Flatworks plyfly Assembly Manual

HOW TO BUILD

YOUR
PLYFLY GO-KART!

For Ages 12+

PlyFly Go‑Kart Instruction Guide • 2015 Release

Thank you for supporting

the FLATWORKS Kickstarter campaign.

Your contribution is a great help, and your

support is much appreciated.

Thank you

Enjoy your new Plyfly Go‑Kart!

Check back soon and see what else we make!

We hope you’re as excited to get

started on your new adventure as we are to

be working on the FLATWORKS.

the Flatworks Crew,

&

150718 PLYFL Y rev A_Cover | A ug u st 7 , 2 01 5 5: 0 6 P M

II

Steven Hynes

Cam McCulloch

Alan Miyasaki

Stephan Schnitker

Chris Patton

Joe Barton

Liam Newman

No Regrets

David Geisinger

Ken Short

Andrew B. Bartels

Brian Kaleida

Matthew & Keri

Zee

Ray Colwell

Henry E.

Carl Moulton

Mark ChengIan

Drummond

CJBCN

James “Udub” Underwood

Jesse Cannone

Luke

Jim Mahoney

Tim Baker

Karl Eberhardt

Tom a s Petr u

David Moore

Jim

K Brotman

Dennis Cox

Chris DePerro

Family Woo

Marcus Leef

Anonymous

Michael Lindahl

JouleLee

Tiegen

Tyr a Hamme t t

Nathan Pelsor

Douglas Dayton

Sam Bowling

Lindsey Zimmerman

Anthony

Joshua Marcus

Lindsay Lauber

Joseph Asti

Nick Vines

Herk

Brian Jepson

Steve Baker

Louis Tovar

Mar k Tracy

Joe W.

Greg Brncick

Grandpa Rex

Alex Gomes

Mohit

Sam Bell

Emily H.

Andrew Marc

Tim Owens

Chris Porter

Matthew Clark

Ryan Bradley

Michael Lindahl

Adam “Hock” Hocherman

Michael McGrath

Dave Krugman

Daniel Cianci

Scott Newman

Russ Kadooka

Mitch

Bob

150718 PLYFL Y rev A_Cover | A ug u st 7 , 2 01 5 5: 0 6 P M

III

What's Inside?

1 Exploring the kit 1

Warnings and safety 2

Handling and storage 2

Why Wood? 3

Good to know 3

What’s in the kit? 3

Unpacking the boxes 4

2 Getting Started 6

Getting started 7

Recommended tools 7

Chisel & hammer method 7

Reciprocating saw method 7

3 Seat Assembly 8

Plywood sheet reference 9

Recommended tools 9

Required hardware 9

Required wooden parts 10

Assembling the seat 11

4 Steering Column Assembly 12

Plywood sheet reference 13

Recommended tools 13

Required hardware 13

Required wooden parts 13

Assembling the steering shaft 14

5 Steering Rack Assembly 15

Plywood sheet reference 16

Recommended tools 16

Required hardware 16

Required wooden parts 17

Assembling the steering rack 17

6 Fixed Steering Column Assembly 18

Plywood sheet reference 19

Recommended tools 19

Required hardware 19

Required wooden parts 20

Assembling the steering column 20

7 Steering Spindle Assemblies 21

Plywood sheet reference 22

Recommended tools 22

Required hardware 22

Required wooden parts 23

Assembling the left & right steering spindles 24

8 Pedal Assemblies 25

Plywood sheet reference 26

Recommended tools 26

Required hardware 26

Required wooden parts 27

Assembling the gas & the brake pedals 27

9 Frame Assembly 28

Plywood sheet reference 29

Recommended tools 30

Required hardware 30

Required assemblies 30

Required wooden parts 31

Assembling the frame 32

10 Putting the go‑kart together 37

Overview of the recommended tools 38

Overview of the required hardware 38

Overview of the required but not provided 41

Overview of the required wooden parts 41

Overview of the required assemblies 41

Part 1 Install the rear axle 43

Part 2 Install the brake caliper 44

Part 3 Install the steering column assembly 45

Part 4 Install the steering spindles 46

Part 5 Install the gas & brake pedals 47

Part 6 Install the gas & brake cables 49

Part 7 Install the engine and drive train 52

Part 8 Install the wheel assemblies 57

Part 9 Install the seat assembly 58

Part 10 Install the fairings 59

11 Master List 60

Visual reference of the plywood sheets 61

List of the wooden parts 62

List of the wooden assemblies 66

List of the tools needed 67

List of loose contents 68

List of the packaged contents 70

12 Legal 72

Legal 73

13 Terms & Conditions 74

Terms & Conditions of Purchase and Use 75

1 5 0 7 1 8 P LY F LY r e v A _ T O C | August 7, 2015 5:06 PM

IV

1

Exploring the kit

Introduction

Each Plyy Go-Kart kit arrives in 3 boxes.

Review the contents of each box to ensure you have all the
necessary parts to begin building your next adventure!

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1

Warnings and safety

Riding karts can be dangerous.

Please use caution and prudence and follow the
guidelines below.

• Avoid operating your kart in crowded or conned areas.

• Any children that use the kart are of an appropriate
age and do so under proper supervision.
The recommended age for this kart is 12+.

• Avoid using your kart near any other vehicular trac or
on public roads.

• Never try to t more than one person in the kart.

• Always wear a DOT‑rated helmet and gloves while
operating the kart.

• Never aim the kart at other people, objects or animals.

• Prior to riding, every rider should familiarize
themselves with:

‒ Their environment

‒ Any obstacles or dangers.

‒ The location and function of the

emergency shuto switch.

• Inspect the kart prior to each run to make sure that each
element is properly functioning. Test:

‒ Brakes lock the rear wheel.

‒ Shut o switch kills engine.

‒ Clutch, chain, sprocket and sprocket guard are

properly tightened and functioning.

‒ The wheels are all on and tightened.

‒ The steering system is functioning properly.

‒ There are no areas of brake discs, wheels, chain or

other moving elements rubbing on the wood.

‒ That all shaft keys (clutch, sprocket, brake disc, wheels)

are installed and secured in place by a tight set screw.

‒ Ensure all fasteners are tight and properly torqued.

‒ The safety ag is installed.

‒ The seat is properly installed and adjusted.

• Do not attempt to leave the ground with the kart.
It is not designed or intended for jumping.

• Ensure the rider has no articles of loose clothing
or hair that could get caught in the spinning
mechanisms of the kart.

Handling and storage

• The kart is heavy.

• Use at least two people to lift or move it.

• Some surfaces may be hot after use, handle with
caution. These may be from friction in bearings and
brakes or from the engine.

• If gasoline is spilled on the wood, leave the kart

outside in a well ventilated area to dry before use
or storage. Be very careful about exposure to potential

ignition sources until it dries.

• Do not tip the kart. Fuel may spill from the carburetor if
inclined too much. If you need to stand up the kart, start

the engine and turn o the fuel valve. Let the engine run the

carburetor dry.

• Store the kart in a dry, clean area and coat the wood with
a paint or coating for the longest life.

1 Exploring the kit

2

1 5 0 7 1 8 P LY F L Y r e v A _ C H 1 | August 7, 2015 5:08 PM

Why Wood?

Sure, steel karts are fun and strong, but they require a large
number of specialized tools to build, repair or modify. Tools
that most people don’t have. Wood, on the other hand, can
be crafted with tools available in most homes and all home
improvement stores. We want to provide kits that people

can make their very own, by painting, xing or modifying and
wood is a natural t for this.

The wood used in this kit is a 3/4 inch Baltic Birch plywood.

It is a natural t for the go-kart due to it’s strength and

appearance. The 13 plies make it incredibly strong and
give the end grain a beautiful contrast. Best of all, it can be

modied, repaired or reworked with common household

tools.

Good to know

It is vitally important that anyone riding a go‑kart wear the
proper protective gear. The rider should wear, at a minimum,
a full‑face DOT‑rated engine cycle helmet, gloves and a
helmet supporting neck brace. These items and other safety
equipment are not supplied with the kits but can be found
through many online or retail sellers.

We aim to provide the best assembly documentation in
the industry and will include written instructions and online
videos for all of the crucial steps. We will be available to
help you through the process, so if you need assistance,
please ask. However, this is a kit and the ultimate
build quality is up to you.

What’s in the kit?

Each Plyy Go-Kart kit arrives in 3 boxes. Box 1 is a at box

with the wooden structural parts. Box 2 is the engine and
box 3 is the hardware.

1.2.3. That’s it!

Packaging reference

Description Reference

Box 1 – wood
Dimension: 30” x 60” x 3”

Box 2 –engine
Dimension: 14” x 14” x 16”

Box 3 – hardware & wheels
Dimensions: 24” x 12” x 12”

For more the complete list of hardware, see Visual reference of the plywood sheets, on page 61.

1 5 0 7 1 8 P LY F L Y r e v A _ C H 1 | August 7, 2015 5:08 PM

PlyFly Go‑Kart Instruction Guide • 2015 Release

3

Unpacking the boxes

Each box should have the following components.

