Carter Talon GSR 150 R2 Owner's Manual
READ THIS MANUAL CAREFULLY,
IT CONTAINS IMPORTANT SAFETY INFORMATION.
Owner's Manual
Parts Manual
This vehicle is designed and manufactured for o-road use only.
USA only:
It does not conform to Federal Motor Vehicle Safety Standards, and in regards
to operation on public streets, roads, or highways is illegal.
FOR OFF-ROAD USE ONLY
MINIMUM
RECOMMENDED
OPERATOR AGE:
16
A Better Built Machine.
GSR150R2
GSR150R2
GSR 150 R 2 Limited Warranty
The warranty policy applies to those new units that are unloaded from its
shipping container, setup, and delivered to, or by, an authorized dealer, and
under normal use and service, is found to have defects in parts or workmanship
under the following terms and conditions. This warranty covers the kart and
engine related components for a period of 180 days.
This warranty does not apply to any part, which in opinion of seller was
defective because of improper maintenance, improper assembly, alterations,
abuse, negligence or accident.
Should warranty service be required on your GSR 150 R 2 during the 180
days warranty period, please contact your nearest authorized dealer for
repairs.
What is not covered under this warranty
Misuse, Negligence, Alterations, Accidents or any abnormal use including
non-genuine parts, renting or leasing, competition or racing. This warranty
does not cover loss of use of the unit or loss of time, or inconvenience or
normal wear and deterioration caused by the use or storage of consumable
items such as - but not limited to - spark plugs, chain, brake shoes, fuses,
clutch plates, sprockets, light bulbs, baery cables and tires.
1. FOREWORD -------------------------------------------------------------------------------------------------------------------------
2. A FEW WORDS ABOUT SAFETY ------------------------------------------------------------------------------------------------
3. IMPORTANT SAFETY INFORMATION ------------------------------------------------------------------------------------------
4. SAFETY LABELS --------------------------------------------------------------------------------------------------------------------
5. ARE YOU READY TO DRIVE ? ----------------------------------------------------------------------------------------------------
6. IS YOUR VEHICLE READY TO DRIVE ? -----------------------------------------------------------------------------------------
7. SAFE DRIVING PRECAUTIONS -------------------------------------------------------------------------------------------------
8. P.D.I. ----------------------------------------------------------------------------------------------------------------------------------
9. SPECIFICATIONS ------------------------------------------------------------------------------------------------------------------
10. OPERATION ------------------------------------------------------------------------------------------------------------------------
11. SERVICE INSTRUCTIONS --------------------------------------------------------------------------------------------------------
12. REPAIR -------------------------------------------------------------------------------------------------------------------------------
13. PERIODICAL CHECK AND SERVICE -------------------------------------------------------------------------------------------
14. WIRING DIAGRAM -------------------------------------------------------------------------------------------------------=------
1. CYLINDER HEAD ASSY. ------------------------------------------------------------------------------------------------------
2. CYLINDER ASSY. --------------------------------------------------------------------------------------------------------------
3. CRANKCASE ASSY. -----------------------------------------------------------------------------------------------------------
4. CRANKCASE ASSY.(2) --------------------------------------------------------------------------------------------------------
5. CRANKSHAFT CON'ROD &PISTON ASSY. -------- -----------------------------------------------------------------------
6. CAMSHAFT ASSY. -------------------------------------------------------------------------------------------------------------
7. LEFT COVER ASSY. ------------------------------------------------------------------------------------------------------------
8. FAN COVER AND SHROUD ASSY. -----------------------------------------------------------------------------------------
9. OIL PUMP ASSY. ---------------------------------------------------------------------------------------------------------------
10. DRIVEN PULLEY AND CLUTCH SUBASSY. -------------------------------------------------------------------------------
11. TRANSMISSION ASSY. -------------------------------------------------------------------------------------------------------
12. ELECTRIC SYSTEM ------------------------------------------------------------------------------------------------------------
13. ELECTRIC STARTER ASSY. ---------------------------------------------------------------------------------------------------
14. DRIVE PULLEY SUBASSY. ----------------------------------------------------------------------------------------------------
15. CARBURETOR ------------------------------------------------------------------------------------------------------------------
