A Better Built Machine.
Owner’s Manual Parts Manual READ THIS MANUAL CAREFULLY CAREFULLY, IT CONTAINS IMPORTANT SAFETY INFORMATION.
INTERCEPTOR GTR 250 MODEL:2861-Live MODEL:2861-Liv e Axle
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-LIVE AXLE-003-03-2007
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 extremely important to the the longevity of you kart. Those who will be servicing this kart should carefullly review this manual before performing any repair or services. All information, illustrations photographs, and 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. 1871 U.S. Highway 231 South Brundidge, Brundi dge, Alaba Alabama ma 36010 36010 Phone: 800-523-5278
INDEX Owner’s Manual Warranty
1
About Safety
5
Important Safety Information
6
Safety Labels
8
Are You Ready Ready To Drive? Drive?
9
Is Your Ve Vehicle hicle Ready To Drive Drive? ?
11
Safe Driving Precautions
13
General Informations
15
Specifications
16
Locations Of Parts
18
Operation
20
Periodical Perio dical Checks And Services
25
Service Instructions
26
Service Information
31
Wiring Diagram
40
Trouble Shooting Charts
41
Set-up Instructions
46
Parts Manual Head Cover
Fig.1
Cylinder Head Comp
Fig.2
Cylinder Cylind er Assem Assembly bly
Fig.3
L Cover Cover Assem Assembly bly
Fig.4
L Crank Case
Fig.5
R Crank Case
Fig.6
R Case Cover
Fig.7
Movable Drive Face
Fig.8
Crank Shaft
Fig.9
AC Gen Flywheel
Fig.10
Balance Shaft
Fig.11
Mission Case
Fig.12
Oil Pump Pump Assem Assembly bly
Fig.13
Cylinder Cylind er Head Side Cover Assem Assembly bly
Fig.14
Driven Pully Set
Fig.15
A.I.C.V.Assembly
Fig.16
Carburetor Carbu retor Assemb Assembly ly
Fig.17
Frame Group
Fig.18
Steering Steer ing Shaft Assem Assembly bly
Fig.19
Suspen Sus pensio sion n Arm Ass Assemb embly ly
Fig.20
Rear Cargo Rack/Seat/Belt
Fig.21
Engine/Muffler/Air Cleaner
Fig.22
Rear Swing Arm
Fig.23
Rear Housing
Fig.24
Wire Harness/Electrical
Fig.25
Trail Board
Fig.26
Tool Kit
Fig.27
Warning Stickers
Fig.28
Stickers
Fig.29
INDEX Services Manual General Informatio Information n
1.1
Service Servic e Mainten Maintenance ance Informa Information tion
2.1
Lubrication System
3.1
Fuel System
4.1
Cylinder Head / Valve
5.1
Cylinder / Pistion
6.1 6. 1
“V” Type Belt Driving System / Kick-Starter
7.1
Final Driving Mechanism
8.1
Alternator
9.1
Crankshaft / Crankcase
10.1
Cooling System
11.1
Electrical Equipment
12.1
WARRANTY
A Better Built Machine.
CARTER KARTS LIMITED WARRANTY REGISTRATION ALL UNITS MUST BE REGISTERED WITHIN 10 DAYS DAYS OF PURCHASE OR THE WARRANTY IS VOID
To register your product, complete the Warranty Warranty Registration form. Fax or mail the warranty registration form with with a copy of the sales receipt to Carter. A warranty registration form MUST be on file with Carter before a warranty claim can be processed. WARRAN ARRANTY TY PERIOD PERIOD
The warranty warranty period starts starts from the date date that the unit unit is sold to the first first retail purchaser purchaser for for all Cart Carter er prod produc ucts ts Duri During ng the warr warran anty ty cover coverag age e 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. WARRATNY 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. 1. Underside scraped sc raped abusively. 2. Wheels are bent bent or broken due due to impact. impact. 3. Spindles are bent due to impact. 4. Paint is worn off of rear bumper, indicating an extra rider. vertically. 5. Axles are bent out of ordinary position either horizontally or vertically. 6. Non-factory altering of engine engine or frame and it’s it’s components. If the frame is found to be defective due to material and/or workmanship when inspected at an authorized Carter Service Center. Center. Carter will at its option - repair or replace defective parts to the original purchaser at no charge. INTERCEPTOR GTR 250 2R PARTS COVERAGE
Warranty starts from the date of purchase by the first retail purchaser. —> Engine: Engine: 2 year
Limited Limited factory factory warranty. warranty. *
—> A-Arm, A-Arm, Spindle Spindles, s, Axles, Rack & Pinion: Pinion: 90 days days —> Electronics, Electronics, Carburetor Carburetor & Muffler: Muffler: 90 days —> Battery Battery : 30 days days ---> Radiator: Radiator: 90 days ---> CVT: CVT: 60 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 in 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.Always 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 beforer eading 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. _____14.Never operate _____14.Never operate the Kart without wearing a proper helmet, eye protection, and protective clothing. _____15.Never operate _____15.Never operate the Kart at night. The attached lights are for ornamental purposes only. only. They will not 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 Brothers Manufacturing y W w.carterbro.com C-A-WR-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 Driving Gear In addition addition to a helmet and eye protection, protection, we also also recommend recommend:: Sturdy Sturdy off-ro off-road ad motorcyc motorcycle le boots boots to help help protect protect your your feet, feet, ankles ankles,, and lower lower legs. legs. Off-road Off-road motorcycle motorcycle gloves to help protect your hands. Driving Driving pants pants with with knee knee and hip pads, pads, a driv driving ing jersey jersey with with padd padded ed elbows, elbows, and a chest chest// shoulder protector. Driver Training Develop Developing ing your your driving driving skills skills is an ongoin ongoing g proces process. s. Even Even if you have have driven driven other other karts, karts, befor before e driv drivin ing g take take time time to beco become me fami famili liar ar with with how how this this kart kart wor works ks and and hand handle les. s. Pract Practice ice drivi driving ng the kart kart in a safe safe area area to buil build d your your skill skills. s. Do not not drive drive in rou rough gh terr terrai ain n until until you you get get accus accustom tomed ed to the the kart's kart's contro controls, ls, and and feel feel comfort comfortabl able e with with its its size and weight. weight.