Box 1 contents

2.5 HP 4.0 HP 4.0 HP 4 .0 HP 4.0 HP

№ DESCRIPTION

3 Plywood Sheet

3/4” depth

1 Plywood Sheet

1/4” de pth

SINGLE WHEEL

10” WHEELS

• • • • •

• • • • •

SINGLE WHEEL

10” WHEELS

SINGLE WHEEL

12” WHEELS

LIVE AXLE

10” WHEELS

LIVE AXLE

12” WHEELS

1 Flag

1 Drive Shaft

Steel, Keyed, 5/8” D

Box 2 contents

№ DESCRIPTION

1 Gas Powered Engine

2.5 HP MODEL

1 Gas Powered Engine

4.0 HP MODEL

• • • • •

18” L 18” L 18” L 33” L 36” L

2.5 HP 4.0 HP 4.0 HP 4 .0 HP 4.0 HP

SINGLE WHEEL

10” WHEELS

•

―

SINGLE WHEEL

10” WHEELS

― ― ― ―

SINGLE WHEEL

12” WHEELS

LIVE AXLE

10” WHEELS

• • • •

LIVE AXLE

12” WHEELS

1 Exploring the kit

4

1 5 0 7 1 8 P LY F L Y r e v A _ C H 1 | August 7, 2015 5:08 PM

Box 3 Contents

DESCRIPTION

2.5 HP 4.0 HP 4.0 HP 4.0 HP 4.0 HP

SINGLE WHEEL

10” WHEELS

SINGLE WHEEL

10” WHEELS

SINGLE WHEEL

12” WHEELS

LIVE AXLE

10” WHEELS

LIVE AXLE

12” WHEELS

Plyy Packaged Hardware Kit Sealed kit of go ‑kart hardware

Clutch #35 Chain, 11 Tooth Pulley for 5/8” shaft 2.5 HP Model

Clutch #35 Chain, 12 Tooth Pulley for 3/4” shaft 4.0 HP Model ―

Clutch Guard Side Engine Mounting Plate

Clutch Guard Top Top C ove r

Clutch Guard Cover Outside Cover

Sprocket 60 Tooth, #35 Chain, 5/8” D bore

Roller Chain #35 Chain, 29‑5/8” L

Chain Link For connecting #35 Roller Chain

Control Cable 1/16” D, throttle & brake control cable

Red Throttle Cable Brake conduit, 5’ L

Green Throttle Cable Gas conduit, 6’ L

VXB Mounted Bearing 5/8” ID

Brake Caliper

1 1 1 1 1

1

― ― ― ―

1 1 1 1

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

2 2 2 2 2

1 1 1 1 1

1 1 1 1 1

3 3 3 3 3

1 1 1 1 1

Brake Disc

Brake Hub

Long Hex Bolt Grade 5, 5/8”‑11, 11” L Single Wheel Kit Only

Shor t Hex Bolt Grade 5, 5/8”‑11, 6.5” L

Precision Rod 1/4” D, 18” L

Drawer Slide Hardware included, 10” L

Green Elastic Cord 3/16” OD, 18”

Spax Screw 1 Box,#8 1‑1/2” L

10” D Wheels Rear driven wheel

10” D Wheels Undriven wheel

12” D Wheels Rear driven wheel ― ―

12” D Wheels Undriven wheel ― ―

PlyFly Flag

1 1 1 1 1

1 1 1 1 1

1 1 1

4 4 4 4 4

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

1 1

3 3

1 1 1 1 1

― ―

―

―

1

3

2

2

―

―

―

―

2

2

1 5 0 7 1 8 P LY F L Y r e v A _ C H 1 | August 7, 2015 5:08 PM

For more the complete list of hardware, see List of the packaged contents, on page 70.

PlyFly Go‑Kart Instruction Guide • 2015 Release

5

2

Getting Started

Introduction

Preparing for a Plyy Go-Kart build, you will need to cut out

each structural wooden part from the plywood sheets.

The more time spent trimming tabs cleanly will save
a lot of sanding time.

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6

Getting started

Chisel & hammer method

INSTRUCTIONS

1. Open the provided boxes to ensure all the parts are
included.

2. To release the structural wooden parts from the
plywood sheets, use the recommended tools and follow
one of the suggested methods:

‒ A chisel and hammer method

‒ The reciprocating saw method

Recommended tools

DESCRIPTION REFERENCE

Chisel

Hammer

Orbital sander

INSTRUCTIONS

1. To free a part from the plywood sheet, place the at side
of chisel against the keeper side of the part.

2. Strike the top of the chisel sharply with a hammer to
remove wood from the notches.

3. Repeat this procedure until all the parts are free.

4. To nish the edges of all the wood parts that become
spalled or rough from the cutting process using an orbital
sander, or sheet of sandpaper.

Reciprocating saw method

INSTRUCTIONS

1. Select the correct blade for the cutting wood

2. Place the plywood sheet on saw horses or a workbench,
or clamp it in a vice, depending on which is best suited for
your purpose.

Note Make sure you have sucient light to see your cutting

marks easily

3. To free a part from the plywood sheet, position the blade
close to the edge of the wood tab (where you will begin
your cut)

Note Complete the cut by continuing through the material,
being careful to support any piece that may drop when the cut is

nished until the blade is free of it.

4. Repeat this procedure until all the parts are free.

5. To nish the edges of all the wood parts that become
spalled or rough from the cutting process using an orbital
sander, or sheet of sandpaper.

Sandpaper

Jigsaw or
Reciprocating saw

(optional)

For more information on What’s in the kit?, see page 3.

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PlyFly Go‑Kart Instruction Guide • 2015 Release

7

3

3

Seat Assembly

Assembly

Introduction

Before beginning this assembly, be sure to chisel out and sand
parts 22 ‑ 33. These 12 components are required to fully assemble
the go‑kart seat

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8

Plywood sheet reference

DESCRIPTION REFERENCE

Recommended tools

DESCRIPTION REFERENCE

Sheet 1

3/4” Plywood Sheet

Sheet 3
3/4” Plywood Sheet

‒ Parts 24

‒ Parts 22‑23
‒ Parts 25‑27

22

24

Dead blow hammer

or mallet

Electric driver

Required hardware

№ DESCRIPTION REFERENCE

32 Spax Screw

#8, 1‑1/2” L

PN 12 519

Sheet 4
1/4” Plywood Sheet

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23

252726

‒ Parts 28‑31

31

302829

PlyFly Go‑Kart Instruction Guide • 2015 Release

9

Required wooden parts

DESCRIPTION REFERENCE

Part 22

Seat Side Left

PLYWOOD SHEET 3

Part 23
Seat Side Right

‒ Gas tank side

PLYWOOD SHEET 3

DESCRIPTION REFERENCE

Part 28

Seat Bolster Left

PLYWOOD SHEET 4

Part 29
Seat Bolster Right

PLYWOOD SHEET 4

Part 30
Seat Thigh Bolster Left

PLYWOOD SHEET 4

Part 31
Seat Thigh Bolster Right

PLYWOOD SHEET 4

Part 24
Seat Crossbar

PLYWOOD SHEET 1

Part 25
Seat Crossbar

PLYWOOD SHEET 3

Part 26
Seat Crossbar

PLYWOOD SHEET 3

Part 27
Seat Crossbar Bracket

PLYWOOD SHEET 3

Part 32
Seat Back

PLYWOOD SHEET 4

Part 33
Seat Bottom

PLYWOOD SHEET 4

1 5 0 7 1 8 P LY F LY r e v A _ S e a t | August 7, 2015 5:06 PM

Note If you received a 1/4” plywood sheet that is nished on one side and

you intend to paint the Plyy go-kart seat; reverse the wooden parts 28-33
(so the unnished side is outward facing and

ready to receive paint).

3 Seat Assembly

10

Assembling the seat

INSTRUCTIONS

1. Align parts 22 & 23 with the slots facing outwards.

2. Using a mallet, tap part 27 into the slots on parts 22 &23.

Note the part orientation and location.

27

23

22

3. Secure part 27 using 2 screws.

‒ Use 1 screw per side.

‒ Total of 2 locations, 2 screws.

Note secure pa rt 27, by screwing the par t in from the outside of par t 22 & 23.

7. Secure part 32 to the seat frame using screws.

‒ Use 8 screws.

‒ Total of 8 locations.

8. Using a mallet, tap part 29 into seat frame.

Note location and orientation of part 29.

29

9. Repeat step 8 with part 28 on the opposite side.

10. Secure parts 28 & 29 to seat frame using screws.

‒ Use 4 screws.

‒ Total of 4 locations.

11. Using a mallet, tap part 33 into the tab connections of
parts 26 &27.

Note location and orientation of part 33.

21

4. Using a mallet, tap parts 24, 25, & 26 into the
remaining slots.

Note the location and orientation of the parts 24-26.

24

25

26

5. Secure parts 24, 25, & 26 by using screws.

‒ Use 2 screws per part, 1 screw per side.

‒ Total of 6 locations, 6 screws.

6. Using a mallet, tap part 32 into the tab connections of
parts 24 & 25.

Note the location and orientation of the part 32.

32

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33

12. Secure part 33 using screws.

‒ Use 8 screws.

‒ Total of 8 locations.

13. Using a mallet, tap part 31 into place using a mallet.

Note location and orientation of part 31.

31

14. Repeat step 13 with part 30 on the opposite side.

15. Secure parts 30‑31 to seat frame using screws.

‒ Use 4 screws.

‒ Total of 4 locations.

PlyFly Go‑Kart Instruction Guide • 2015 Release

11

Steering Column

4

Assembly

Introduction

Before beginning this assembly, be sure to chisel out and
sand parts 19‑20. These 3 components are required to
fully assemble the steering shaft.

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12

Plywood sheet reference

DESCRIPTION REFERENCE

Recommended tools

DESCRIPTION REFERENCE

Sheet 1

3/4” Plywood Sheet

Sheet 2
3/4” Plywood Sheet

‒ Part 20

‒ Part 19
‒ Part 21

20

Dead blow hammer

or mallet

Hammer

Electric driver

Required hardware

№ DESCRIPTION REFERENCE

4 Small Metal Bushing

Flanged 3/8” ID, 1/4” L

PN 12 53 8

521 19

4 Spax Screw

#8, 1‑1/2” L

PN 12 519

Required wooden parts

DESCRIPTION REFERENCE

Part 19

Steering Column Shaft

PLYWOOD SHEET 2

Part 20
Steering Pinion

PLYWOOD SHEET 1

Part 21
Steering Wheel

PLYWOOD SHEET 2

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PlyFly Go‑Kart Instruction Guide • 2015 Release

13

Assembling the steering shaft

20

19

INSTRUCTIONS

1. Press bushings into each side of part 20.

Note there are 2 bushings, 1 bushing per side.

2. Hammer securely until the top of each bushing is ush.

3. Press bushings into each side of part 21.

Note there are 2 bushings, 1 bushing per side..

6. Secure the parts using screws.

‒ Use 2 screws on part 20

‒ Total of 2 locations.

7. Using a mallet, tap part 21 to the assembly.

Note the location and orientation of par t 21.

The bushings should point in the sa me direction.

21

19

20

4. Hammer securely until the top of each bushing is ush

5. Using a mallet, tap part 19 to part 20.

Note The orientation of the par ts.