16. FRAME GROUP ----------------------------------------------------------------------------------------------------------------
17. STEERING SHAFT ASSY. ------------------------------------------------------------------------------------------------------
18. SUSPENSION ARM ASSY. ----------------------------------------------------------------------------------------------------
19. GAS TANK/SEAT/BELT --------------------------------------------------------------------------------------------------------
20. REAR SWING ARM ASSY. UPPER -------------------------------------------------------------------------------------------
21. ENGING/MUFFLER/AIR CLEANER/OIL COOLER ------------------------------------------------------------------------
22. REAR SWING ARM ------------------------------------------------------------------------------------------------------------
23. REAR HOUSING ----------------------------------------------------------------------------------------------------------------
24. WIRE HARNESS/ELECTRICAL ------------------------------------------------------------------------------------------------
25. REVERSE ASSY. -----------------------------------------------------------------------------------------------------------------
26. WARNING STICKERS ----------------------------------------------------------------------------------------------------------
Page
Figure
CONTENTS
OWNER' S MANUAL
PARTS MANUAL
1
2
3
5
6
7
8
10
11
13
17
21
23
24
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig.10
Fig.11
Fig.12
Fig.13
Fig.14
Fig.15
Fig.16
Fig.17
Fig.18
Fig.19
Fig.20
Fig.21
Fig.22
Fig.23
Fig.24
Fig.25
Fig.26
Thank you for purchasing a Carter Talon GSR 150 R 2. We hope you will enjoy
your new kart. Before you start to operate your kart, please read through this
Owner's Manual carefully as it contains important safety and maintenance
information. Failure to follow the warnings contained in this manual can result
in serious injuries or death.
Be sure to follow the recommended maintenance schedule and service your
kart accordingly. Preventive maintenance is extremely important to the
longevity of your kart.
Beginners should seek instructions from your dealer or qualified instructors
before and during initial use of the kart. It is also recommended to practice in a
large open area and to be familiar with the operations of this kart.
We hope you will have a pleasant experience with our products and thanks
again for choosing a Carter kart.
1
FOREWORD
In order to keep everyone safe, you must take responsibility for the safe operation
of your Kart.
To help you make informed decisions about safety, we have provided operating
procedures and other information on labels and in this manual. This information alerts
you of the potential hazards that could hurt you or others.
It is not practical or possible to warn you about all hazards associated with
operating or maintaining a Kart. You must use your own good judgment.
You will find important safety information in a variety of forms, including:
Safety Labels _ On the Kart.
Safety Messages _ Preceded by a safety alert symbol and one of two signal
words: WARNING, or CAUTION.
Physical harm may result from failure to adhere to the instructions that are described
within the WARNING labels.
Safety Headings — such as Important Safety Reminders or Important Safety Precautions.
Safety Section — such as Kart Safety.
Instructions — how to use this Kart correctly and safely.
This entire manual is filled with important safety information—please read it carefully.
2
WARNING
These signal words mean:
A FEW WORDS ABOUT SAFETY
Your Kart will provide you with many years of service and pleasure.Providing
you take responsibility for your own safety and understand the challenges you can
meet while driving.
There is much that you can do to protect yourself while operating your kart. You'll
find many helpful recommendations throughout this manual. The following are a
few that we consider most important.
Follow the Age Recommendation
Adult Supervision should be present for all people under the age of 16.
Always Wear a Helmet
It's a proven fact: helmets significantly reduce the number and severity of head injuries.
Always wear an approved motorcycle helmet. We also recommend that you wear eye
protection, sturdy boots, gloves, and other protective gear.
Drive Off-Road Only
Your Kart is designed and manufactured for off-road use only. The tires are not
made for pavement, and the Kart does not have turn signals and other features
required for use on public roads. If you need to cross a paved or public road, get off and
walk your Kart across.
Take Time to Learn & Practice
Even if you have driven other Karts, take time to become familiar with how this
Kart works and handles. Practice in a safe area until you build your skills and get
accustomed to this Kart
's size and weight.
Because many accidents involve inexperienced or untrained drivers, we urge all drivers
to take a training course approved by the Go-Kart Safety Institute. Check with your dealer
for more information on training courses.
Be Alert of Off-Road Hazards
The terrain can present a variety of challenges when you drive off-road. Continually
"read" the terrain for unexpected turns, drop-offs, rocks, ruts, and other hazards. Always
keep your speed low enough to allow time to see and react to hazards.