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 the kart, kart, causing causing serious serious injury injury or death. death.
Age Recommenda Recommendation tion It is strong strongly ly recom recommen mended ded that that no one under under the the age of 16 16 be permitt permitted ed to oper operate ate this go-kar go-kart. t.
WARNING A child child drivin driving g a kart kart that that is not recom recommen mended ded beca because use he/she he/she coul could d lose lose contro controll of the kart resulti resulting ng in severe severe injury injury or death. death.
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 impa impair ir your your abi abili lity ty 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 medication.
WARNING Operating Operating this this kart after consuming consuming alcohol alcohol or drugs drugs can seriousl seriously y affect affect your your judgmen judgment, t, cause you to to react more slowly slowly,, affect affect your your balance balance and perceptio perception, n, and and could could result result in serio serious us injury injury or death. death. Never consum consume e alcohol alcohol or drugs drugs before before or while while operati operating ng this 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. accident. Always Always driv drive e at a speed speed that that is prop proper er for your your kart, kart, the the terrai terrain, n, visib visibili ility ty and other operating operating conditions, and and 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 slowly slowly and be extra careful careful when operating operating on unfam unfamilia iliarr terrain. terrain. Always Always be alert alert to changing changing terrain terrain conditio conditions ns when operatin operating g 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 on excessively rough, slippery, slippery, or loose loose terrain until 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 ------------------------------------------------------------------------------------------------------------------------------------------- 90 in. (2286mm) (2286mm) Overall Width ------------------------------------------------------------------------------------------------------------------------------------------------------ 62 in. (15748mm) Overall Height -------------------------------------------------------------------------------------------------------------------------------------------------------- 63 in. (1600mm) Wheelbase ------------------------------------------------------------------------------------------------------------------------------------------------------------------ 68 in. (1727mm) Front Track ---------------------------------------------------------------------------------------------------------------------------------------------------------- 47.1 in. (1060mm) Rear Track Track ------------------------------------------------------------------------------------------------------------------------------------------------- 39.4 in. (1000 mm) Ground Clearance ------------------------------------------------------------------------------------------------------------------------------------------------ 5.1 in. (130mm)
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 ----------------------------------------------------------------------------------------------15L/4Gal ----------------------------------------------------------------------------------------------15L/4Gal Engine Oil -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 1200cc Starting -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------5s --------------------------------------5s
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
CHASSIS Front, Rear Brake ----------------------------------------------------------------------------- Hydraulic disc Front Tire Tire ------------------------------------------------------------------------------------------------------------------------------------------------------------------23x7-23x7-10 10 14psi Rear Tire -----------------------------------------------------------------------------------------------------------------------------------------------------25x7-12 ------------------------------25x7-12 14ps 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 -----------------------------------------------------------------------------------------------------------------------------------------------------372kgs/819lbs ----------------------------372kgs/819lbs
*The *The speci specifi fica cati tion ons s are subj subjec ectt to chan change ge with withou outt noti notice ce..
1
LOCATION OF PARTS
MIRROR SEAT BELT
HEADLIGHTS
STEERING WHEEL
R.R.WHEEL
FR.WHEEL
REAR REA R CAR CARGO GO RA RACK CK
DRIVE CHAIN
TOW BALL
18
LOCATION OF PARTS 12V OUTLET HORN KEY SWITCH
HEADLIGHT SWITCH
BLINKER
ENGINE STOP BUTTON
REAR REA R CAR CARGO GO RA RACK CK
RADIATOR
ENGINE
FUEL TANK
19
OPERATION
A. Operatio Operation n Control Controls s WARNING - Do not attempt attempt to to start start or opera operate te the engine engine until until you are are comple completely tely familia familiar r with the locatio location n and use of each each contr control ol necessa necessary ry to operat operate e this this vehi vehicle cle.. The operat operator or must must know know how how to stop stop this this mach machin ine e befo before re start startin ing g and and driv drivin ing g it. it. a. Throttle The The righ rightt foot foot peda pedall is the the throt throttle tle that that contro controls ls the the kart kart speed speed.. As the the engi engine ne spee speed d increa increases ses above above idle, idle, the clutch clutch auto automati maticall cally y engage engages s and moves moves the vehic vehicle le forwar forward. d. To dise diseng ngag age e the the clutc clutch h at any any time, time, allo allow w the the thro throttl ttle e to retu return rn to the the idl idle e pos positi ition on..
WARNING Each time prior prior to start start the the engine engine,, check the throttle throttle assemb assembly ly 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 smooth smoothly ly and and return returns s to idle idle when when relea released sed.. Do not operat operate e if pedal pedal or engine engine thrott throttle le linkage linkage fail to return return to idle. idle. If unable unable to correct correct the problem problem through through lubricati lubrication, on, adjustment, or replacement replacement of worn parts, contact your dealer for assistance.
b. Brake The The brak brake e is loca locate ted d on the left left side side of of the the kart kart.. Appl Applyin ying g pres pressur sure e to the pedal pedal draws draws the brake brake cali caliper per around around the brake brake pump at the the rear rear wheel wheel and slows slows or or stops stops the kart. kart. KEY SWITCH
ENGINE STOP BUTTON
c. Star Startt engi engine ne.. Inser Insertt the the key into into key-s key-swi witch tch,, turn turn the key clockwise, release the key when the engi engine ne start starts. s. Kart Kart must must be in neutr neutral al.. The The engi engine ne will will warm warm up with within in 5 minu minutes tes if the the engi engine ne is is cold cold you you will will nee need d to pull pull the the chok choke e leve leverr unde underr the seat seat.. (Warn (Warning ing:: Don’t Don’t crank starte starterr more more than than 5 seco second nds s at one one time time). ). e. Engine Engine stop button. IMPORTANT IMPORTANT STOP BUTTON BUTTON TEST Befor Before e drivin driving g 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 is oper operat atin ing g prop proper erly ly.. With With the engi engine ne run runni ning ng,, push push and and hol hold d the engi engine ne stop stop butto button n for for two two secon seconds ds for for the the engi engine ne to 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. Passengers 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 slide. SEAT ADJUSTMENT HANDLE
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 Bef ore att attemp emptin ting g to adjust adjust the sea seat, t, ensur ensure e tha thatt kar kartt eng engin ine e is sto stoppe pped. d.