8. Secure the parts using screws.

‒ Use 2 screws on part 21.

‒ Total of 2 locations.

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4 Steering Column Assembly

14

Steering Rack

5

Assembly

Introduction

Before beginning this assembly, be sure to pre‑cut and sand
parts 9 ‑ 12. These 4 components are required to fully assemble
the go‑kart steering rack.

150718 PLYFL Y rev A_Steer rack | A u gu s t 5 , 2 01 5 1 0: 3 8 P M

15

Plywood sheet reference

DESCRIPTION REFERENCE

Recommended tools

DESCRIPTION REFERENCE

Sheet 1

3/4” Plywood Sheet

Sheet 2
3/4” Plywood Sheet

12 11

‒ Parts 9‑10

‒ Parts 11‑12

Dead blow hammer
or mallet

Hammer

Screwdriver

109

Electric driver

Required hardware

№ DESCRIPTION REFERENCE

4 Spax Screw

#8, 1‑1/2” L

PN 12 519

150718 PLYFL Y rev A_Steer rack | A u gu s t 5 , 2 01 5 1 0: 3 8 P M

5 Steering Rack Assembly

16

Required wooden parts

DESCRIPTION REFERENCE

Part 9

Steering Rack Bracket

PLYWOOD SHEET 1

Part 10
Steering Rack Bracket

PLYWOOD SHEET 1

Part 11
Steering Rack

PLYWOOD SHEET 2

Part 12
Steering Rack Center
Bracket

PLYWOOD SHEET 2

Assembling the steering rack

INSTRUCTIONS

1. Using a mallet, tap parts 9 & 10 into the slots on part 11.

Note the part ori entation

9 1011

2. Secure parts 9 & 10 using screws.

‒ Use 1 screw per part.

‒ Total of 2 locations, 2 screws.

3. Using a mallet, tap part 12 into the tab connections on
parts 9 & 10.

Note the part 12 orientation – the gear teeth should point in the same direction.

12

150718 PLYFL Y rev A_Steer rack | A u gu s t 5 , 2 01 5 1 0: 3 8 P M

4. Secure part 12 to the assembly using screws.

‒ Use 2 screws.

‒ Total of 2 locations.

PlyFly Go‑Kart Instruction Guide • 2015 Release

17

Fixed SteeringColumn

6

Assembly

Introduction

Before beginning this assembly, be
sure to pre‑cut and sand parts 13 ‑ 18.
These 6 components are required to fully assemble

the go-kart xed steering column.

150718 PLYFL Y rev A_Steer fixed | A ug u s t 7 , 2 01 5 5: 0 6 PM

18

Plywood sheet reference

DESCRIPTION REFERENCE

Recommended tools

DESCRIPTION REFERENCE

Sheet 1

3/4” Plywood Sheet

13

Sheet 2

3/4” Plywood Sheet

‒ Parts 13

Dead blow hammer
or mallet

Hammer

Required hardware

№ DESCRIPTION REFERENCE

‒ Parts 14‑18

2 Small Tee Nut

Zinc Plated, 5/16”‑18

PN 12 510

15 1814

12 Spax Screw

#8, 1‑1/2” L

PN 12 519

1716

150718 PLYFL Y rev A_Steer fixed | A ug u s t 7 , 2 01 5 5: 0 6 PM

PlyFly Go‑Kart Instruction Guide • 2015 Release

19

Required wooden parts

DESCRIPTION REFERENCE

Part 13

Steering Column Left

PLYWOOD SHEET 1

Assembling the steering column

INSTRUCTIONS

1. Press t ee nuts into parts 15 & 18

Note the orientation of par t 15.

15

Note the orientation of par t 18.

18

Part 14
Steering Column Right

PLYWOOD SHEET 2

Part 15
Steering Column Top

PLYWOOD SHEET 2

Part 16
Steering Column Phone
Mount

PLYWOOD SHEET 2

Part 17
Steering Column Bracket

PLYWOOD SHEET 2

Part 18
Steering Pinion Mount

PLYWOOD SHEET 2

2. Using a hammer, tap the t ee nut until the top is ush with
the wooden part.

3. Using a mallet, tap parts 15 , 16, 17, & 18 into the
corresponding slots on part 13.

Note the location and orientation of each part.

17 18 16 15

13

4. Align part 14 to the assembly so that the part mirrors
part 13 exactly.

5. Using a mallet, tap part 14 into the tab connections.

6. Secure the parts using screws on each part.

‒ Use 1 screw per part, per side.

‒ Total of 4 locations, 4 screws.

7. Secure the parts on the opposite side, turn the assembly
on its side, and then screw in each part.

‒ Use 1 screw per part, per side.

‒ Total of 4 locations, 4 screws.

150718 PLYFL Y rev A_Steer fixed | A ug u s t 7 , 2 01 5 5: 0 6 PM

6 Fixed Steering Column Assembly

20

SteeringSpindle

7

Assemblies

Introduction

Before beginning this assembly, be sure to chisel
out and sand parts 1‑8. These 8 components
are required to fully assemble 2 steering spindle.
Each assembly contains 4 parts.

150718 PL YFLY rev A_Steer spindle | A ug u s t 7, 2 01 5 5 : 06 P M

21

Plywood sheet reference

DESCRIPTION REFERENCE

Sheet 1

3/4” Plywood Sheet

‒ Part 1
‒ Parts 3‑4
‒ Parts 6‑8

Recommended tools

DESCRIPTION REFERENCE

Dead blow hammer

or mallet

3

Hammer

Electric Driver

61874

Sheet 2

3/4” Plywood Sheet

5

‒ Part 2
‒ Part 5

Required hardware

№ DESCRIPTION REFERENCE

2

2 Shor t Hex Bolt

Grade 5, 5/8”‑11, 6.5” L

PN 12503

6 Large Metal Bushing

Flanged, 3/4” OD, 5/8” ID

PN 12 50 4

2 Small Tee Nut

Zinc Plated, 5/16”‑18

PN 12 510

150718 PL YFLY rev A_Steer spindle | A ug u s t 7, 2 01 5 5 : 06 P M

7 Steering Spindle Assemblies

22

20 Spax Screw

#8, 1‑1/2” L

PN 12 519

Required wooden parts

DESCRIPTION REFERENCE

Part 1

Steering Spindle Outer Spacer

PLYWOOD SHEET 1

Part 2
Steering Spindle Outer Spacer

PLYWOOD SHEET 2

Part 3
Steering Spindle Inner Spacer

PLYWOOD SHEET 1

Part 4
Steering Spindle Inner Spacer

PLYWOOD SHEET 1

Part 5
Steering Spindle Bottom Left

PLYWOOD SHEET 2

Part 6
Steering Spindle Bottom Right

PLYWOOD SHEET 1

Part 7
Steering Spindle Top

PLYWOOD SHEET 1

Part 8
Steering Spindle Top

PLYWOOD SHEET 1

150718 PL YFLY rev A_Steer spindle | A ug u s t 7, 2 01 5 5 : 06 P M

PlyFly Go‑Kart Instruction Guide • 2015 Release

23

Assembling the left & right steering spindles

INSTRUCTIONS

1. Press bushings into parts 1‑2, 5‑6, & 7‑8

Note the orientation of par t 1 & 2.

1

Note Be sure to insert the bushing on the opposite side of the alignment mark.

Parts 5 & 6 a re left and a right side biased.

2

5 6

Note the location of the bushings.

7. Using a mallet, cap the parts 1, 3, 5 with part 7.

8. Using a mallet, cap the parts 2, 4, 6 with part 8.

Note the location of the bushings.

87

9. Secure the parts using screws on each part.

‒ Use 2 screws on part 5

‒ Use 2 screws on part 6

‒ Use 4 screws on part 7

‒ Use 4 screws on part 8

‒ Total 20 locations, 20 screws.

10. Using a hammer, insert the 5/8” long bolt into each
steering spindle assembly.

Note the location of the bushings

7

8

2. Using a hammer, tap the bushings until the top is ush
with the wooden part.

3. Using a mallet, tap parts 1 into the outer slot on part 5.

4. Using a mallet, tap parts 2 into the outer slot on part 6.

5. Using a mallet, tap parts 3 into the inner slot on part 5.

6. Using a mallet, tap parts 4 into the inner slot on part 6.

Note the location of the bushings. The bushing should face ou twards.

Try to ensure 90°

1

3

4

2

150718 PL YFLY rev A_Steer spindle | A ug u s t 7, 2 01 5 5 : 06 P M

5

7 Steering Spindle Assemblies

24

6

8

Pedal Assemblies

Introduction

Before beginning this assembly, be sure to chisel out and sand
parts 34 ‑ 39. These 6 components are required to fully assemble
the go‑kart gas and brake pedals. Each assembly contains 3 parts.

150718 PLYFL Y rev A_Pedal | Au g us t 7, 2 01 5 5: 0 6 P M

25

Plywood sheet reference

DESCRIPTION REFERENCE

Recommended tools

DESCRIPTION REFERENCE

Sheet 1

3/4” Plywood Sheet

3736

Sheet 3

3/4” Plywood Sheet

‒ Parts 34
‒ Parts 36‑39

Dead blow hammer
or mallet

38 39

Hammer

Electric Driver

34

‒ Parts 35

Required hardware

№ DESCRIPTION REFERENCE

35

4 Plastic Bushing

Flanged, 1/4” ID, 3/8” OD

PN 12 50 9

8 Spax Screw

#8, 1‑1/2” L

PN 12 519

150718 PLYFL Y rev A_Pedal | Au g us t 7, 2 01 5 5: 0 6 P M

8 Pedal Assemblies

26

Required wooden parts

DESCRIPTION REFERENCE

Part 34

Brake Pedal

PLYWOOD SHEET 1

Part 35
Gas Pedal

PLYWOOD SHEET 3

Assembling the gas & the brake pedals

INSTRUCTIONS

1. Insert and hammer into place the bushings into parts

‒ Part 36

‒ Par t 37

‒ Part 38

‒ Part 39

Note the part orientat ion. The n al 2 assemb lie s are mirror ima ges of each other.

