------------------------------------------------SAE140/650cc ------------------------SAE140/650cc Towing ----------------------------------------------------------------------------------------------500 lbs max
16
SPECIFICATIONS
CHASSIS Front, Rear Brake ----------------------------------------------------------------------------- Hydraulic disc Front Tire Tire ------------------------------------------------------------------------------------------------------------------------------------------------------------------23x7-23x7-10 10 14psi Rear Tire -----------------------------------------------------------------------------------------------------------------------------------------------------25x ------------------------------25x10 10-12 -12 14psi Front Suspension -------------------------------------------------------------------------------------------------------------------------------------------------------------Dual ----Dual A-Arm Rear Suspension ---------------------------------------------------------------------------------------------------------------------------------------------Dual --------------------Dual A-Arm Restraint System --------------------------------------------------------------------- Dual 4-point Harness Final Drive Chain ---------------------------------------------------------------------------------------------------------------------------------------------------
520 x 66
WEIGHT Net Weight -----------------------------------------------------------------------------------------------------------------------------------------------------3 ----------------------------345 45kgs/ kgs/761 761lbs lbs
*The *The speci specifi fica cati tion ons s are subj subjec ectt to chan change ge with withou outt noti notice ce..
17
LOCATION OF PARTS
MIRROR
SEAT BELT
STEERING STEE RING WHEE WHEEL L
HEADLIGHTS
R.R.WHEEL
FR.WHEEL
REAR REA R CAR CARGO GO RAC RACK K
DRIVE CHAIN 18
TOW BALL
LOCATION OF PARTS
KEY SWITCH
ENGINE STOP BUTTON
BLINKER
HEADLIGHT SWITCH
HORN 12V OUTLET
REAR RE AR CAR CARGO GO RAC RACK K
RADIATOR
ENGINE
FUEL TANK
19
OPERATION
A. Operatio Operation n Control Controls s WARNING - Do not not attem attempt pt to start start or oper operate ate the engi engine ne until until you are are comp comple letel tely y fami famili liar ar with with the the loca locati tion on and and use use of each each cont contro roll nece necess ssar ary y to oper operat ate e this this vehi vehicl cle. e. The The oper operat ator or must must know know how how to stop stop this this mach machin ine e befo before re star starti ting ng and and drivi driving ng it. it. a. Thro Thrott ttle le The The righ rightt foot foot peda pedall is the the thro throttl ttle e that that con contro trols ls the the kart kart spe speed ed.. As the the engi engine ne spe speed ed incr increa eases ses abov above e idle idle,, the clutch clutch autom automat atica icall lly y engage engages s and moves moves the the vehicl vehicle e forwar forward. d. To dise diseng ngag age e the the clutc clutch h at any any time, time, allo allow w the the throt throttle tle to retur return n to the the idle idle posit positio ion. n.
WARNING Each Each time time prior prior to start start the engine engine,, check check the the thrott throttle le assem assembly bly to to ensure ensure that that when when the the peda pedall is push pushed ed all all the the way way forw forwar ard d the the asse assemb mbly ly is work workin ing g smoo smooth thly ly and and retu return rns s to idle idle when when relea release sed. d. Do not not oper operat ate e if peda pedall or engi engine ne throt throttl tle e linkag linkage e fail fail to retur return n to idle. idle. If unab unable le to corre correct ct the probl problem em throug through h lubri lubricat cation ion,, adjustmen adjustment, t, or replacem replacement ent of worn parts, parts, contact your deale dealerr for assistance assistance..
b. Brake The The brak brake e is loca locate ted d on on the the left left side side of of the the kart kart.. Appl Applyi ying ng pres pressu sure re to the the peda pedall draw draws s the the brak brake e calip caliper er arou around nd the the brake brake pump pump at the the rear rear wheel wheel and and slow slows s or stop stops s the kart. kart. ENGINE STOP BUTTON
KEY SWITCH
c. Star Startt engi engine ne.. Inse Insert rt the the key key into into keykey-sw swit itch ch,, turn turn the the key clock clockwis wise, e, rele releas ase e the the key when when the the engi engine ne star starts ts.. Kart Kart must must be in neut neutra ral. l. The The engi engine ne will will warm warm up with within in 5 minu minute tes s if the the engine is cold you will need to pull the the chok choke e leve leverr unde underr the the seat seat.. (Warn (Warning ing:: Don’t Don’t crank starter starter more than than 5 seco second nds s at one one time time). ). e. Engin Engine e stop stop butto button. n. IMPORTANT IMPORTANT STOP BUTTON BUTTON TEST Befor Before e drivi driving ng this this vehi vehicle cle,, test test the the engi engine ne
BRAKE
THROTTLE
stop stop butto button n to assur assure e that that it is oper operat atin ing g prop proper erly ly.. With With the the engi engine ne runn runnin ing, g, push push and and hold hold the engi engine ne stop stop butto button n for for two two secon seconds ds for for the the engi engine ne to shut shut down. down.