WARNING Never opera operate te this kart when when the provid provided ed seat is 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 to adju adjust st the seat, seat, ensure ensure the kart kart engine engine is stopp stopped. ed.
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 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 kart before before changing changing gears. gears.
22
OPERATION
F.
Gear Shift Lever YOKE
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 hold hold this this leve leverr 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
PERIODICAL 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 Inspection 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 Replacement for every 1000 km/600 miles I I I I I L I Replacement for every 5000 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
SE RVICE INSTRUCTI INSTRUCTIONS ONS
Torque Tor que Val Values ues The tor The torqu que e va valu lues es li liste sted d in th this is ta tabl ble e ar are e fo forr mor more e im impo port rtan antt tig tight hten en torque values. values. Please see see standard 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
Kg.m
Ib-ft
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
ELEMENT
A. Service Air Clea Clean ner
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 must must be dispos disposed ed of at a proper proper collec collectio tion n center center..
a. Remove drain plug located on the right rear side of engine. Tip kart 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 10W30 oil. e. Check oil level before each use of kart or after each 10 hours of operation. Add oil to bring up to proper level. Do not mix various grades of oil.
ENGINE OIL PLUG COVER
C. Gear Oil Check and Change
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.
Figure 8
DRAIN BOLT
27
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
clean dint or carbon 0.8~0.9mm
washer
proclean
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. NOTE: When pushing the engine forward the front 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. How to Lubricate Chain:
FRONT PLATE BOLTS
AIR BOX BOLTS
Lubricate chain with a spray-on type chain lubricant to increase the life of the 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.
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.
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
SERVICE INFORMA INFORMATION TION
J. Front Wheel Replacement Do not disass disassemb emble le the castle castle nuts nuts when when you replac replace e the front front wheels wheels.. It is is only only nec neces essar sary y to remov remove e the the four four 4 lug lug nuts nuts to to remo remove ve the the whee wheel. l. Tight ighten en the the nuts nuts afte afterr repl replac acin ing g the the whee wheels ls..
Figure Figure711
K. Rear Wheel Replacement
Do not not disas disassem sembl ble e the castl castle e nuts nuts when when you you repl replace ace the the rear wheel and hub assembly assembly.. Remo Remove ve the the cotte cotterr pin pin and and the 24mm 24mm nut. nut. Then Then slid slide e off off wheel wheel and and hub hub asse assemb mbly ly.. It is is only only nec necess essar ary y to remo remove ve the the four four 4 lug lug nuts nuts to to remo remove ve the the whee wheell by itse itself. lf.
Figure 8
31
SERVICE INFORMATION
L. Fr Fron ontt Wheel Wheel Alig Alignm nmen entt a. The The fron frontt whee wheels ls sho shoul uld d be “toe “toe-i -in” n” from from 1/8” 1/8” to 1/4”. 1/4”. To chec check k for for alig alignm nmen ent, t, mea measu sure re dista distanc nce e A and and B bet betwee ween n the the cent center erli line ne (CL) (CL) of the the whee wheels. ls. The The prop proper er toe toe-i -in n dime dimensi nsion on A shou should ld be 1/8” 1/8” – 1/4” 1/4” grea greate terr than than dime dimens nsio ion n B. b. To adju adjust st the the alig alignm nmen ents ts,, loos loosen en the the lock lock nuts nuts on both both side sides s of Fron Frontt Tie Rods Rods.. To make make Dimensi Dimension on B smalle smallerr, turn turn the the rod to the the left. left. Adjust Adjust the rod to the the right right dire directi ction on to to make make Dimensi Dimension on B larger larger.. After After adjusti adjusting ng to to the the desire desired d length, length, tighte tighten n the the lock lock nut nut again against st the the rod end. end. Recheck Recheck the dimens dimension ions s for proper proper alignm alignment ent..
A LOOK NUT, FR. WHEEL WHEE L TIE ROD
CL CL LEFT ROTATE RIGHT ROTA R OTATE TE
RIGHT ROTA ROTATE TE
LEFT ROTA ROTATE TE
FRONT WHEEL WHEEL TIE ROD
B
32
SERVICE INFORMATION
M. Fuel Switch (Petcock) This vehicle has a manually operated fuel with three positions. Please follow maintenance procedures accordingly ac cordingly.. a. Periodically clean the petcock externally with grease remover and water. b. Check for any leaks or seeping fuel.
“ON” Position The normal operating position for the fuel valve lever is the “ON” position. In this position, fuel will flow to the carburetor. “RES” Position If the fuel level in the fuel tank becomes too low for the engine to operate with the fuel valve lever in the “ON” position, turn the lever to the “RES” position to use the reserve fuel supply, and refuel as soon as possible. “OFF” Position The closing position for the fuel valve is the “OFF” position. When the vehicle is not in use, always make sure the petcock is in the “OFF” position.
N. Chassis Grease chassis bushings and bearings with grease every six-months to assure smooth operation and extended life of the bushings and the components. If used in extreme wet, muddy, or dusty conditions, greasing is recommended more often.
33
SERVICE INFORMATION
O. Steering Shaft a. Remove nutssteering block rease inside of steer-block periodically periodically..
Nut
Steering Column
b. Loosen steering shaft, clamp nut and steering gear box. Steering Shaft Link
Steering Gear Box
Clamp Nut
c. Remove steering shaft. Steering Shaft
34
Needle Bearing
SERVICE INFORMA I NFORMATION TION
P. Steering Gear Box and Ball HEAD AND STEERING STEERING GEAR BOX a. Remove four bolts on LH and RH clamp nut and steering gear box.
b. Remove and check ball head dust cover and steering gear box for wear. Ball Head Dust Cover
Bolts and Nuts
Steering Gear Box
c. Check steering cover on sides of steering gear box gear box and grease the ball head.