38

39

Part 36
Pedal Side

PLYWOOD SHEET 1

Part 37
Pedal Side

PLYWOOD SHEET 1

Part 38
Pedal Side

PLYWOOD SHEET 1

Part 39
Pedal Side

PLYWOOD SHEET 1

36

37

2. Using a mallet, tap parts 36 & 37 into the slots on part 34.

Note par t location and orientation of par ts 36-37. Be sure to squa re the parts.

34

36

37

3. Secure parts 34, 36 & 37 using screws.

‒ Use 2 screws per part & per side.

‒ Total of 4 locations, 4 screws.

4. Repeat step 2 using parts 35, 38 & 39.

Note par t location and orientation of par ts 36-37. Be sure to squa re the parts.

150718 PLYFL Y rev A_Pedal | Au g us t 7, 2 01 5 5: 0 6 P M

38

39

5. Secure parts 35, 38 & 39 using screws.

‒ Use 2 screws per part & per side.

‒ Total of 4 locations, 4 screws.

PlyFly Go‑Kart Instruction Guide • 2015 Release

35

27

9

Frame Assembly

Introduction

Before beginning this assembly, be sure to chisel
out and sand parts 40‑55. These 11 components
and assemblies1‑3 are required to fully assemble
the go‑kart frame.

150718 PLYFL Y rev A_Frame | A ug u st 7 , 2 0 15 5: 0 6 P M

28

Plywood sheet reference

DESCRIPTION REFERENCE

DESCRIPTION REFERENCE

Sheet 1

3/4” Plywood Sheet

Sheet 2
3/4” Plywood Sheet

‒ Parts 40‑43
‒ Part 49

‒ Parts 44‑46
‒ Part 48
‒ Part 52

4941 40 43 42

45 44

Sheet 4

1/4” Plywood Sheet

Sheet 4
1/4” Plywood Sheet

‒ Part 47
‒ Part 50

50

47

‒ Part 51
‒ Part 53‑54
‒ Part 55

55

46 5248

150718 PLYFL Y rev A_Frame | A ug u st 7 , 2 0 15 5: 0 6 P M

51

53 54

PlyFly Go‑Kart Instruction Guide • 2015 Release

29

Recommended tools

DESCRIPTION REFERENCE

Dead blow Hammer

or mallet

Hammer

Electric Driver

Required assemblies

DESCRIPTION REFERENCE

1

Steering rack

Assembly

Parts 9‑12

2

Screwdriver

Required hardware

№ DESCRIPTION

1 Drawer Slide

Hardware included, 10” L

PN 12 50 8

Large Metal Bushing
Flanged, 3/4” OD, 5/8” ID

SINGLE WHEEL KIT PN 125 0 4

5
4 LIVE A XLE KIT P N 12 50 4

10 Large Tee Nut

Zinc Plated, 3/8”‑16

PN 12 54 5

10 Small Tee Nut

Zinc Plated, 5/16”‑18

PN 12 510

Fixed steering column
Assembly

Pa r t s 13‑18

REFERENCE

3

Steering column

Assembly

Par ts 19‑21

30 Spax Screw

#8, 1‑1/2” L

PN 12 519

3 VXB Mounted Bearing

5/8” ID

PN 12 521

4 Hex head cap screw

5/16”‑18, 1.25 L

PN 12 54 3

4 Flat Washer

5/16” ID, 7/8” OD

PN 12 516

9 Frame Assembly

30

150718 PLYFL Y rev A_Frame | A ug u st 7 , 2 0 15 5: 0 6 P M

Required wooden parts

DESCRIPTION REFERENCE

Part 40

Frame Rail Inner Lef t

PLYWOOD SHEET 1

Part 41
Frame Rail Inner Right

PLYWOOD SHEET 1

Part 42
Frame Rail Outer Left

PLYWOOD SHEET 1

Part 43
Frame Rail Outer Right

PLYWOOD SHEET 1

DESCRIPTION REFERENCE

Part 48

Frame Rail Rear

PLYWOOD SHEET 2

Part 49
Frame Rail Engine Mount

PLYWOOD SHEET 1

Part 50
Engine Mounting Plate

PLYWOOD SHEET 3

Part 44
Front‑end Bottom

PLYWOOD SHEET 2

Part 45
Fr o nt‑ e n d Top

PLYWOOD SHEET 2

Part 46
Frame Rail Bracket

PLYWOOD SHEET 2

Part 51
Floor Panel

PLYWOOD SHEET 4

Part 52
Frame Gusset

PLYWOOD SHEET 2

Part 47
Sprocket Guard

PLYWOOD SHEET 3

150718 PLYFL Y rev A_Frame | A ug u st 7 , 2 0 15 5: 0 6 P M

PlyFly Go‑Kart Instruction Guide • 2015 Release

31

Assembling the frame

INSTRUCTIONS

1. To begin this assembly

‒ Start at Step 2 if you have a

‒ Start at Step 4 if you have a

2. Press the bushing into part 40.

Note the location of the bushing on par t 40. Install on the opposite side of the L.

40

SINGLE WHEEL KIT.

LIVE A XLE KIT.

5. Press the large tee nuts into

‒ Part 42‑43

‒ Par t 47

‒ Part 50; on the opposite side of the small tee nut

installation.

Note the location of 2 large tee nuts on par t 42. Install on the same side of

the L.

3. Using a hammer, tap the bushing until the top is ush with
the wooden part.

4. Press the small tee nuts into

‒ Pa rt 40‑41

‒ Part 49

‒ Part 50; be sure to follow installation pattern for the

correct engine model.

Note the location of the small tee nut on part 40; install on the same side of

the L.

40

Note the location of the small tee nut on part 41. Install on the same side of

the L.

41

1

1 2

Note the location of 2 large tee nuts on par t 43. Install on the same side of

the L.

43

Note the location of 2 large tee nust on part 47.

1 2

47

Note the location of 4 large tee nuts on par t 50. Install on opposing side of the

small tee nut installion on part 50.

50

1 2

42

1 2

Note the location of 4 small tee nuts on par t 49.

49

32

1

2

Note the location of 4 small tee nuts on par t 50

1

50

2.5 HP

2

9 Frame Assembly

3

4

3

50

4

3 4

6. Using a hammer, tap the tee nuts until the top is ush with
the wooden part.

‒ Parts 41‑43, 47, 49 & 50.

‒ Use 20 tee nuts; 10 small and 10 large.

150718 PLYFL Y rev A_Frame | A ug u st 7 , 2 0 15 5: 0 6 P M

‒ Total of 20 locations.

7. Screw in the llester head machine screws into the
tee nuts located parts 40 & 41.

1

4.0 HP

2

3

4

‒ Tighten down until it stands ush with 3/8” protrusion.

8. Press 2 bushings into part 45.

Note the location of the bushing on par t 45

1 2

9. Using a hammer, tap the bushings until the top is ush
with the wooden part.

10. Press 2 bushings into part 44.

Note the location of the bushings on par t 44

1 2

11. Using a hammer, tap the bushings until the top is ush
with the wooden part.

12. Install the drawer slide on part 44, by extending the slide
to its furthest extended position.

13. Align the 4 screw holes on the drawer slide with holes
found in the recess on part 44.

Note the location and pos iti on of the mou nting hol es. Th e drawer slide shou ld t

into the recessed pocket on par t 44.

16. Extend the drawer slide until the last two holes on the
drawer slide are accessible from the underside through
the slot located on part 44.

Note the location of the referenced slot on part 44.

Mount

1

to the drawer slide.

Note the cor rect assembly

17. Secure 1 using screws.

‒ Use the remaining screws included in the

Drawer Slide Kit.

18. Using a mallet, tap part 40 into the tab connections on
the left side of part 44.

Note the location and orientation of the tee nut on pa rt 40;

the letter L should face inwa rd to the centerline of the go-ka rt.

1

2

3 4

14. Secure the drawer slide to part 44 using screws.

‒ Use a screwdriver and the screws provided in the

Slide Drawer Kit.

‒ Use 4 screws

‒ Total 4 locations

15. Test the drawer slide t by moving the
slide back and forth.

‒ Be sure there are no interferences between any

screw head and the slide.

44

40

19. Using a mallet, tap part 41 into the tab connections on the
left side of part 44.

Note the letter L should face part 41, away from the centerline of the go-kart.

41

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PlyFly Go‑Kart Instruction Guide • 2015 Release

33

20. Repeat steps 18 and 19 using

‒ Part 42

‒ Part 43

Note the let ter L should face part 41, away from the centerline of the go-kar t.

42

43

25. Secure part 44 to the assembly using screws.

‒ There is a purposeful gap in alignment to allow part 51

to sit ush with the assembly.

‒ Use 12 screws.

‒ Total of 12 locations.

26. Flip the assembly right side up again.

27. Using a mallet, tap part 46 into place.

Note the orientation and posi tion the tabs on part 46.

46

21. Using a mallet, tap

2

into the tab connections in the

center of part 44.

Note the orientation and location of the assembly.

2

22. Using a mallet, tap part 45 slots into the tab connections
of go‑kart front‑end (parts 40‑43).

Note the correct orientation for part 45; the bushings face(down) par t 44.

45

28. Using a mallet, tap part 47 into the center slot of part 46.

Note the orientation and posi tion of part 47.

23. Secure part 45 using screws.

‒ Use 12 screws.

‒ Total of 12 locations.

24. Flip the assembly over and using a mallet, tap any
unseated tabs into place.

2

‒ It is best to do this with

hanging o the edge of

a table or saw horses.

9 Frame Assembly

34

47 46

29. Secure parts 46 to part 47 using screws.

‒ Use 2 screws.

‒ Total of 2 locations.

150718 PLYFL Y rev A_Frame | A ug u st 7 , 2 0 15 5: 0 6 P M

30. Using a mallet, tap part 48 into the 5 connection tabs.

Note the orientation and posi tion of cut-out tabs, it should face upward.

To ensure alig nment of all 5 tab connections; prior to using a mallet, tack 1 corner of

part 48 with a screw that is not tightened down all the way.

48

31. Secure part 48 to the assembly using screws on the
rear face, left and right side faces.

‒ Use 12 screws.

‒ Total of 12 locations.

32. Using a mallet, tap part 52 into place.

Note the orientation and posi tion of part 52.