20
OPERATION
B. Pre-D Pre-Dri rive ve Ins Inspe pect ctio ion n
WARNING Perform this pre-drive inspection everyday everyday before driving driving vehicle. If not performed performed,, serious serious damage damage to the vehicle vehicle or personal personal injury injury may result. result.
a. Check Check engine engine oil level. level. Check for leaks, leaks, add oil if requir required. ed. b. Check Check fuel fuel leve level. l. Add Add fuel fuel as nece necessa ssary ry and and do not not over overfi fill ll.. Chec Check k for for leak leaks. s. c. Check Check brakes. brakes. Depress Depress the rear rear brake brake pedal pedal several several times, times, then then check check for proper proper brake brake pedal pedal freep freeplay lay.. Make sure sure there there is no brake brake fluid fluid leakag leakage. e. Adjust Adjust ifif necessa necessary ry.. d. Check Check tires. tires. Check Check tire tire condit condition ion and pressur pressure. e. The pressur pressure e on both both front front and rear rear tires tires is 14 psi, respectively. e. Check Check drive drive chain. chain. Check Check drive drive chain’ chain’s s conditi condition on and tension tension.. Lubric Lubricate ate if necessa necessary ry.. f. Check Check throttl throttle. e. Check Check for smooth smooth operat operation ion.. Assure Assure throttl throttle e “snaps “snaps”” back back to idle. idle. g. Check Check engine engine stop button button.. Perform Perform engine engine stop stop button button test. test. Repair Repair as necessar necessary y. h. Check Check all nuts, nuts, bolts, bolts, and fastene fasteners. rs. Check Check wheels wheels to see that that all axle axle nuts and lug nuts are tighten tightened ed proper properly ly.. Check Check and and tighte tighten n as necess necessary ary all other other fasten fasteners ers to to specifi specified ed conditi condition. on. i.
Check Check occupa occupant nt protect protection ion bar. bar. Ensure Ensure all occupa occupant nt protect protection ion bars bars are in place place before before operating the kart.
j.
Check Check brake brake light. light. Check Check for proper proper operat operation ion..
k. Check wheels. Check for tightness tightness of wheel nuts and axle nuts; check that axle nuts are secur secured ed by cotter cotter pins pins.. l.
Check Check steerin steering. g. Check Check for free free operati operation on for any unusual unusual loosen looseness ess in any area. area.
WARNING Always Alwa ys foll follow ow rules rules for safe oper operation ation and wear a helmet helmet..
21
OPERATION
C. Pass Passen enge gers rs The The vehi vehicl cle e allo allows ws for for two two ride riders rs only only.. Comb Combin ined ed maximum maximum weight weight of driver driver and the passeng passenger er should should not not exce exceed ed 180k 180kg g or 400l 400lbs bs..
D. Seat eat Adju Adjust stm ment ent The seat must always always be securely fastened fastened in the posi positi tion on whic which h best best affor affords ds the oper operato atorr contr control ol of the foot foot pedals, pedals, steerin steering g wheel, and the the remote stop button. button. a. Pull Pull seat adjustm adjustment ent handle handle upward upward to diseng disengage age SEAT ADJUSTMENT HANDLE
seat slide. b. Move seat seat to desire desired d positi position. on. c. Be sure sure seat adjustme adjustment nt handle handle snaps snaps back into place place and and that that seat seat is locke locked d into into posi positi tion on..
WARNING Before Befor e attem attemptin pting g to adju adjust st the seat, ensur ensure e that engi engine ne is stop stopped. ped.
WARNING Never operate operate this buggy buggy when the provid provided ed seat is not securely securely fastened, fastened, to do so could result in a strong possibility possibility of severe personal injury or loss loss of life. Before Before attemp attemptin ting g to adjust adjust the seat, seat, ensure ensure the engine engine is stopped. stopped.