Ball Head
d. Fill steering gear box with grease after cleaning the dust. Replace the ball joint if it is loose or not smooth.
Steering Knuckle Support
Ball Joint 35
SERVICE INFORMA INFORMATION TION
Q. Steering Knuckle Support a. Remove rubber dust cover of the knuckle support. Ball Head Dust Cover
b. Check the grease of ball joint. Clean it if it is dirty and fill with grease grease.. Filled With Grease
c. Replace the steering knuckle support if the ball joint is loose or steering isn’t flexible.
Steering Knuckle Support
Ball Joint
36
SERVICE INFORMATION
R. Throttle and Brake Pedal a. Remove throttle, throttle pedal and axle nut, check for signs of wear. Replace if wear is present. b. Fill with grease in order to make the throttle and brake pedal swing more flexibly before installation.
S. A-Arms a. Grease the flex points of upper and and lower lower A-arm, front wheel periodically.
Rear upper A-arm
Frontal upper A-arm
b. Remove bolt of upper and lower A-arm, front front wheel. c. Check the nylon bushing of upper and lower A-arm, front wheel for wear. Replace immediately if wear is present.
T. Ti Tie e Rod Rod a. Ti Tie e rods should be checked checked for ease of movement movement in their full rotation.
Rear lower A-arm Frontal lower A-arm
b. Remove protective boot and apply grease. c. Check tie rod ends periodically for tightness at the adjusting nuts. d. Always use a new cotterpin cotterpin after removal. removal.
U. Seat a. Remove all the nuts and bolts underneath the seat rail. b. Remove seat.
37
SERVICE INFORMATION
V. Radiator Ra diator
WARNING While While engine engine is running, running, never never attempt attempt to open the radiato radiatorr filler filler cap. The pressuri pressurixed xed hot coolant coolant may may shoot shoot out and cause serious serious scald scalding ing injury. injury. No mainte maintenanc nance e work is allowed allowed to be performe performed d unless unless the engine engine is complete completely ly cooled cooled down. down.
a. Refill the radiator with distilled water or specified additives. b. Add coolant coolant to the reservo reservoir ir.. c. The cooling cooling system can be serviced serviced on the kart. d. Never spill the coolant on the painted surface. e. Test the cooling system for any leakage after the repair.
W. Storage Instructions
WARNING Do not not drai drain n fuel fuel wh whil ile e engi engine ne is hot. hot. Be sure sure to move move kart kart outs outsid ide e befo before re drai draini ning ng fuel fuel..
In the event that your kart is not to be operated for a period exceeding 30 days or at the end of each driving season, prepare for storage as follows:
a. Drain fuel tank and carburetor by allowing engine to run out of fuel and use a fuel stabilizer.
b. Lubricate engine cylinder by removing the air cleaner, then spray engine, fogging oil through the carburetor until motor dies.
c. Do not save or store gasoline over winter. Using old gasoline, which deteriorates from storage, will cause hard starting and affect engine performance.
38
SERVICE INFORMA I NFORMATION TION
X. Front Hubs a. Check seals for rips or tears and replace if any exist. b. Inspect bearings for ease of movement. If bearings are dirty or muddy, wash them in cleaning solvent and spin with your finger. c. Apply an ample amount amount of grease grease to the bearing and reinstall with bearing tool, making sure it goes in straight: Damage to the hub can occur. d. Install seals into hub. It is recommended to that your apply a small amount of grease to the lip of the seal. If the retention spring is in bad shape, replace it.
39
WIRING DIAGRAM
p m a L l i a T
e g n a r O
n e e r G
r o t a r e n e G y t i c o l e V
l a n g i S n r u T e u l b t h g i L
e t i h W / w k n o c e l e l a r e l B G Y
n w n e o w e l l o r e r Y B G / n e e r G
n e e r G
n e e r G
g n i d n i W r e g g i r T
o t i n g a M
n e e r g
h c t i w S l a r t u e N
n e e r g t h g i L
w w w o l o l o l l l l e e e Y Y Y
d e R / e t i h W
n e e r
G
B d e R n e e r G
k c a l
l h a t c n n i r i u g w T S S
r e t s o o B
k c a l
B / e u l B
d e R / e t i h W t i n U r e h s a l F
y r e t t a B
e t i h W d e R
Red/White
y a r G
h c t i w S l a n g i S n r u T
e t i h
e u l b t h g i L
W
White/Red e g n a r O
n e e r G
k c a l
B
r o t o M r e t r a t
w o l l e Y / n e e r G
h c t i w S t h g i L e k a r B
S
Yellow/Red
k c a l B
d e R / e t i h W
h c t i w S n r o H
n e e r g t h g i L
n e e r G
k c a l B / n e e r G
r o s n e S
e s r e v e R
Blue/White I D C
n e e r G r o s n e r e u S t g a n r e i p n n r e a T W
e t i h W / d e R
t h g i L h c d i a t e w H S
n e e r G
l i o C n o i t i n g I
e t i h W / n w o r B
e t i h W e u l B
g u l P k r a p S k n i P
e u l B
n w o r B
w o l l e Y / k c a l B
n e e r G
e u l B / e t i h W e x r u o t B a r l e r o p t m n e o T C
White/Black
k c a l B
n w o r B
e u l b t h g i L
n e e r G
n e k e e u i n r l B P G
n e e r G
l a n g i S n r u T
t h g i L n o i t i s o P
t h g i L
d a e H
n e e r G n e e r g t h g i L
n e e r G
n t e w i o h r W B /
e g n a r O
e t i h W e u l B
n k e c a e r l B G /
e u l B
n r o H
e u l b t h g i L
d k k e c c a l a R / l e B B t i / e t h i h W W
e d t e i h R / W / w o l d l e e R Y
h c t i w S n o i t i n g I
r e t e M o d e e p S
40
n e e r g t h g i L
n e k e e u i n r l B P G
n n e w e o r r G B
n e e r G
n r o H
t h g i L d a e H
t h g i L
n o t i s o P
e u l b n t e h r e g i L G
l a g n i S n r u T
TROUBLE SHOOTING CHARTS
A. Engine hard to start or can not be started. Check an and Adjustment
Fault Co Condition
Loos Loosen en carb carbur uret etor or drai drain n bolt bolt to chec check k if ther there e is gaso gasolin line e insi inside de the carburetor carburetor..