3
IMPORTANT SAFETY INFORMATION
4
IMPORTANT SAFETY INFORMATION
Drive within Your Limits
Pushing limits is another major cause of Kart accidents. Never drive beyond your
personal abilities or faster than conditions warrant. Remember that alcohol, drugs, fatigue,
and inaention can significantly reduce your ability to make good judgments and drive
safely.
Don't Drink and drive
Alcohol and driving don't mix. Even one drink can reduce your ability to respond to
changing conditions, and your reaction time gets worse with every additional drink. So
don't drink and drive, and don't let your friends drink and drive either.
Do not operate this Kart at night.
Dark vision can greatly reduce a driver's visibility and judgment. So driving at night
is dangerous and can increase the possibility for an accident.
Never run your Kart indoors.
The exhaust from the engine contains a tasteless, odorless and poisonous gas called
carbon monoxide.
Keep away from moving parts of the Kart
The operator of the Kart should never place their hands or other parts of their body
near any moving part of the Kart. Failure to adhere to this warning will cause physical
harm to your body.
Skidding or Sliding
The terrain surface can be a major factor affecting turns. Skidding in a turn is more likely to
occur on slippery surfaces such as snow, ice, mud and loose gravel. If you skid on ice, you
may lose all directional control. To avoid skidding on slippery terrain, keep you speed low
and drive carefully.
SAFETY LABELS
This section presents some of the most important information and recommendations to help
you drive your Kart safely. Please take a few moments to read these pages.
The labels should be considered permanent parts of the Kart. If a label comes off or
becomes hard to read, contact your dealer for warning label replacements.
WARNING
WARNING
Loss of control, collision,or getting caught in moving parts
can result in serious injuries.
3031107
Adult supervison for under 16 years old
Wear a D.O.T. approved motorcycle helmet
Secure long hair and loose clothing
Wear protective eye wear and clothing
Keep arms, legs and feet inside kart
Do not use alcohol or drugs
303115
THIS GO-KART CAN BE HAZARDOUS TO OPERATE
if driven carelessly.
INJURIES can result if you do not follow these
instructions:
3031112
WARNING
WARNING
ALL HAIR MUST BE TIED UP AND
SECURED AT OR ABOVE SHOULDER
LENGTH.
ALL LOOSE CLOTHING MUST BE
SECURED. ALL NECKLACES AND
SCARVES MUST BE
SECURED.
NO
LONG
HAIR
READ OWNER'S MANUAL AND ALL LABELS BEFORE
YOU OPERATE THIS GO-KART.
NEVER OPERATE THIS GO-KART WITHOUT PROPER
INSTRUCTIONS. Beginners require adult
supervision.
NEVER OPERATE THIS GO-KART ON PUBLIC ROADS.
It is intended for off-road use only.
ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET,
eye protection and protective clothing.
NEVER OPERATE THIS GO-KART AT EXCESSIVE
SPEEDS. You increase your risk of losing control if
you operate it at speeds too fast for the terrain,
visibility conditions or your experience.
NEVER ATTEMPT WHEELIES, JUMPS, OR
OTHER STUNTS.
WARNING
Seat Belt Must Be Worn At All Times
CAUTION
THIS VEHICLE MANUFACTURED
FOR OFF-ROAD USE ONLY.
DO NOT OPERATE ON PUBLIC
STREETS, ROADS OR HIGHWAYS.
3031105
NO RIDING
WARNING
5
Before each drive, you need to make sure you and your Kart are both ready to drive.
To help get you prepared, this section discusses how to evaluate your driving readiness,
what items you should check on your Kart, and adjustments to make for your comfort,
convenience, or safety.
Before you drive your Kart for the first time, we urge you to:
Read this owner's manual and the labels on your Kart carefully.
Make sure you understand all the safety messages.
Know how to operate all the controls.
Have adult present if under 16 years old.
Before each drive, be sure:
You wear your seat belt all times while driving your kart.
You feel well and are in good physical and mental condition.
You are wearing an approved motorcycle helmet (with chin strap tightened securely), eye
protection, and other protective clothing.
You don't have any alcohol or drugs in your system.
Protective Apparel
For your safety, we strongly recommend that you always wear an approved motorcycle
helmet, eye protection, boots, gloves, long pants, and long-sleeved shirt or jacket whenever
you drive.
Although complete protection is not possible, wearing proper gear can reduce the chance of
injury when you drive.
The following suggestions will help you choose the proper driving gear.