52

34. Using a mallet, tap part 49 into place.

Note the orientation and posi tion of part 49.

49

35. Secure part 49 using screws.

‒ Use 8 screws.

‒ Total of 8 locations.

2

36. Flip assembly over allowing
saw horses.

37. Install the 3 mounted bearings

Note the orientation, location and position of each mounted bearing.

to hang o table or

33. Secure part 52 using screws.

‒ Use 2 screws.

‒ Total of 2 locations.

150718 PLYFL Y rev A_Frame | A ug u st 7 , 2 0 15 5: 0 6 P M

1

2

3

PlyFly Go‑Kart Instruction Guide • 2015 Release

35

38. Using a mallet, tap part 51 into place.

39. Secure part 51 to the assembly using 21 screws.

‒ Total of 21 locations, 21 screws.

40. Flip assembly right side up.

41. Lay part 50, with the small tee nuts facing upwards, into
place.

Note the orientation and position of tee nut pattern on part 50.

50

42. Secure part 50 to the assembly using washers &
hex head cap screw.

‒ Use 4 washers

‒ Use 4 hex head cap screw.

‒ Total 4 locations.

Note the orientation and posi tion of the hex hed bolts; tee-nuts should face up.

150718 PLYFL Y rev A_Frame | A ug u st 7 , 2 0 15 5: 0 6 P M

9 Frame Assembly

36

Putting the go-kart

10

together

Introduction

Before beginning this nal assembly, be sure to have

assemblies 1‑7 completed. These 8 assemblies are required to
fully assemble the go‑kart.

This chapter contains 10 individual procedural parts to
successfully complete the full go‑kart assembly.

150718 PLYFL Y rev A_GoKart | A ug u st 7, 20 1 5 5:0 8 PM

37

Overview of the recommended tools

DESCRIPTION REFERENCE

Overview of the required hardware

№ DESCRIPTION REFERENCE

PART 1

Dead blow Hammer

or mallet

Hammer

Electric Driver

Allen Wrench

or ratcheting Allen wrench

Metric Allen Wrench
included with mounted bearing

1 Sprocket

5/8” bore diameter
60 Tooth, #35 Chain

PN 12 52 2

1 Drive Shaft

Steel, Keyed, 5/8” D, 18” L

SINGLE WHEEL KIT PN 125 8 0

1 Drive Shaft

Steel, Keyed, 5/8” D, 33” L

LIVE A XLE KIT – 10” WHEELS PN 125 81

1 Drive Shaft

Steel, Keyed, 5/8” D, 36” L

LIVE A XLE KIT – 12” WHEELS PN 12 5 82

1 Brake Disc

PN 12 53 2

1 Brake Disc Hub

PN 12 53 3

Socket Wrench

Needle Nose Pliers

Note There are 2 types of button socket head cap screws

provided in every kit. They appear to be similar in

size but are not. The easiest way to dierentiate the

2 sizes, is by the number of screws provided.

1 Long Hex Bolt

Axle Grade 5, 5/8”‑11, 11” L

SINGLE WHEEL KIT PN 12 5 02

4 Button Socket Head Cap Screw

Zinc Plated, Steel, 5/16”‑24, 1/2” L

TOTAL OF 4 PROVID ED P N 125 59

4 Thin Nut

Grade 5, 5/16”‑24

PN 12 52 0

1 Key

3/16” square, 1”L

PN 12 53 9

PART 2

1 Brake Caliper

PN 12 53 1

1 Short Aluminum Spacer

1/2” OD, 1/4” ID, 7/8” L

PN 12 547

150718 PLYFL Y rev A_GoKart | A ug u st 7, 20 1 5 5:0 8 PM

10 Putting the go‑kart together

38

Overview of the required hardware

№ DESCRIPTION REFERENCE

Overview of the required hardware

№ DESCRIPTION REFERENCE

1 Long Aluminum Spacer

1/2” OD, 1/4” ID, 1‑1/16” L

PN 12 54 8

2 Oversized Flat Washer

Zinc, M6

PN 12 54 9

2 Socket Head Cap Screw

Black oxide, M6, 55mm L

PN 12 55 0

PART 3

1 Nylon Spacer

3/4” OD, 3/8” ID, 1‑1/4” L

PN 12 54 6

4 Flat Washer

5/16” ID, 7/8” OD

PN 12 516

Shor t Shoulder Screw

1

3/8” D, 1” L, 5/16”‑18

PN 12 513

Long Shoulder Screw

1

3/8” D, 2‑1/4” L, 5/16”‑18

PN 12514

PART 4

2 Short Hex Bolt

Grade 5, 5/8”‑11, 6.5” L

PN 12503

2 Lock Nut

5/8” ID

PN 12 50 6

4 Flat Washer

5/8” ID, 1‑3/8” OD

PN 12 50 5

PART 5

1 Precision Rod

1/4” D, 18” L

PN 12 50 7

PART 6

1 Control Cable

1/16” D, throttle & brake control cable

PN 12525

1 Red Throttle Cable

Brake conduit, 5’ L

PN 12 527

1 Green Throttle Cable

150718 PLYFL Y rev A_GoKart | A ug u st 7, 20 1 5 5:0 8 PM

Gas conduit, 6’ L

PN 12 52 8

6 Zip Tie

10lb Nylon, White, 7/8” D, 4” L

PN 12 55 8

PART 7

Gas Powered Engine

1

2.5 HP MODEL

Gas Powered Engine

1

4.0 HP MODEL

1 Clutch

#35 Chain, 11 Tooth Pulley for 5/8” D

2.5 HP MODEL PN 125 76

1 Clutch

#35 Chain, 12 Tooth Pulley for 3/4” D

4.0 HP MODEL PN 12 57 7

1 Roller Chain

#35 Chain, 29‑5/8” L

PN 12 524

1 Master Chain Link

#35 Roller Chain connector

PN 12 53 4

1 Part 56

Clutch Guard Side

Engine Mounting Plate

PN 12 0 0 5

1 Part 57

Clutch Guard Top

Top C o ver

PN 12 0 0 6

1 Part 58

Clutch Guard Cover

Outside Cover

PN 12 0 07

1 Control Cable

1/16” D, throttle & brake control cable

PN 12525

1 Throttle cable clamp

PN 12 53 7

1 Extension Spring

Black‑Oxide, Precision

PN 12 56 0

1 Throt tle Return Clip

4.0 HP MODEL

PN 12 56 1

8 Sheetmetal Screw

Galvanized, #6

PN 12 551

Box 2

Box 2

PlyFly Go‑Kart Instruction Guide • 2015 Release

39

Overview of the required hardware

№ DESCRIPTION REFERENCE

Overview of the required hardware

№ DESCRIPTION REFERENCE

5 Button Socket Head Cap Screw

Zinc Plated, Steel, M8, 12mm L

TOTAL OF 5 PROVID ED P N 12515

1 Hex head cap screw

5/16”‑18, 1.25 L

4.0 HP MODEL PN 12 5 43

1 Hex Cap Screw

1/4”‑20, 1” L

2.5 HP MODEL PN 12554

1 Flat Washer

5/16” ID, 7/8” OD

PN 12 516

1 Fender washer

5/16” ID, 1‑1/8” OD

PN 12555

1 Lock washer

5/16” ID

1 Clutch Key

3/16”, 1/2” L

PN 12 55 7

2 Set Screw

Clutch

PN 12 56 3

1 Pan head

M6, 12 mm L

4.0 HP MODEL P N 125 64

PART 8

Flat Washer

5/16” ID, 7/8” OD

3 SINGLE WHEEL KIT PN 12 516
2 LIVE A XLE KIT P N 12516

2 Shaf t Collar

5/8” ID

PN 12540

2 Undriven wheel

10” D

LIVE A XLE KIT PN 125 91

1 Rear driven wheel

12” D

SINGLE WHEEL KIT PN 12 59 2

3 Undriven wheel

12” D

SINGLE WHEEL KIT PN 1259 3

1 Key

3/16” square, 1”L

PN 12 53 9

PART 9

2 Fillister Head Screw

5/16”‑18, 3/4” L

PN 125 5 3

1 T‑Handle

Quick Release Pin

PN 125 4 2

1 Flag

Plyy ag

PN 125 3 5

PART 10

20 Spax Screw

1 #8, 1‑1/2” L

PN 12519

1 Green Elastic Cord

3/16” OD, 18” L

PN 12 517

Note There are 2 types of button socket head cap screws

provided in every kit. They appear to be similar in

size but are not. The easiest way to dierentiate the

2 sizes, is by the number of screws provided.

2 Lock Nut

5/8"‑11

PN 12 50 6

1 Rear driven wheel

10”D

SINGLE WHEEL KIT PN 12 59 0

3 Undriven wheel

10” D

SINGLE WHEEL KIT PN 12 59 1

2 Rear driven wheel

10”D

LIVE A XLE KIT PN 125 9 0

10 Putting the go‑kart together

40

150718 PLYFL Y rev A_GoKart | A ug u st 7, 20 1 5 5:0 8 PM

Overview of the required but not provided

DESCRIPTION REFERENCE

Overview of the required assemblies

DESCRIPTION REFERENCE

Motor Oil

Gas

Approximately 1 quart of 10W30 Motor Oil

Regular unleaded gas.

Overview of the required wooden parts

DESCRIPTION REFERENCE

Part 53

Fairing Left

PLYWOOD SHEET 4

Part 54
Fairing Right

PLYWOOD SHEET 4

Part 55
Fairing Front

PLYWOOD SHEET 4

2

Fixed steering column

Assembly

PAR TS 13 ‑18

3

Steering column

Assembly

PARTS 19 ‑21

4

Seat

Assembly

PARTS 22‑33

5

Gas Pedal

Assembly

PARTS 34, 3 6‑37

6

Brake Pedal

Assembly

PARTS 35, 3 8‑3 9

7

Left Spindle

Assembly

PARTS 1, 3, 5, 7

8

Right Spindle

Assembly

PARTS 2, 4, 6, 8

9

Frame

Assembly

150718 PLYFL Y rev A_GoKart | A ug u st 7, 20 1 5 5:0 8 PM

PARTS 21‑28

PlyFly Go‑Kart Instruction Guide • 2015 Release

41

Chapter 10

1

PAR T

Required hardware

№ DESCRIPTION REFERENCE

1 Sprocket

5/8” bore diameter
60 Tooth, #35 Chain

PN 12 52 2

Recommended tools

DESCRIPTION REFERENCE

Dead blow Hammer

or mallet

Allen Wrench

Socket Wrench

Note There are 2 types of button socket head cap screws

provided in every kit. They appear to be similar in

size but are not. The easiest way to dierentiate the

2 sizes, is by the number of screws provided.