Fuel Fuel supp suppli lied ed to carburetor carburetor sufficient. sufficient.
No fuel fuel is supp suppli lied ed to carburetor.
Remo Remove ve spar spark k plug plug,, inst instal alll it into into spar spark k plug plug cap, cap, and and perf perfor orm m a spar spark k test test agai agains nstt engi engine ne ground.
Chec Check k for for spar sparks ks..
Weak Weak spar sparks ks,, no spar spark k at all.
Perform Perform cylinder cylinder compression compression pressure pressure test.
Cylinder Cylinder compressio compression n pressure pressure normal. normal.
No fuel uel in fuel fuel tank tank.. Chec Check k if the the pipe pipes, s, fuel fuel tank tank to carb carbur uret etor or,, and and inta intake ke vacu vacuum um,, are are clog clogge ged. d. Float Float valve valve clogge clogged. d. Line Lines s in fuel fuel tank tank evap evapor orat atio ion n syst system em clogged. Malf Malfun unct ctio ion n of fuel fuel pump pump.. Loos Loose e or dama damage ged d fuel fuel pump pump vacu vacuum um hose. Fuel Fuel filter filter clogge clogged. d. Malfun Malfuncti ction on of spark spark plug. plug. Spark Spark plug plug fouled fouled.. Malf Malfun unct ctio ion n of CDI CDI set. set. Malfun Malfuncti ction on of AC genera generator tor.. Igni Igniti tion on coil coil is in open open or shor shortt circ circui uite ted. d. Igni Igniti tion on coil coil lead leads s open open or shor shortt circ circui uite ted. d. Malfun Malfuncti ction on of main main switch switch..
Low compressio compression n pres pressu sure re or no pres pressu sure re..
Piston Piston ring ring seized seized.. Malfun Malfuncti ction on of cylind cylinder er valves valves.. Worn Worn cyli cylind nder er and and pist piston on ring ring.. Cylind Cylinder er gasket gasket leak. leak. Sand Sand hole hole in comp compre ress ssio ion n part parts. s.
There are some signs of igni igniti tion on;; nut nut engi engine ne can can not be started.
Malfun Malfuncti ction on of thrott throttle le valve valve operat operation ion.. Air Air suck sucked ed into into inta intake ke mani manifo fold ld.. Incorrect Incorrect ignition ignition timing. timing.
Wet sp spark pl plug.
Fuel Fuel leve levell in carb carbur uret etor or too too high high.. Malfun Malfuncti ction on of thrott throttle le valve valve operat operation ion.. Thro Thrott ttle le valv valve e open openin ing g too too wide wide..
Blowing cl c logged.
Malfun Malfuncti ction on of automa automatic tic by-sta by-starte rter. r.
Re-sta Re-start rt by follow following ing the starti starting ng procedures.
No ignition.
Probable Ca Causes
Remo Remove ve the the spar spark k plug plug agai again n and and chec check k it. it.
Dry spark pl plug.
Remove Remove carbur carbureto etorr after after 30 minu minute tes s and and conn connec ectt a hose hose onto onto fuel fuel rich rich circ circui uitt then then blow blow the the hose hose with with air. air.
Blowing is is no n ormal.
41
TROUBLE SHOOTING CHARTS B. Engi Engine ne Runs Runs Slug Sluggi gish sh (Spe (Speed ed does does not not pick pick up, up, lack lack of powe power) r).. Check and Adjustment
Fault Condition
Probable Causes
Try gradua graduall accele accelerat ration ion and check check engine engine speed. speed.
Engi Engine ne spee speed d can can be increased.
Engi Engine ne spee speed d can can not not be increased.
Check Check igniti ignition on timing timing (using (using ignition ignition lamp). lamp).
Ignition timing correct.
Incorrect ignition timing.
Check cylinder compression using cylinder compression guage.
Compression Compression pressure pressure correct.
Air Air cleane cleanerr clogge clogged. d. Poor Poor fuel fuel supp supply ly.. Line Lines s in fuel fuel tank tank evap evapor orat atio ion n syst system em clogged. Exhaus Exhaustt pipe pipe clogge clogged. d. Fuel Fuel nozzle nozzle clogge clogged d in carbur carbureto etor. r.
Malfun Malfuncti ction on of CDI. CDI. Malfun Malfuncti ction on of AC altern alternato ator. r.
No compre compressi ssion on pressu pressure. re.
Cyli Cylind nder er & pist piston on ring ring worn worn out. out. Cylind Cylinder er gasket gasket leaked leaked.. Sand Sand hole hole in comp compre ress ssio ion n part parts. s. Valve deteriorat deterioration. ion. Seized Seized piston piston ring. ring.
Clogged
Remove Remove foreign foreign .
Fouled an a nd di d iscoloration.
Remove Remove dirt. dirt. Inco Incorr rrec ectt spar spark k plug plug heat heat rang range. e.
Chec Check k if carb carbur uret etor or jet jet is clogged. No clog.
Remove Remove spark spark plug. plug.
No di d iscoloration.
Chec Check k if engi engine ne over over heat heated ed..
Normal
Engine overheated.
Pist Piston on and and cyli cylind nder er worn worn out. out. Lean mixture. mixture. Poor Poor fuel fuel qualit quality. y. Too Too much much carb carbon on depo deposi site ted d in combustion combustion chamber. chamber. Igniti Ignition on timing timing too advanc advanced. ed. Poor Poor circ circui uitt on the the cool coolin ing g syst system em..
Knock
Too Too much much carb carbon on depo deposi site ted d in combustion combustion chamber. chamber. Lean mixture. mixture. Poor Poor fuel fuel qualit quality. y. Igniti Ignition on timing timing too advanc advanced. ed.
Contin Continual ually ly drive drive in accele accelerat ration ion or high high spee speed. d.
No knock.