Helmets and Eyes Protection
Your helmet is your most important piece of driving gear because it offers the best protection
against head injuries. A helmet should fit your head comfortably and securely.
An open-face helmet offers some protection, but a full-face helmet offers more. Regardless of
the style, look for a DOT (Department of Transportation) sticker on any helmet you buy. Always
wear a face shield or goggles to protect your eyes and help your vision.
Operating this Go-Kart without wearing an approved motorcycle helmet, eye protection,
and protective clothing could increase your chances of head and/or eye injury, and the
possibility of death in the event of a severe accident.
Always wear an approved motorcycle helmet that fits properly and wear eye protection
(goggles or face shield), gloves, boots, long-sleeved shirt or jacket and long pants.
ARE YOU READY TO DRIVE ?
6
WARNING
Additional Driving Gear
In addition to a helmet and eye protection, we also recommend:
Sturdy off-road motorcycle boots to help protect your feet, ankles, and lower legs.
Off-road motorcycle gloves to help protect your hands.
Driving pants with knee and hip pads, a driving jersey with padded elbows, and a chest/
shoulder protector.
Driver Training
Developing your driving skills is an on-going process. Even if you have driven other Karts,
before take time to become familiar with how this Kart works and handles. Practice driving the
Kart in a safe area to build your skills. Do not drive in rough terrain until you get accustomed
to the Kart's controls, and feel comfortable with its size and weight.
Age Recommendation
It is strongly recommended that no one under the age of 16 be permied to operate this Go-Kart
without adult supervision.
No Alcohol or Drugs
Alcohol, drugs and Karts don't mix. Even a small amount of alcohol can impair your ability
to operate a Kart safely. Likewise, drugs-even if prescribed by a physician-can be dangerous
while operating a Kart. Consult your doctor to be sure it is safe to operate a vehicle aer
taking medication.
WARNING
Operating this Kart without your seat belt could cause you to be thrown
from the kart, causing serious injury or death.
WARNING
A child driving a Kart that is not recommended for his/her age could lose contol
of the Kart and result in severe injury or death.
A child under 16 should have adult supervision when operating the Kart.
WARNING
Operating this Kart after consuming alcohol or drugs can seriously
affect your judgment, cause you to react more slowly, affect your balance
and perception, and could result in serious injury or death.
Never consume alcohol or drugs before or while operating this Kart.
ARE YOU READY TO DRIVE ?
WARNING
Improperly maintaining this Kart or failing to correct a problem before
driving can 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.
7
IS YOUR VEHICLE READY TO DRIVE ?
Before each drive, it is important to inspect your Kart and make sure any problems you find
are corrected. A pre-drive inspection is a must, not only for safety, but because having a
breakdown, or even a flat tire, can be a major inconvenience.
If your Kart has overturned or has been involved in a collision, do not drive it until your
Kart
has been inspected by your dealer. There may be damages or other problems you can
not see.
7
8
SAFE DRIVING PRECAUTIONS
Keep Hands and Feet on Controls
When driving your kart, always keep both hands on the steering wheel and both feet
on the foot controls. It is important to maintain your balance and to control the kart.
Removing hands or feet away from the controls can reduce your ability to react and
control the kart.
Operating this kart on paved surfaces may seriously affect handling and control of
the kart, and may cause the vehicle to go out of control.
Never operate the kart on any paved surfaces, including sidewalks, driveways, parks
lots and streets.
WARNING
WARNING
Removing your hands from the steering wheel or feet from the foot controls during
operation can reduce your ability to control the kart or could cause you to lose your
balance and fall off the kart.
Always keep both hands on the steering wheel and both feet on the foot controls
of your kart during operation.
WARNING
Off-Road Use Only
Your kart and its tires are designed and manufactured for off-road use only, not for use on
paved surfaces. Driving on paved surfaces can affect the kart handling and control.
When driving off-road, also remember to always obey local off-road driving laws and
regulations. Obtain permission to drive on private property. Avoid posted areas and obey
"no trespassing" signs.
You should never drive your kart on public streets, roads or highways, even if they are not
paved. Drivers of street vehicles may have difficulty seeing and avoiding you, which could
lead to a collision.
Operating this kart on public streets, roads or highways could cause a
collision with another vehicle.
Never operate this kart on any public streets, roads or highways, whether
they are dirt, gravel or paved surfaces.