E. Parking Parking Brake Adjustment Adjustment a. Push Push forwa forward rd the the brak brake e lever lever so that that the unit unit can can roll roll
ADJUSTING NUT #2 , REVERSE CABLE REVERSE
free freely ly.. Pull Pull back back the the leve leverr to enga engage ge the the park parkin ing g brak brake. e. b. When When brak brake e leve leverr is in forw forwar ard d posi positi tion on,, ther there e needs needs to be 1/2” of freepl freeplay ay.. If If the the adjustm adjustment ent is not correct, correct, loosen loosen lock nut nut #2, then adjust lock nut nut #1 to the proper amount of freeplay freeplay..
Always Always stop the before before changing changing gears.
ADJUSTING NUT #1,
22
SE CABLE REVERSE REVER
OPERATION YOKE
F. Gear Shift Le Lever
YOKE YOKE ADJUST ADJUSTMENT MENT a. Each Each end end of the the cab cable le has has a thre thread aded ed yoke yoke on it. it. b. You must must remov emove e the the pin pin or bolt bolt in eith either er end end of the cable cable to which the yoke yoke is attatched attatched.. c. To adju adjust st an end, end, loose loosen n the the jam jam nut nut and and turn turn the the yoke the approp appropria riate te way. way.
CABLE MOUNT
CABLE MOUNT ADJUSTMENT a. The cabl cable e has has a thre thread aded ed stud stud and and jam jam nuts nuts on each each end that that is used to attatch itself to the frame. b. To adjust, loosen one jam nut on on one or both ends and adjust adjust the approp appropria riate te directi direction. on. c. Tighten jam nuts.
SHIFT LEVER ADJUSTMENT ADJUSTMENT
SHIFT LEVER
a. On the the rear rear end end of the cabl cable e a shift shift leve leverr is attatc attatche hed d to both both it and the engine engine.. b. The The leve leverr is on a spl splin ined ed shaf shaftt pro protru trudi ding ng from from the the engi engine ne.. c. Remove Remove the bolt bolt which which holds holds this this lever lever to the engine engine.. d. Slide Slide the lever lever off the shaft shaft and turn turn the approp appropria riate te way, way, one splin spline e at a time. time. e. Once Once in the the appr approp opri riat ate e posi positi tion on tigh tighte ten n all all bolts bolts back. back.
23
OPERATION
G. Start Startin ing g And And Oper Operati ating ng Instr Instruc ucti tion ons s a. Before Before starting starting the engine engine,, be sure sure that the driver driver is seated seated prop properl erly y in the the kart kart with the seat belt belt fasten fastened. ed. b. Test est the the kart kart in an open open spac space e at the the begi beginn nnin ing g to lear learn n how how to star start, t, turn turn,, and and stop stop.. c. Oper Operat ate e the the kart kart slow slowly ly unti untill you you are are fami famili liar ar with with it. it. d. The The turn turnin ing g rad radiu ius s of this this kart kart is small small and and agil agile, e, so the centr centrifu ifuga gall force force is very very high high when when turni turning ng at high high speed speed.. Slow Slow down down to to a more more con contr trol olla labl ble e spee speed d when when turni turning ng to pre preve vent nt the the kart from from rolling rolling over. over. e. Alwa Always ys turn turn the the vehi vehicl cle e at a slow slow,, contr control olla labl ble e speed speed to preven preventt the the vehi vehicle cle press the the brake. brake. If If at any time time the vehi vehicle cle from from turnin turning g over over. Keep Keep your your left foot foot read ready y to press feels unstable, unstable, reduce your speed.
24
PERIODIC CHECK AND SERVICES
Have your kart checked, adjusted, and record maintenance maintenance performed.Have these services performed periodically by your Carter Authorized Dealer to maintain the kart at the optimum condition. condition.