42
TROUBLE SHOOTING CHARTS C. Engi Engine ne Runs Runs Slug Sluggi gish sh (esp (espec ecia iall lly y in low low spee speed d and and idli idling ng)) Check an and Adjustment
Fault Co Condition
Probable Ca Causes
Check Check igniti ignition on timing timing (using (using ignition ignition lamp). lamp). Normal
Abnormal
Incorr Incorrect ect igniti ignition on timing timing (malfu (malfunct nction ion of CDI CDI or AC alte altern rnat ator or). ).
Poor
Rich Rich mixt mixtur ure e (loo (loose sen n the the scre screw) w).. Lean Lean mixtur mixture e (tight (tighten en the screw) screw)..
Adj Adjus ustt the the air air scre screw w of carburetor. Good
Air sucked sucked throug through h carbur carbureto etor r gasket.
No air sucked.
Poor Poor heat heat insula insulatio tion n gasket gasket.. Carbur Carbureto etorr lock lock loose. loose. Poor Poor intake intake gasket gasket.. Poor Poor carbur carbureto etorr O-ring O-ring.. Vacuum Vacuum hose hose crack. crack.
Air sucked.
Remove Remove spark spark plug, plug, instal installl spar spark k plug plug into into spar spark k plug plug cap cap and and perf perfor orm m spar spark k test test agai agains nstt engine engine ground. ground.
Good spark.
Spark Spark plug plug fouled fouled.. Malfun Malfuncti ction on of CDI. CDI. Malfun Malfuncti ction on of AC genera generator tor.. Malfun Malfuncti ction on of igniti ignition on coil. coil. Open Open or shor shortt circ circui uitt in spar spark k plug plug lead leads s to malfunction of main switch.
Poor spark.
D. Engi Engine ne Runs Runs Slug Sluggi gish sh (Hig (High h spee speed) d) Check and Adjustment
Fault Condition
Probabl Probable e Causes Causes
Check Check igniti ignition on timing timing..
Normal
Abnormal
Malfun Malfuncti ction on of CDI. CDI. Malfun Malfuncti ction on of AC altern alternato ator. r.
Chec Check k for for fuel fuel supp supply lyin ing g syst system em in auto automa mati tic c fuel fuel cup. cup.
Good
Abnormal
Insu Insuff ffic icie ient nt fuel fuel in fuel fuel tank tank.. Fuel Fuel filter filter clogge clogged. d. Restri Restricte cted d fuel fuel tank tank vent. vent.
Clogged
Clean.
Check Check for carbur carbureto etorr clog. clog.
No clog.
43
TROUBLE SHOOTING CHARTS E. Clut Clutch ch,, Driv Drivin ing g and and Driv Drivin ing g Pull Pulley ey Probable Causes
Fault Conditions
Driv Drive e belt belt worn worn out out or defo deform rmed ed.. Ramp Ramp plat plate e of mova movabl ble e driv drive e face face dama damage ged. d. Drivin Driving g pulley pulley spring spring broken broken.. Clutch Clutch weigh weights ts broken broken.. Drive Drive slideslide-sha shaft ft gear gear groove groove broken broken.. Transmissi Transmission on gear damaged. damaged.
Engi Engine ne can can be star starte ted d but but kart kart can can not not be move moved. d.
Engi Engine ne runn runnin ing g and and misf misfir ire e when when kart kart begi begins ns movi moving ng forw forwar ard d or jumps jumps sudden suddenly ly (rear (rear wheel wheel rota rotate tes s whil while e engi engine ne is ).
Clutch Clutch weigh weights ts spring spring broken broken.. Clut Clutch ch oute outerr stuc stuck k with with clut clutch ch weig weight hts. s. Conn Connec ecti tion on part parts s in clut clutch ch and and shaf shaftt worn worn out out or burn burned ed..
Driv Drive e belt belt worn worn out out or defo deform rmed ed.. Weig Weight ht roll roller er worn worn out. out. Mova Movabl ble e driv drive e face face shaf shaftt worn worn out. out. Driven Driven pulley pulley spring spring deform deformed. ed. Driv Driven en pull pulley ey shaf shaftt worn worn out. out. Grea Grease sed d in driv drive e belt belt and and driv driven en face face..
Poor Poor initia initiall drivin driving g (poor (poor climbi climbing ng performance).
F. Poor Poor Hand Handli ling ng Probable Causes
Fault Conditions
Steeri Steering ng is heavy. heavy.
Damaged Damaged steering steering bearing. bearing. Damage Damaged d steeri steering ng shaft shaft bushin bushing. g.
Bent Bent rim. rim. Improp Improperl erly y instal installed led wheel wheel hub. hub. Excess Excessive ive wheel wheel bearin bearing g play. play. Bent Bent swin swing g arm. arm. Bent Bent frame. frame. Swing Swing arm pivot pivot bushin bushing g excess excessive ively ly worn worn..
One One whee wheell is wobb wobbli ling ng..
Bent Bent tie-ro tie-rod. d. Incorrect Incorrect tie-rod tie-rod adjustment adjustment.. Rear Rear tire tire air air pres pressu sure re inco incorr rrec ect. t. Improper Improper wheel wheel alignment. alignment. Bent Bent frame. frame.
Vehi Vehicl cle e pull pulls s to one one side side..
44
SET-UP INSTRUCTIONS INTERCEPTOR GTR 250
TOOLS NEEDED
Floor jack Flat head screw driver Nee Needl dlee no nose se pl pliier erss Phiill Ph llip ipss he head ad sc scre rew w dr driv iver er Protective gloves Adjustable wrench Metric wrench and socket set 1.
LIFT THE KA KART RT In order to assemble the front suspension sus pension and steering the unit must be lifted high enough to put the front tires on it. Place a floor jack under the front of the unit in the center and lift the kart.
2.
FRONT TO FRONT TOP P A-A A-ARM RM a. Insert top a-arms a-arms into into top front suspension mounts with the grease fittings pointing upwards. The top a-arms are the shortest a-arms. The mounting brackets are located both in front and behind of each front blinker. b. Tighten bolts with 13mm and 14mm wrench.
3.
FRONT BOTT FRONT BOTTO OM A-AR A-ARM M a. Insert bottom a-arms into bottom front suspension mounts with the grease fittings pointing downwards. The bottom a-arms have shock mount brackets. The mounting brackets are located underneath the floorboard. b. Tighten bolts with 13mm and 14mm wrench.