Never drive past the limit of visibility. Maintain a safe distance between your Kart and other
off-road vehicles. Always exercise caution and use extra care on rough, slippery and loose terrain.
Use Care on Unfamiliar or Rough Terrain
Before driving in a new area, always check the terrain thoroughly. Don't drive fast on unfamiliar
terrain or when visibility is limited.(it's sometimes difficult to see obstructions like hidden rocks,
bumps, or holes in time to react.)
Control Speed
Driving at excessive speed increases the chance of an accident. In choosing a proper speed, you
need to consider the capability of your Kart, the terrain, visibility and other operating
conditions, plus your own skills and experience.
Do Not Perform Stunts
You should always operate your Kart in a safe and reasonable manner. When driving,
always keep all four wheels on the ground.
Operating this Kart at excessive speeds increases your chances of
losing control of the Kart, which can result in an accident.
Always drive at a speed that is proper for your Kart, the terrain, visibility
and other operating conditions, and your experience.
WARNING
Failure to use extra care when Operating this Kart on unfamiliar terrain
could result in the Kart overturning or going out of control.
Go slowly and be extra careful when operating on unfamiliar terrain. Always
be alert to changing terrain conditions when operating the Kart.
WARNING
Failure to use extra care when operating on excessively rough, slippery or
loose terrain could cause loss of traction or vehicle control, which could result
in an accident, including an overturn.
Do not operate on excessively rough, slippery or loose terrain until you have
learned and practiced the skills necessary to control the Kart on such
terrain. Always be especially cautious on these kinds of terrain.
WARNING
Attempting wheelies, jumps, and other stunts increases the chance of an
accident, including an overturn.
Never attempt stunts, such as wheelies or jumps. Don't try to show off.
WARNING
9
SAFE DRIVING PRECAUTIONS
6
b
c
d
e
f
g
h
j
a
DIMENSIONS
Overall Length --------------------------------------------------------------------------- 88.2 in. (2240mm)
Overall Width ---------------------------------------------------------------------------- 55.9 in. (1420mm)
Overall Height --------------------------------------------------------------------------- 57.1 in. (1450mm)
Wheelbase ----------------------------------------------------------------------------------- 59 in. (1500mm)
Front Track ------------------------------------------------------------------------------- 45.7 in. (1160mm)
Rear Track -------------------------------------------------------------------------------- 39.4 in. (1000 mm)
Ground Clearance -------------------------------------------------------------------------- 6.7 in. (170mm)
ENGINE
Type --------------------------------------------------------------------------- Forced air-cooled. 4-Stroke
Engine capacity -------------------------------------------------------------------------------------- 149.89 cc
Bore / Stroke ----------------------------------------------------------------------------- 57.4mm x 57.8mm
Displacement ----------------------------------------------------------------------------------------- 149.6cm
3
Corrected compression ratio --------------------------------------------------------------------------- 9.2:1
Carburator -------------------------------------------------------------------------------------------- KF,CB24J
Output Power ----------------------------------------------------------------------------- 7.4Kw/7500 rpm
Maximum Torque ------------------------------------------------------------------13/5500 foot lbs/r/min
Starting -------------------------------------------------------------------------------------------------- Electric
Ignition ----------------------------------------------------------------------------------------------------- C.D.I.