Item Air Cleaner Fuel Filter Engine Oil Change Tire Pressure Battery Inspec Inspection tion Brake Check Steering Check Tightness of Screws Frame Lubrication Gear Oil Check Gear Oil Change Spark Plug Exhaust Pipe Ignition Timing Emission Throttle Engine Bolt Tightening CVT Driving Device (belt) CVT Driving Device (roller) Drive Chain Lights/Electrical Equipment Fuel Lines Cam Chain Valve Clearance Lines/Cooling Connections Coolant Reservoir Coolant
Code:
Every 300km 180 mi I I R I I I I I I R I I I I I I
I/L I I I I I I I
1 Month
3 Months 6 Months
1 Year
C
R I R Replacemen Repla cementt for every 1000 km/600 miles I I I I I L I Replacement Repla cement for every 5000 km/3000 km/3000 miles I R I I I I I I R C I/L C I I I I I I I R
I=Inspection, I=Inspec tion, Cleanin Cleaning g and Adjustment C=Cleaning (replace if necessary)
R= Replace Replacement ment L=Lubrication
The above maintenace schedule is established by taking the monthly 1000km/600 miles as a reference, which ever comes first. Clean or replace the air cleaner element more often when the kart is operated in a dusty or polluted environment. Maintenance should be performed more often if the kart is frequently operated at high speeds and after the kart has accumulated higher mileage.
25
SERVICE INSTRUCTIONS
Torque Tor que Val Values ues The torq torque ue val values ues lis listed ted in thi this s tab table le are for mor more e imp import ortant ant tig tighte htened ned torqu torque e val values ues.. Ple Please ase see sta standa ndard rd values for torques torques not listed listed in the table.
Torque Tightenin Tightening g Char t Bolt
Conventional Mar ked Bolt
Diameter
N.m
Kg.m
4
1 ~2
5
8.8 Mar ked Bolt Ib-ft
N .m
0.1 ~0.2
0.7 ~1.5
1.5 ~3
0.15 ~0.3
1.0 ~2.0
1 ~4
0.2 ~0.4
1.5 ~3.0
3 ~6
0.3 ~0.6
2.0 ~4.5
6
4 ~7
0.4 ~0.7
3.0 ~5.0
8 ~12
0.8~1.2
6.0 ~8.5
8
10 ~16
1.0 ~1.6
7.0 ~11.5
18 ~28
1.8 ~2.8
13.0 ~20.0
10
22 ~35
2.2 ~3.5
16.0~25.5
40 ~60
4.0 ~6.0
29.0 ~43.5
12
35 ~50
3.5 ~5.5
25.5 ~40
70 ~100
7.0 ~10.0
50.5 ~72.5
14
50 ~80
5.0 ~8.0
36.5 ~58
110 ~160
11.0 ~16.0
79.5 ~115.5
16
80 ~130
8.0 ~13.0
58 ~94
170 ~250
17.0 ~25.
123.0 ~181.0
18
130 ~190
13.0~19.0
94 ~137.5
200 ~280
20 ~28.0
144.5 ~202.5
A. Service Air Clea Clean ner
Kg.m
Ib-ft
ELEMENT CLAMP
Serv Servic ice e air air clean cleaner er ever every y 20 hour hours s . NOTE NOTE:: Servic Service e more more often often unde underr dusty dusty condi conditio tions ns.. a. Loo Loose sen n 4 ho hook oks s from from the ai airr cl clea eane nerr co cove verr an and d then th en re remo move ve th the e co cove ver. r. b. Loos Loosen en the the cla clamp mp stri strip p and 1 screw screw of air air clea cleaner ner elemen ele ment, t, and the then n rem remove ove the air cle cleane anerr ele elemen ment. t. c. Clean Clean th the e el elem emen entt with no nonn-fl flam amma mabl ble e or high-flash high-f lash point solven solventt and then then squeeze squeeze it dry.
WARNING Never Nev er use gas gasoli oline ne or aci acid d org organi anized zed solv solvent ent to to clean clean the elem element ent..
Soap the Soap the el elem emen entt in cle clean an en engi gine ne oi oill an and d then then sq sque ueez eze e it out out.. Ins Insta tall ll the the el elem emen entt on the the elementt seat and elemen and then instal installl the air cleaner cleaner cover. cover.
26
SERVICE INSTRUCTIONS
B. Engine Lubrication You must change the oil in the crankcase after the first 5 hours of operating your new engine and after 10 hours of use thereafter. thereafter. This will insure proper lubrication of internal parts and prevent costly repairs due to excessive wear.
WARNING Used Used oil oil must must be disp dispos osed ed of at a prop proper er coll collec ecti tion on cent center er..
a. Remove drain plug located on the right rear side of engine. Tip backwards slightly by blocking the front tires and drain oil into suitable container. b. Remove and clean oil screen. c. Replace drain plug and tighten securely. Place kart in a level position. d. Refill crankcase (approximately 1200 cc or 1 1/4 quarts) to top of filler neck with SAE 10W 30 oil. e. Check oil level before each use of kart of kart or after each 10 hours of operation. Add oil to bring up to proper level. Do not mix various grades of oil.