4.
FRONT SHO FRONT SHOCK CK a. Place the bottom eye hole of the shock into the shock mounts on the bottom a-arms & insert bolt. b. Place the top eye hole of the shock into the shock mount located on the frame and insert bolt. c. Tighten bolts with 13mm and 14mm 14mm wrench. wrench.
5.
FRONT STRUT a. On each end end of the struts struts is a threaded threaded stud. stud. On the bottom of each stud you can see a square. b. Align each square of the threaded stud with that of the tabs on each a-arm. The squares of the stud and a-arms MUST be aligned. c. Be sure the steering steering arm arm on each strut is pointing pointing towards the front of the unit. d. Tighten each castle nut with an 18mm wrench and lock into place with a cotter pin and needle nose pliers. The cotter pins are in a zip lock bag in the hardware box. e. Cap the top end of each stud with a provided rubber cap. 46
SET-UP INSTRUCTIONS INTERCEPTOR INTERCEPT OR GTR 250
6.
STEERING LI STEERI LINKAGE NKAGE a. Attach each tie-rod end to the struts struts by inserting the ball joint studs into the steering arm of each strut. b. On each stud place flat washer, lock washer, tighten with 17mm wrench and lock with cotter pin and needle nose pliers.
7.
FRONT BRAK BRAKE E CAL CALIPER IPER a. Slide each brake brake caliper over the brake discs and align the mounting holes with those those of each strut. b. Tigh Tighten ten bolts with a 10mm 10mm wrench.
8.
FRONT WHE FRONT WHEE EL AND CAP CAP a. In the the hardware box you will find 4 chrome wheel caps. The smaller set will be used on the front. Also get out 8 acorn shaped lug nuts. b. Slide the wheel cap into the center hole of the wheel from the back. c. Place the the wheel wheel assembly into position by aligning the holes in the wheel with the lugs on the front hubs. d. Tighten the lug nuts with a 15mm socket. With the wheels off the ground ground you may not be able to tighten the lugs completely. Lower the kart and tighten the lug nuts completely.
9.
HEAD LIGHT a. Place the front head lights in their mounts. Each mount is on either side of the front hood. b. Tight Tighten en with with 10mm 10mm and and 12mm wrenc wrench. h.
10.
REAR BO REAR BOTTOM TTOM A-ARM A-ARMS S a. Place the floor jack jack under the rear of the unit and lift off the ground. b. The rear bottom a-arm a-arm is the large large a-arm without shock mounts. c. Insert bottom a-arms into bottom bottom rear suspension mounts with the grease fittings pointing downwards. Finger tighten only. It is easier to assemble the rear suspension without the bolts tight. 47
SET-UP INSTRUCTIONS INTERCEPTOR INTERCEPT OR GTR 250
11.
CV SHAFT a. Slide the female female end of each CV shaft over the male male end of each side of the center axle. b. Lock into place with lock ring. ring. The lock ring should already be in place place on each end of the center axle.
12.
REAR TO REAR TOP P A-A A-ARMS RMS a. Insert top a-arms a-arms into top rear rear suspension mounts with the grease fittings pointing upwards. The top a-arms have shock mounts on them. b. Fin Finger ger tigh tighten ten onl only. y.
13.
REAR KNUC REAR KNUCKLE KLE a. Connect the the rear rear knuckle knuckle to the rear rear suspension by inserting the outer ends of each a-arm into the top and bottom of the knuckle. b. Insert top and bottom bolt of the knuckle. With h all susp suspension ension bolt boltss in pla place ce tight tighten en with c. Wit 14mm 14m m and 17m 17mm m wr wren ench ch..
14.
REAR REA R SHOC SHOCKS KS
a. Place the bottom eye hole of the shock into the shock mounts on the top a- arms and insert bolt. b. Place the top eye hole of the shock into the shock mount located on the frame and insert bolt. c. Tigh Tighten ten bolts bolts with with 15mm 15mm and 17mm 17mm wrench wrench
15.
REAR WH REAR WHEE EEL L AND CAP a. In the hardware box you will find 4 chrome wheel caps. The larger set will be used on the rear. Also get out 8 acorn shaped lug nuts. b. Slide the the wheel cap into into the center center hole of the wheel from the back. c. Place the wheel assembly into into position position by aligning the holes in the wheel with the lugs on the front hubs. d. Tighten the lug nuts with a 15mm socket. With the wheels off the ground ground you may not be able to tighten the lugs completely. Lower the kart and tighten the lug nuts completely.
48
SET-UP INSTRUCTIONS INTERCEPTOR GTR 250
16.
STUMP GUAR GUARD D AND TRAIL TRAILE ER HITCH a. Place the stump guard under the rear suspension box/ under the rear sprocket. b. Alig Align n the 4 holes holes of the stump stump with the holes on the frame. c. Be sure all bolts are in place then tighten with 10mm and 12mm wrench. d. Place trailer hitch plate under trailer trailer hitch mount. mount. Align the 2 bolt holes, insert the 2 large bolts and washers and tighten with a 19mm and 21 mm wrench. e. Tighten ball with 24mm or adjustable wrench.
17.
CARGO RACK a. Place a black rubber end cap on each mounting post of the cargo rack. There will be 6 in all. The black rubber end caps are in the hardware box. Also remove 6 black anodized bolts and washers. b. Hold the top section of the rack about 1” off the rear frame and start the rear bolts. Go ahead and tighten these rear bolts most of the way. This will prevent the heads of the bolts from scratching the frame. c. Insert the remaining bolts and washers and tighten with a 10mm wrench. Be sure all bolts are started before tightening.
18.
TAIL LIGHT a. Insert the mounting bolts bolts of the tail light into the tail light bracket located under the cargo rack. b. Tight Tighten en with a 10mm wrench. Be sure not to over tighten.
19.
FRONT FENDE FRONT FENDERS RS a. Place the fender brackets over each strut strut above the steering arm. b. Start each bolt first then tighten with a 10mm and 12mm wrench.