Lubrication ----------------------------------------------------------------------------------- Force & Splash
Transmission ------------------------------------------------------------------- Automatic (C.V.T system)
Spark plug ------------------------------------------------------------------------------------- C7HSA(NGK)
Plug gap ---------------------------------------------------------------------------------------------0.6-0.7mm
Fuel Type ---------------------------------------------------------------------------------- RQ90 (unleaded)
Lubricate oil ------------------------------------------------------------------------------------- SAE-10W/40
CAPACITIES
Maximum load------------------------------------------------------------------------- Double Seat/400lbs
Fuel tank ------------------------------------------------------------------------------------------------1.75 Gal
Engine oil ------------------------------------------------------------------------------------------------ 600 mL
Starting ------------------------------------------------------------------------------------------------------- < 5s
Climbing ------------------------------------------------------------------------------------------------ 20。- 25
。
Baery ------------------------------------------------------------------------------------------------ 12V 10Ah
Head Light ------------------------------------------------------------------------------------- 12V 35W/35W
Tail Light ----------------------------------------------------------------------------------------- 12V 21W/5W
Fuse ----------------------------------------------------------------------------------------------------------- 10A
11
SPECIFICATIONS
Brake Track --------------------------------------------------------------------------------- < 7 m@20miles/h
Top speed ------------------------------------------------ 30 miles/h(or limited as customers require)
CHASSIS
Front, Rear brake ------------------------------------------------------- Hydraulic disc, le foot control
Front tire ------------------------------------------------------------------------------------------------ 20 x 7-8
Rear tire ---------------------------------------------------------------------------------------------- 22 x 10 -10
Front Suspension ------------------------------------------------------------- Independent Dual A-Arm
Rear Suspension -------------------------------------------- Swing Arm/Double Oil Damped Shock
Restraint System -------------------------------------------------------------------- Dual 4-point Harness
Final Drive Chain ------------------------------------------------------------------- (KMC) O-Ring Chain
TIRE PRESSURE
Front -----------------------------------------------------------------------------------147kPa 1.5kg/cm2 3psi
Rear ------------------------------------------------------------------------------------196kPa 2.0kg/cm
2 4psi
WEIGHT
Net Weight ---------------------------------------------------------------------------------------------- 465 lbs
12
SPECIFICATIONS
A. Operation controls
WARNING - Do not aempt to start or operate the engine until completely familiar with the
location and use of each control necessary to operate this vehicle. The operator must know how
to stop this machine before starting and driving it.
a. Throle
The right foot pedal is the throle that controls the Kart speed. As the engine speed
increases above idle, the clutch automatically engages and moves the vehicle forward. To
disengage the clutch at any time, allow the throle to return to the idle position.
(See Fig. 1)
b. Brake
The brake is located on the le side of the kart (See Fig.1). Applying pressure to the
pedal draws the brake caliper around the brake pump at the rear wheel and slows or stops
the kart.
c. Start engine
Insert the key into key-switch, turn the
key clockwise, release the key when the
engine starts. The engine will warm up
within 5 minutes and the engine choke
will close automatically and operate at
the normal RPM (Warning: Don’t crank
starter more than 5 seconds at one time).
d. Engine stop buon
Important-stop buon test.
Before driving this vehicle, test the Engine
Stop Buon to assure that it is operating properly. With the engine running, push and hold the
Engine Stop Buon for two seconds for the engine to shut down.
Figure 1
Each time prior to starting the engine, check the throttle assembly to ensure
that when the pedal is pushed all the way forward the assembly is working
smoothly and returns to idle when released. Do not operate if pedal or engine throttle
linkage fail to return to idle. If unable to correct the problem through lubrication,
adjustment or replacement of worn parts, contact your dealer for assistance.
WARNING
OPERATION
13
IGNITION START SWITCH
ENGINE STOP BUTTON
LIGHT SWITCH
BRAKE PEDAL
THROTTLE PEDAL
REVERSE LEVER
PARKING BRAKE
HORN BUTTON
P0WER OUTLET
MIRROR
SWITCH UNIT - TURN SIGNAL
a. Check for Engine Oil Level. Check for leaks, add oil if required.
b. Check for Fuel Level. Add fuel as necessary and do not overfill. Check for leaks.
c. Check for Brakes. Depress the rear brake pedal several times, then check for proper brake
pedal freeplay. Make sure there is no brake fluid leakage. Adjust if necessary.
d. Check Tires. Check tires condition and pressure. The pressure on both Front and Rear tire
is 5 and 8 lbs respectively.
e. Check the Drive Chain. Check for drive chain’s condition and tension. Lubricate if necessary.
f. Check Throle. Check for smooth operation. Assure throle “snaps” back to idle.
g. Check Engine Stop Buon. Perform engine stop buon test. Repair as necessary.
h. Check all Nuts, Bolts, and fasteners. Check wheels to see that all axle nuts and lug nuts are
tightened properly. Check and tighten as necessary all other fasteners to specified condition.
i. Check the Custom Bar Cage (C.B.C.). Ensure all protective C.B.C. bars are in place before operating the Kart.
j. Check Brake Light. Check for proper operation.
k. Check Wheels. Check for tightness of wheel nuts and axle nuts; check that axle nuts are
secured by Coer Pins.
l. Check steering. Check for free operation for any unusual looseness in any area.
14
OPERATION
Always follow rules for safe operation and wear a helmet.
CAUTION
Perform this pre-drive inspection everyday before driving vehicle. If not
performed, serious damage to the vehicle or personal injury may result.