1 Drive Shaft

Steel, Keyed, 5/8” D, 18” L

SINGLE WHEEL KIT PN 125 8 0

1 Drive Shaft

Steel, Keyed, 5/8” D, 33” L

LIVE A XLE KIT – 10” WHEELS PN 125 81

1 Drive Shaft

Steel, Keyed, 5/8” D, 36” L

LIVE A XLE KIT – 12” WHEELS PN 12 5 82

1 Brake Disc

PN 12 53 2

1 Brake Disc Hub

PN 12 53 3

1 Long Hex Bolt

Axle Grade 5, 5/8”‑11, 11” L

SINGLE WHEEL KIT PN 12 5 02

4 Button Socket Head Cap Screw

Zinc Plated, Steel, 5/16”‑24, 1/2” L

TOTAL OF 4 PROVID ED P N 125 59

4 Thin Nut

Grade 5, 5/16”‑24

PN 12 52 0

1 Key

3/16” square, 1”L

PN 12 53 9

150718 PLYFL Y rev A_GoKart | A ug u st 7, 20 1 5 5:0 8 PM

10 Putting the go‑kart together

42

Part 1 Install the rear axle

INSTRUCTIONS

1. Assemble the hub and brake disc using the
button head screws and locknuts.

‒ Use 4 button head screws and 4 locknuts

‒ Total of 4 locations.

Note orientation of the par ts.

2. Loosen set screws on all 3 of the mounted bearings

‒ Be sure no screw extends into the interior

of the bearings; as this will prevent

the drive shaft insertion.

3. Insert the drive shaft and bolts

‒

SINGLE WHEEL KIT; continue to step 4.

LIVE A XLE KIT; continue to step 5.

‒

4. Insert the long hex bolt from the interior of the frame
through the bushing located on part 40 and the
mounted bearing located on part 42.

‒ If there is too much resistance to insert the

long hex bolt, temporarily loosen the mounting screws

so the mounted bearing is loose; or remove the

mounted bearing, slide the long hex bolt through and
then re‑mount the mounted bearing.

Note location of the long hex bolt.

5. Insert the drive shaft by sliding it through
the outer mounted bearing located on part 43 only.

‒ If there is too much resistance to insert the

drive shaft, temporarily loosen the mounting screws

so the mounted bearing is loose; or remove the

mounted bearing, slide the drive shaft and then
re‑mount the mounted bearing.

‒ Rotate the bearing in its seat so that it is parallel to the

center frame rails.

6. Once the drive shaft is through the outer
mounted bearing, insert the brake disc on the end.

‒ Use the key to lock the brake disc to the drive shaft.

Note the orientation of the disc brake.

43

7. Continue to slide the drive shaft through the assembly,
through the center mounted bearing, and then insert the
sprocket on then end.

‒ Use the key to lock the brake disc to the drive shaft.

‒

SINGLE WHEEL KIT is complete.

LIVE A XLE KIT continue to step 8.

‒

Note location and orientation of the bushing

4042

150718 PLYFL Y rev A_GoKart | A ug u st 7, 20 1 5 5:0 8 PM

8. Continue to insert the drive shaft through the assembly

and through the nal mounted bearing located on part 42.

Note the drive shaf t extends equal distances on both sides of the assembly.

9. Ensure all the hardware on mounted bearings are fully
tightened

.

PlyFly Go‑Kart Instruction Guide • 2015 Release

43

Chapter 10

2

PAR T

Recommended tools

DESCRIPTION REFERENCE

Dead blow Hammer

or mallet

Allen Wrench

Socket Wrench

Part 2 Install the brake caliper

The brakes will initially be installed and then adjusted.

INSTRUCTIONS

1. Insert the socket head cap screws with an oversized at
washer through the holes located on part 43,

‒ Use 1 socket head cap screw with

1 oversized at washers per location.

‒ Total 2 locations

2. Insert into the aluminum spacers on the opposite side of
part 43.

Note the location and orientation of the brake caliper. As well as the locations of

the shor t spacer and the long spacer.

43

Required hardware

№ DESCRIPTION REFERENCE

1 Brake Caliper

PN 12 53 1

1 Shor t Aluminum Spacer

1/2” OD, 1/4” ID, 7/8” L

PN 12 547

1 Long Aluminum Spacer

1/2” OD, 1/4” ID, 1‑1/16” L

PN 12 54 8

2 Oversized Flat Washer

Zinc, M6

PN 12 54 9

2 Socket Head Cap Screw

Black oxide, M6, 55mm L

PN 12 55 0

3. Place brake caliper into the cutout located at the rear of
part 43 and insert the hardware.

4. Secure the brake caliper in place, using
the metric Allen wrench provided.

Note the location and orientation of the brake caliper.

43

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10 Putting the go‑kart together

44

Chapter 10

3

PAR T

Part 3 Install the steering column assembly

INSTRUCTIONS

1. Position 3, so that the gear aligns with those on 1.

‒ Be sure the gear alignment marks located on

parts 20 & 12 line up.

Note-the orientation and alignment of the gear teeth

Recommended tools

DESCRIPTION REFERENCE

Electric Driver

Allen Wrench

or ratcheting Allen wrench

Required hardware

№ DESCRIPTION REFERENCE

1 Nylon Spacer

3/4” OD, 3/8” ID, 1‑1/4” L

PN 12 54 6

4 Flat Washer

5/16” ID, 7/8” OD

PN 12 516

3

20

12

2. Insert the shoulder screws.

‒ Insert the short shoulder screw through the bushing

located on part 20 of

.

3

‒ Insert the long shoulder screw with the nylon spacer

through the tee nut located on part 21.

‒ Total 2 locations, 2 shoulder screws.

Note-the orientation of the bolt; be sure the head faces down

(toward the g round).

21

Shor t Shoulder Screw

1

3/8” D, 1” L, 5/16”‑18

PN 12 513

Long Shoulder Screw

1

3/8” D, 2‑1/4” L, 5/16”‑18

PN 12514

Required assemblies

DESCRIPTION REFERENCE

1

Steering rack

Assembly

Pa r t s 9 ‑12

3

Steering Column

Assembly

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PARTS 19 ‑21

3

21

3. To secure, tighten both the shoulder screws 3.

‒ Total 2 locations.

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45

Chapter 10

8

4

PAR T

Recommended tools

DESCRIPTION REFERENCE

Hammer

Required hardware

№ DESCRIPTION REFERENCE

2 Shor t Hex Bolt

Grade 5, 5/8”‑11, 6.5” L

PN 12503

2 Lock Nut

5/8” ID

PN 12 50 6

Part 4 Install the steering spindles

INSTRUCTIONS

1. Slide the steering rack all the way to the right.

7

2. Insert

‒ Check that the bushings on

before installing.

Note the location and orientation of the assemblies.

3. Align the gear teeth of 7 with the gear alignment mark
located on the steering rack assembly gear.

Note the location and orientation of the alignment mar ks.

with the bolt facing out.

7

7

7

are completely seated

4 Fender Washer

3/4” OD, 5/8” ID

PN 12 50 5

Required assemblies

DESCRIPTION REFERENCE

7

Left Spindle

Assembly

PARTS 1, 3, 5, 7

8

Right Spindle

Assembly

PARTS 2, 4, 6, 8

4. Insert the short hex bolt with a washer, starting from the
bottom and insert through the bushings found on

7

and

then through the top of the frame.

Note the order of the hardware insertion.

7

5. Using a hammer, tap into place.

6. Insert a washer over the short hex bolt and secure it with
a locknut.

Note the order of the hardware insertion.

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10 Putting the go‑kart together

46

7

7. Repeat steps 1 through 6 on the opposite side using

8

.

Chapter 10

5

PAR T

Part 5 Install the gas & brake pedals

INSTRUCTIONS

1. Each assembly has a long tab with a hole. The position of
the pedal is dictated by these holes. The holes should be

pointing towards the middle of the xed steering column.

Note the right and left pedals tabs, holes, and their position in the Assembly.

Recommended tools

DESCRIPTION REFERENCE

Dead blow Hammer

or mallet

Electric Driver

Required hardware

№ DESCRIPTION REFERENCE

1 Precision Rod

1/4” D, 18” L

PN 12 50 7

Required Assemblies

DESCRIPTION REFERENCE

5

1

6 5

2

2. Position 5 on the right of the xed steering column.

6

3. Position

Note location and or ientation of the assembly 5 & 6.

on the left of the xed steering column.

5

6

4. Insert the precision rod through the holes located in
and then through the holes located in

Note location of the precision rod.

.

6

5

Gas Pedal
Assembly
Parts 34, 36‑37

6

Brake Pedal
Assembly
Parts 35, 38‑39

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5. Using a hammer, tap into place.

6. Test the alignment of each pedal assembly.

‒ Each pedal should be able to move freely and

independently (some drag is expected).

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Chapter 10

Reference Assemblies

DESCRIPTION REFERENCE

6

PAR T

Recommended tools

DESCRIPTION REFERENCE

Needle Nose Pliers

Allen Wrench

Socket Wrench

Required Assemblies

№ DESCRIPTION REFERENCE

1 Control Cable

1/16” D, throttle & brake control cable

PN 12525

2

Fixed steering
column

Assembly

PAR TS 13 ‑18

5

Gas Pedal
Assembly
Parts 34, 36‑37

6

Brake Pedal
Assembly
Parts 35, 38‑39

9

Frame

Assembly

PARTS 21‑28

1 Red Throttle Cable

Brake conduit, 5’ L

PN 12 527

1 Green Throttle Cable

Gas conduit, 6’ L

PN 12 52 8

6 Zip Tie

10lb Nylon, White, 7/8” D, 4” L

PN 12 55 8

10 Putting the go‑kart together

48

150718 PLYFL Y rev A_GoKart | A ug u st 7, 20 1 5 5:0 8 PM

Part 6 Install the gas & brake cables

INSTRUCTIONS

1. Loop 4 zip ties through the holes located on 2.

‒ Loosely tighten the zip ties, leaving a large loop so later,

the cables can slide through easily.