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SET-UP INSTRUCTIONS INTERCEPTOR GTR 250
20.
REAR FENDERS REAR a. Behind each seat seat is a mounting mounting post for for the rear fenders. b. Align the holes holes and slots slots of the the fender bracket with those of the mounting post. c. Tight Tighten en with 10mm wrench.
21.
SEATS AND SEAT BE BEL LTS a. Remov Removee the seat hardware hardware from the hardware hardware box. box. This will be the the silver bolts, bolts, nuts and washers. b. The seat belts are shipped bolted together. It It is easier to install the seat belts with them separated. c. Start on the driver driver side by bolting bolting the outer outer end of the seat belt belt to the seat belt mount mount located behind the driver seat and in front of the rear fender. d. With the driver driver seat turned turned upside down, down, slide the the seat adjusters adjusters all the way back. back. e. Put the seat seat in place by aligning the front front brackets and and rear holes. holes. f. Insert a bolt in each hole from top to bottom leaving the head of the bolt in the seat adjuster track. g. You will have to hold the top of the the bolt with a flat flat head screw driver. Wedge the flat head screw driver between the bolt head and the seat adjuster track and tighten with a 12mm wrench. h. Feed the seat belt belt through through the holes holes in the the top of of the seat. i. Bolt the top top seat seat belt belt bracket bracket to to the seat belt belt mount mount located directly behind the drivers head. j. Follow the same steps with the the passenger passenger seat. The bolts for the passenger seat will be inserted from bottom to top because the passenger seat does not have an adjuster. k. Tight Tighten en the passenge passengerr seat bolts with a 10mm wrench. l. Tight Tighten en the the seat belt bolts with a 14mm 14mm and 19mm wrench.
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SET-UP INSTRUCTIONS INTERCEPTOR GTR 250
22.
BRUSH BAR BRUSH BARS S a. Place the main bars bars in proper location location by inserting inserting the open open ends over the bar mount posts on the frame. The bar mounting posts for the main bars are at the hood and behind the seat. b. From the the hardware hardware box remove remove the remaining remaining black black anodized anodized bolts, washers and lock nuts. c. On each end of of the main main bar cage place 1 bolt, bolt, 2 washers washers and 1 lock nut. Finger tighten only. Do not tighten any bolts for the brush bars until all bolts are in place. d. Place each each shoulder shoulder bar bar over the the shoulder shoulder bar mount posts on the frame. These posts are on each arm rest. e. Align the top top of the shoulder shoulder bars with with the holes in the main bars and insert bolt and washer and finger tighten. At the bottom of each shoulder bar insert 1 bolt, 2 washers and 1 lock nut and finger tighten. f. Place the top top cross-bar cross-bar between the main main bars bars with with hoop pointing towards the front of the kart. Align holes of the top cross bar with holes in the main bars. g. Insert a bolt and and washer in each hole hole and finger finger tighten. tighten. h. Place the the bottom bottom cross-bar cross-bar between between the the main bars toward the rear of the kart just above the back of the seats. Align holes of the bottom cross-bar with the holes in the main bars. i. Insert a bolt and washer washer in each hole hole and finger tighten tighten.. j. Wit With h all me memb mber erss of the br brush bar in pla place, ce, tighten tighten with a 10mm 10m m and 12m 12mm m wr wren ench ch..
23.
REAR VIE REAR VIEW W MI MIRRO RROR R a. From the hardware box remove the rear view mirror. The rear view mirror will be in a small white box. b. With a Phillips head screw driver, remove the screw in the mounting hole of the mirror. c. Remo Remove ve black black metal metal clip and and discard. discard. Phillips head screw
Black metal clip
d. From the the white box remove remove the chrome chrome spacer and and Phillips head screw. 51
SET-UP INSTRUCTIONS INTERCEPTOR INTERCEPT OR GTR 250 24.
BATTERY a. Put on protect protective ive gloves b. Remov Removee red strip strip covering covering acid acid ports from battery. battery. c. Place funnel into acid ports on battery. Press acid container firmly into funnel allowing acid to flow into battery. d. Let acid acid settle settle in battery battery for about 10 minute minutes. s. e. Place black black cap into acid acid ports and press press firmly firmly to secure. secure. f. Let battery charge on 2A for about 30 minutes. minutes. g. Remov Removee electric electric box cover cover from from behind behind driver seat. h. Place battery into electr electric ic box. box. i. Place rectang rectangular ular nuts under under each each pole pole of the battery battery.. j. Bolt the the green green cable to to the – pole and and the red red cable to the + pole. k. Secure battery battery with with rubber strap strap and reinstall reinstall electric electric box box cover.
25.
ENGINE OIL ENGINE a. Remov Removee the dipstic dipstick k from engin enginee and wipe clean clean b. Place the dipstick dipstick back into into engine engine but but do not tighten. c. Remov Removee dipstick dipstick and check oil level. d. If oil does does not cover the marked portion of the dipstick, add oil. e. The engi engine ne hold holdss approximately 1.2 liters.
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SET-UP INSTRUCTIONS INTERCEPTOR INTERCEPT OR GTR 250
26.
FILLING THE CO COOL OLING ING SYSTE SYSTEM M WI WITH TH CO COOL OLANT ANT
It is very important that you do not just fill the radiator and reservoir with coolant and begin to ride the unit. The cooling system MUST have all the air bled from it or the system will not cool the engine. a. Remov Removee the radiator radiator filler filler cap and by-pass by-pass hose from from the by-pass by-pass valve. valve. Radiator filler cap
By-pass hose
b. With the engine running at idle fill the radiator with coolant. Fill the radiator until coolant comes out of the by-pass valve. When ONLY coolant comes out of the by-pass valve and there are no air bubbles in the coolant, reconnect the by-pass hose.
c. Continue Continue to fill the radiator radiator until until the coolant coolant level reaches reaches the top of the radiator radiator neck where the cap goes. After several minutes of idling the coolant level will drop. Refill the radiator to the same level and monitor for several more minutes for air bubbles. If the coolant level drops again, refill. Once the coolant level is stable and you no longer see air bubbles, screw the radiator cap back on and fill the reservoir to the appropriate level.
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