C. Gear Oil Check and Change
ENGINE OIL PLUG COVER
JOIN BOLT
a. Remove oil join bolt. Remove drain bolt and drain oil out. b. Install the drain bolt after drained. Torque value: 1.1~1.5kgf-m 1.1~ 1.5kgf-m c. Make sure that the drain bolt washer can be re-used. d. Add oil to specified quantity from the join hole. Gear Oil Quantity: 650 cc when replacing. e. Make sure that the join bolt washer can be re-used, and install the bolt. Torque value: 3.5~4.5kgf-m f. Start engine and run run engine for 2-3 minutes. Turn off engine and make sure that oil level is at correct level. Make sure that there is no oil leakage.
27
DRAIN BOLT BO LT
SERVICE INSTRUCTIONS
D. Carbur Carburetor etor Adjus Adjustment tment Never make unnecessary adjustments. adjustments. The factory recommended settings are correct for most applications.
WARNING Air screw was set at at factory factory,, so no adjust adjustment ment is needed. needed. Note the number number of turns it takes to scew it all the way in for ease of installation. The parking brake must be used to stop the kart to perform the adjustments. THROTTLE VALV ALVE E STOPPER SCEW
a. War Warm m up engine (5~10min (5~10min). ). b. Tighten the air screw gently. gently. Backout 2 turns. c. Connect the tachometer, adjust the throttle to limit the idle speed. speed. The standard standard value is 1700 RPM. RPM. d. Tu Turn rn the air screw counter-clockwis counter-clockwise e slowly and observe the RPM of the engine, stop adjusting as the RPM reaches top speed. e. Adjust the screw screw and adjust the idle idle speed to an ideal value. f. Recheck and readjust the idle speed if necessary.
AIR ADJUSTMEN ADJUSTMENT T SCREW
E. Spark Plug a. Remove the spark plug and inspect it each time you change the oil. (Use a spark plug wrench). Keep the electrodes electro des clean and free of carbon. The presence presence of carbon or excess oil will gently reduce proper engine performance. If possible, check the spark plug gap (area between electrodes) using a wire feeler guage. This specification is 0.8~0.9mm. b. Before installing the spark plug, coat threads lightly with graphite grease, if possible, to ensure easy removal in the future. c. It is advisable to replace the spark plug at least once a year to insure easy starting and good engine performance.
28
SEAM,DIRT,CARBON 0.8~0.9mm
WASHER
SEAM
SERVICE INSTRUCTIONS
F. Cleaning Instructions Keep your kart clean. With clean rag, wipe off dirt and oil from around controls. Wipe off any spilled fuel and oil. Keep the engine clean of foreign objects, and be sure to check that air intake fan is free of debris for proper cooling.
G. Drive Chain How to Tighten Chain: a. On this unit in order to tighten the chain the entire engine must be “slid” forward.
DRIVE CHAIN
b. Loosen the engine plate bolts (2 front and 2 rear).
REAR PLATE BOLTS
c. Loosen air box bolts (4 total). d. Loosen muffler bolts (2 total). e. Slide engine forward and tighten all bolts.
How to Lubricate Chain: Lubricate chain with a spray-on type chain lubricant to increase the life of the chain.
FRONT PLATE BOLTS
NOTE: When pushing the engine forward the front AIR BOX BOLTS engine mount will try and tilt forward. This will cause the engine to return to its original position once force is removed. You will need to tap the bottom of the engine plate to keep it from tilting. Check gear positions after adjusting chain.
MUFFLER BOLTS
29
SERVICE INSTRUCTIONS
H. Adjust Adjustment ment of Front Front and Rear Shocks Shocks There are five adjustable positions on each shock. The default position is in the middle.
a.Use a round nut wrench to adjust the shock. b.The tension of the shock spring will increase as you scew to the right. c. Adjust accordingl accordingly y to the weight of the riders.
LEFT ROTATE
I. Front or Rear Shock Removal a. You must first lift either the front or the rear of the kart off the ground, depending on which shocks you want to remove.
RIGHT ROTATE
SPRING ADJUSTMENT CAM
b. Once the kart is off the ground remove the bolt from both top and bottom of each shock.
BOLT
BOLT
BOLTS BOLTS
BOLTS
Figur e 8
REAR SHOCKS
FRONT SHOCKS
30