Note the locations of the zip ties.

4. Continue to run the red cable on the left side of
the go‑kart

‒ Through the cable ties located on

9

,

‒ through the slots located on part 40 & 43,

‒ and into the brake caliper assembly.

Note path of the red cable.

2

1

2

3

2. Loop 2 zip ties through the holes located 9.

‒ Loosely tighten the nylon cable ties, leaving a large loop

so later, the cables can slide through easily.

Note the locations of the zip ties.

1

9

2

43

41

9

4

5. Run the green cable on the right side of the go‑kart

‒ Through the interior of

‒ through the cable ties located on

‒ through the hole located on the right side of part 17.

Note the location and direction of the green cable. Be sure to seat the

green cable in the notches located on part 17 of 3.

and then

2

and then

2

3. Run the red cable on the left side of the go‑kart

‒ Through the interior of

2

‒ through zip ties located on part 13 and then

‒ through the hole located on the left side of part 17.

Note the location and direction of the red cable. Be sure to seat the red cable in

the notches located on part 19 of

.

3

13

2

17

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19

14

2

3

17

PlyFly Go‑Kart Instruction Guide • 2015 Release

3

19

49

6. Continue to run green cable on the right side of
the go‑kart

‒ Through the cable ties located on

9

,

‒ through the slots located on part 40 & 43,

‒ and leave slack to secure to the engine later.

Note path of the red cable.

43

41

11. Feed the brake control cable through a washer into the

tting located on the brake.

Note path of the brake control cable throug h the brake caliper.

12. Secure the control cable in place using a small wrench or
pliers.

13. Test brake pedal to ensure proper movement of brake.

7. Secure the nylon cable ties by tightening them.

8. Use the needle nose pliers to clip any excess
cable tie material.

9. Feed the brake control cable through the hole located in

6

the

and into the red cable.

Note path of the brake control cable throug h the brake pedal.

6

10. Fish the brake control cable through the red cable all the
way to the end.

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10 Putting the go‑kart together

50

Chapter 10

Required but not provided

№ DESCRIPTION REFERENCE

7

PAR T

Recommended tools

DESCRIPTION IMAGE REFERENCE

Dead blow Hammer

or mallet

Metric Allen Wrench
included with mounted bearing

Wrench

Socket Wrench

Oil Type & Amount

Ga s Type

TYPE & AMOUNT

TYPE

Required hardware

№ DESCRIPTION REFERENCE

Gas Powered Engine

1

2.5 HP MODEL

Gas Powered Engine

1

4.0 HP MODEL

1 Clutch

#35 Chain, 11 Tooth Pulley for 5/8” D

2.5 HP MODEL PN 125 76

1 Clutch

#35 Chain, 12 Tooth Pulley for 3/4” D

4.0 HP MODEL PN 12 57 7

1 Roller Chain

#35 Chain, 29‑5/8” L

PN 12 524

Box 2

Box 2

Electric Driver

Note Be sure not to lose attached key,

set screws and bolt to hold clutch in place.

Required assemblies

DESCRIPTION REFERENCE

5

Gas Pedal
Assembly
Parts 34, 36‑37

9

Frame

Assembly

PARTS 21‑28

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1 Master Chain Link

#35 Roller Chain connector

PN 12 53 4

1 Part 56

Clutch Guard Side

Engine Mounting Plate

PN 12 0 0 5

1 Part 57

Clutch Guard Top

Top C o ver

PN 12 0 0 6

1 Part 58

Clutch Guard Cover

Outside Cover

PN 12 0 07

1 Control Cable

1/16” D, throttle & brake control cable

PN 12525

1 Throttle cable clamp

PN 12 53 7

1 Extension Spring

Black‑Oxide, Precision

PN 12 56 0

1 Throt tle Return Clip

4.0 HP MODEL

PN 12 56 1

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51

Required hardware

№ DESCRIPTION REFERENCE

Part 7 Install the engine and drive train

The engine arrives with no oil, no conguration is required.

8 Sheetmetal Screw

Galvanized, #6

PN 12 551

5 Button Socket Head Cap Screw

Zinc Plated, Steel, M8, 12mm L

TOTAL OF 5 PROVID ED P N 12515

1 Hex head cap screw

5/16”‑18, 1.25 L

4.0 HP MODEL PN 12 5 43

1 Hex Cap Screw

1/4”‑20, 1” L

2.5 HP MODEL PN 12554

1 Flat Washer

5/16” ID, 7/8” OD

PN 12 516

1 Fender washer

5/16” ID, 1‑1/8” OD

PN 12555

1 Lock washer

5/16” ID

1 Clutch Key

3/16”, 1/2” L

PN 12 55 7

INSTRUCTION

1. Stand the engine on part 50 located on

9

,

aligning the engine mounting holes to the tee nut pattern
(installed previously) appropriate for the engine model.

Note the location of the engine mount.

50

Note the location of the tee nut bolting pattern on part 50.

1

50

2.5 HP

2

3

1

50

4

4.0 HP

2

9

3

4

2 Set Screw

Clutch

PN 12 56 3

1 Pan head

M6, 12 mm L

4.0 HP MODEL P N 125 64

Note the direction and orientation of the engine within the go-kart.

2. For next installation step:

2.5 HP MODEL continue to step 3.

‒

4.0 HP MODEL continue to step 4.

‒

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10 Putting the go‑kart together

52

3. Remove the 2 bolts holding the throttle linkage; to be able
to secure the engine to part 50.

‒ Remove 2 bolts.

‒ Total of 2 locations.

Note the location of the 2 throttle linkage bol ts.

1

8. Slide part 56 into the space located on the engine side.

Note the location of slot.

5656

2

4. Using a socket wrench secure the engine bolts to part 50.

‒ Use 4 bolts.

‒ Total of 4 locations.

5. For next installation step:

2.5 HP MODEL continue to step 6.

‒

4.0 HP MODEL continue to step 8.

‒

6. Secure the throttle linkage back into place using the bolts.

‒ Use 2 bolts.

‒ Total of 2 locations.

7. Install the extension spring, by hooking one end
through the hole located on the throttle linkage. Then
using pliers, stretch the extension spring and hook it
through the second hole on the opposite side of the
throttle linkage.

Note the location of the extension spring.

1

9. Secure part 56, using M8 screws.

‒ Use 3 screws.

‒ Total of 3 locations.

Note the locations of the 3 screws.

1

3

2

10. Slide the clutch over the engine crank shaft.

‒ Be sure the set screws on the clutch are backed‑out

enough to be able to slide the clutch over
the crankshaft.

‒ Be sure the small sprocket is facing toward the engine

and the set screws are facing away from the engine.

‒ Be sure to align the keyway on the clutch with the

keyway on the drive shaft.

Note the orientation of clutch; the small sprocket should face the engine.

2

!

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53

11. Insert 1/2” clutch key through the center of the clutch.

12. Using an Allen wrench tighten the set screws.

‒ 2 set screws.

‒ Total of 2 screws.

Note the locations of the 3 set screws.

2

1

13. Using a wrench, tighten the hex head cap screw
assembled with a lock washer and a fender washer to
secure the clutch.

‒ Tighten hex head cap screw until the lock washer is

compressed.

‒ If necessary, pull the starter cord to prevent the

crankshaft from rotating while tightening.

Note the order of the assembled hardware.

15. Connect the chain by sliding the posts of the master link
into the holes located at the ends of the chain.

Note the order of the assembled hardware.

16. Add the master link plate.

Note the order of the assembled hardware.

17. Secure the master link, using the retaining clip; snapping
it into place.

Note the order of the assembled hardware.

14. Slide the chain, over both sprockets.

‒ Be sure to align the clutch sprocket with the

drive shaft sprocket vertically.

10 Putting the go‑kart together

54

18. Tension the chain.

‒ Slide the engine forward until chain is taut.

19. Secure the engine in place using the bolts located on
part 50.

20. Test the rear wheel drive by spinning the drive shaft.

‒ Be sure the shaft can spin freely with the chain.

21. For instructions on how to install the throttle control cable

2.5 HP MODEL continue to step 22.

‒

4.0 HP MODEL continue to step 26.

‒

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22. Secure the green cable loosely in the
throttle control linkage.

Note the location of the green cable.

26. Secure the green cable loosely in the clamp.

Note the location of the green cable.

23. Feed the throttle control cable through the hole
located on the throttle control linkage and then into the
green cable.

Note the location of the green cable.

1

2

24. For the next installation instruction, continue to step 32.

25. Thread the green cable into the right side of the engine.

Note the location of the green cable.

27. Feed the throttle control cable through the hole located
on the throttle linkage.

Note the locations of the throttle control cable.

1

2

28. Install the extension spring, by hooking one end to the
hole located on the throttle linkage.

Note the location of the extension spring.

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55

29. Using pliers, hook the other end of the extension spring to
the throttle return clip.

Note the location of the extension spring.

30. Secure the throttle return clip to the engine using a screw.

‒ Use 1 M6 screw.

‒ Total 1 location

Note the location of the throttle return clip.

32. Continue to feed the throttle control cable all the way
through to

Note the location of the throttle control cable.

5

.

5

33. Secure the throttle control cable using the
throttle cable clamp at the bottom of

.

5

‒ Be sure the control cable is taut, before tightening the

throttle clamp.

34. Secure the green cable fully at the start location of the
throttle linkage.

35. Test the gas pedal to ensure proper movement of throttle.

36. Place part 57 over part 56.

Note the location part 57.

57

!

1

31. Slightly loosen this nut so that the throttle can move freely
when the gas pedal is pressed.

Note the location of the nut.

!

56

37. Secure part 57 to part 56, using sheet metal screws.

‒ Use 4 sheet metal screws.

‒ Total of 4 locations.