WARNING
B. Pre-Drive Inspection
Figure 2
15
REAR CARGO RACK
FUEL TANK CAP
TANK COMP. FUEL
TOW BALL
OPERATION
SEAT BELT
STEERING WHEEL
MIRROR
HORNS
Component locations
16
C. Passengers
The vehicle allows for two riders only. Combine
maximum weight of driver and the passenger should
not exceed 180kg or 400lbs.
D. Seat Adjustment
The seat must always be securely fastened in the
position which best affords the operator control of
the foot pedals, steering wheel, and the remote
stop buon.
a. Pull seat adjustment handle upward to disengage
seat slide.
b. Move seat to desired position.
c. Be sure seat adjustment handle snaps back into
place and that seat is locked into position.
R
D
ADJUSTING NUT #1，
REVERSE CABLE
ADJUSTING NUT #2，
REVERSE CABLE
Figure 4
Figure 3
Before attempting to adjust the seat, ensure that kart engine is stopped.
Never operate this Kart when the provided seat is not securely fastened, to
do so could result in a strong possibility of severe personal injury or loss of life.
Before attempting to adjust the seat, ensure the kart engine is stopped.
E. Reverse Adjustment
a. Push forward the reverse lever to the "D"
position so that the unit can move forward, pull
back the lever to "R" so that the unit can move
backward. (See Fig.4)
b. When reverse lever is in the drive position,
there needs to be 1/2 inch of freeplay in the reverse
level. If the adjustment is not correct, then loosen
the lock nut #2, then adjust lock nut #1 to the
proper amount of freeplay. Sometimes you may
need to adjust the freeplay more or less than 1/2 inch.
WARNING
WARNING
２
１
OPERATION
Always stop the kart before changing gears.
A. Service Air Filter
Service air filter every 20 hours
NOTE: Service more oen under dusty
conditions.
a. Remove the air filter cover
b. Remove the air filter element 2 (See Fig.6)
c. Blow clean the air filter with compressed air
or replace as needed.
17
2
1
OPERATION/SERVICE INSTRUCTIONS
F. Starting And Operating Instructions
a. Before starting the engine, be sure that the driver is seated properly in the Kart with the seat belt.
b. Testing the Kart in an open space at the beginning to learn how to start, turn and stop.
c. Operate the Kart slowly until you are familiar with it.
d. The turning radius of this Kart is small and agile, so the centrifugal force is very high when
turning at high speed. Slow down to a more controllable speed when turning to prevent the
Kart from rolling over.
e. To prevent vehicle from rolling over, be sure
to only turn the vehicle at slow, controllable
speeds. Keep your heel on the ramp of the main
board when turning. (See Fig.5) Keep your foot on
the foot pedal at all times.
SERVICE INSTRUCTIONS
Figure 5
Figure 6
Main Board
0.6-0.7mm
SEAM,DIRT,CARBON VERIFY
WASHER VERIFY
SEAM VERIFY
Figure 8
B. Engine Lubrication
You must change the oil in the crankcase aer the first 5 hours of operating your new
engine (See Fig. 7) and aer 10 hours of use thereaer. This will insure proper lubrication of
internal parts and prevent costly repairs due to excessive wear.
a. Remove drain plug located on the right rear side of
engine. Tip kart backwards slightly by blocking up the
front end 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 600 mL) with
SAE 10W40 oil. Use the same grade of oil as used
originally.
e. Check oil level before each use of kart or aer
each 10 hours of operation. Add oil to bring up to
proper level. Do not mix various grades of oil.
C. Spark Plug
a. Remove the spark plug and inspect it each time you
change the oil (use a spark plug wrench). The electrodes
should be kept clean and free of carbon. The presence of
carbon or excess oil will greatly reduce proper engine
performance. If possible, check the spark plug gap
(area between electrodes) using a wire feeler gauge.
This specification is 0.6~0.7mm.
b. Before installing spark plug, if possible, coat threads
lightly with graphite grease, to ensure easy removal next
time the spark plug needs inspection.
c. It is advisable to replace the spark plug at least once
a year to insure easy starting and good engine performance.
D. Carburetor Adjustment
Never make unnecessary adjustments. The factory recommended seings are correct for most
applications.
18
Used Oil Must Be disposed of at a proper collection center.
WARNING
WARNING
SERVICE INSTRUCTIONS
Figure 7
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