38. Place part 58.

Note the location part 58.

58

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57

10 Putting the go‑kart together

56

39. Secure part 58 to part 57, using sheet metal screws.

‒ Use 4 sheet metal screws.

‒ Total of 4 locations.

Chapter 10

8

PAR T

Recommended tools

DESCRIPTION REFERENCE

Socket Wrench

Wrench

Required hardware

№ DESCRIPTION REFERENCE

Flat Washer

5/16” ID, 7/8” OD

3 SINGLE WHEEL KIT PN 12 516
2 LIVE A XLE KIT PN 12516

2 Shaf t Collar

5/8” ID

PN 12540

2 Lock Nut

5/8"‑11

PN 12 50 6

1 Rear driven wheel

10”D

SINGLE WHEEL KIT PN 12 59 0

3 Undriven wheel

10” D

SINGLE WHEEL KIT PN 12 59 1

2 Rear driven wheel

10”D

LIVE A XLE KIT PN 125 9 0

2 Undriven wheel

10” D

LIVE A XLE KIT PN 125 91

1 Rear driven wheel

12” D

SINGLE WHEEL KIT PN 12 59 2

3 Undriven wheel

12” D

SINGLE WHEEL KIT PN 1259 3

1 Key

150718 PLYFL Y rev A_GoKart | A ug u st 7, 20 1 5 5:0 8 PM

3/16” square, 1”L

PN 12 53 9

Part 8 Install the wheel assemblies

INSTRUCTIONS

1. Mount the undriven wheels (the wheels with bearings)
by sliding them over the axles.

‒

SINGLE WHEEL KIT continue to step 2.

LIVE A XLE KIT continue to step 4.

‒

2. Mount 3 undriven wheels.

‒ 2 located on the front axles.

‒ 1 located on the back, left axle.

‒ Total of 3 locations.

SINGLE WHEEL KIT continue to step 5.

3.

4. Mount 2 undriven wheels.

‒ 2 located on the front axles.

‒ Total of 2 locations.

5. Secure the undriven wheels using lock nuts.

Hint To keep the wheels from rotating, place a
large slotted screwdriver into the heads of the front axle bolts.

6. Slide the shaft collar over drive shaft.

SINGLE WHEEL KIT continue to step 7.

‒

LIVE A XLE KIT continue to step 9.

‒

7. Install 1 shaft collar.

‒ 1 on the back, right drive shaft.

SINGLE WHEEL KIT continue to step 10.

8.

9. Install 2 shaft collars.

‒ 2 located on the rear drive shaft.

‒ Total of 2 locations.

10. Secure the shaft collar using an Allen wrench.

11. Mount the driven wheel (the wheels with the xed hub)
by sliding them over the drive shaft.

‒ Use the key to lock the driven wheel to the drive shaft.

SINGLE WHEEL KIT continue to step 12.

‒

LIVE A XLE KIT continue to step 14.

‒

12. Mount 1 driven wheel.

‒ 1 located on the back, right drive shaft.

‒ Total of 1 location.

SINGLE WHEEL KIT continue to step 15.

13.

14. Mount 2 driven wheels.

‒ Use the key to lock the driven wheel to the drive shaft.

‒ 2 located on the rear drive shaft.

‒ Total of 2 locations.

15. Secure the driven wheel to the drive shaft using
the set screws.

‒ Be sure the set screw aligns with the keyway.

16. Secure the axle to the driven wheel using the shaft collar.

‒ Use a socket wrench to tighten the locknut; while

holding the locknut on alternate side with wrench.

PlyFly Go‑Kart Instruction Guide • 2015 Release

57

Chapter 10

9

PAR T

Recommended tools

DESCRIPTION REFERENCE

Dead blow Hammer

or mallet

Required hardware

№ DESCRIPTION REFERENCE

2 Fillister Head Screw

5/16”‑18, 3/4” L

PN 125 5 3

1 T‑Handle

Quick Release Pin

PN 125 4 2

1 Flag

Plyy ag

PN 125 3 5

Part 9 Install the seat assembly

INSTRUCTIONS

1. Place the Fillister head screws into the parts 41 & 42
located on

Note the location of the Fill ister head screws.

2. Secure the Fillister head screws to be ush with the
wooden surface of part 41.

3. Position

‒ Align the side slots located on

located on parts 41 & 42.

4. Slide

4

the way through slots.

5. To secure
through part 41 located on the right side of the go‑kart.

6. Insert the ag through holes located on the back right
side of Seat Assembly and the go‑kart frame.

Note the location of the a g hol es.

.

9

41

42

4

at the forward most position.

4

to the screw heads

backwards into position so that the pins slide all

4

in place, insert the T‑handle, pin side,

Required assemblies

DESCRIPTION REFERENCE

4

Seat

Assembly

PARTS 22‑33

9

Frame

Assembly

PARTS 21‑28

10 Putting the go‑kart together

58

150718 PLYFL Y rev A_GoKart | A ug u st 7, 20 1 5 5:0 8 PM

Chapter 10

10

STEP

Part 10 Install the fairings

INSTRUCTIONS

1. Place the front tab of part 53 into the slot located on
part 40.

Note the location of the tab on part 40.

Recommended tools

DESCRIPTION REFERENCE

Dead blow Hammer

or mallet

Electric Driver

Required hardware

№ DESCRIPTION REFERENCE

20 Spax Screw

1 #8, 1‑1/2” L

PN 12519

1 Green Elastic Cord

3/16” OD, 18” L

PN 12 517

40

53

2. Using the mallet, tap part 53 into the recess.

3. Secure part 53 to the assembly using screws.

‒ Use 7 screws.

‒ Total of 7 locations.

4. Repeat steps 1 through 3 on the opposite side using
par t 54.

5. Thread the green elastic cord, from the top through left
hole located in part 16 of

Note the part 16

16

.

2

6. Tie an overhand knot on the bottom side.

7. Thread the green elastic cord, from the top through right
side hole located in part 16 of

Note the location of part 16.

2

.

2

Required wooden parts

DESCRIPTION REFERENCE

Part 53

Fairing Left

PLYWOOD SHEET 4

Part 54
Fairing Right

PLYWOOD SHEET 4

Part 55
Fairing Front

PLYWOOD SHEET 4

Note If you received a 1/4” plywood sheet that is nished on one side

and intend to paint the fairings; reverse wooden par ts 53-55 (so the
unn ished side is facing out ward and ready to rece ive paint). For more

150718 PLYFL Y rev A_GoKart | A ug u st 7, 20 1 5 5:0 8 PM

information on Visual reference of the plywood sheets, see page 61.

16

8. Pull green elastic cord tight and tie overhand knot on
the underside.

9. Align part 55 to the front of

Note the location of the orientation of part 55.

55

10. Screw part 55 to the assembly using 6 screws.

‒ Use 6 screws.

‒ Total of 6 locations

FINISHED!! TIME TO RIDE!!

PlyFly Go‑Kart Instruction Guide • 2015 Release

.

2

2

59

Master List

11

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60

Visual reference of the plywood sheets

DESCRIPTION REFERENCE

Visual reference of the plywood sheets

DESCRIPTION REFERENCE

Sheet 1

3/4” Plywood Sheet

3736

‒ Parts 1, 3‑4
‒ Parts 6‑10
‒ Part 13

Sheet 2
3/4” Plywood Sheet

‒ Parts 20
‒ Parts 24
‒ Parts 34

38 39

10913 34

4941 40 43 42

3

61874 20

‒ Parts 36‑43
‒ Parts 49

24

Sheet 3

3/4” Plywood Sheet

35

‒ Parts 22‑23
‒ Parts 25‑27

Sheet 4
1/4” Plywood Sheet

22

50

252726

47

‒ Parts 35
‒ Part 47

23

‒ Parts 50

12 11 15 1814

46 5248

‒ Parts 2, 5
‒ Parts 11‑12
‒ Parts 14‑18

Note If you received a 1/4” plywood sheet that is nished on one side and you

intend to paint the Plyy go-kart seat or fairings; reverse wooden parts 28-33 and
parts 53-55 (so the unnished side is outward facing and ready to receive paint).

For a complete list of wooden par ts, go to “List of the wooden par ts” on page 62.

‒ Parts 20‑21
‒ Parts 44‑46
‒ Parts 48

45 44

171625521 19

‒ Parts 52

‒ Parts 28‑33
‒ Parts 51

31

302829

‒ Parts 53‑55

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61

List of the wooden parts

DESCRIPTION

reference image

List of the wooden parts

DESCRIPTION

reference image

Part 1

Steering Spindle Outer Spacer

PLYWOOD SHEET 1

Part 2
Steering Spindle Outer Spacer

PLYWOOD SHEET 2

Part 3
Steering Spindle Inner Spacer

PLYWOOD SHEET 1

Part 4
Steering Spindle Inner Spacer

PLYWOOD SHEET 1

Part 9
Steering rack Bracket

PLYWOOD SHEET 1

Part 10
Steering rack Bracket

PLYWOOD SHEET 1

Part 11
Steering rack

PLYWOOD SHEET 2

Part 12
Steering rack Center Bracket

PLYWOOD SHEET 2

Part 5
Steering Spindle Bottom Left

PLYWOOD SHEET 2

Part 6
Steering Spindle Bottom Right

PLYWOOD SHEET 1

Part 7
Steering Spindle Top

PLYWOOD SHEET 1

Part 8
Steering Spindle Top

PLYWOOD SHEET 1

Part 13
Steering column Left

PLYWOOD SHEET 1

Part 14
Steering column Right

PLYWOOD SHEET 2

Part 15
Steering column Top

PLYWOOD SHEET 2

1 50 7 1 8 P LY F LY r e v A_E M | August 7, 2015 5:06 PM

Part 16
Steering column Phone Mount

PLYWOOD SHEET 2

11 Master List

62

List of the wooden parts

DESCRIPTION

reference image

List of the wooden parts

DESCRIPTION

reference image

Part 17

Steering column Bracket

PLYWOOD SHEET 2

Part 18
Steering Pinion Mount

PLYWOOD SHEET 2

Part 19
Steering column Shaft

PLYWOOD SHEET 2

Part 20
Steering Pinion

PLYWOOD SHEET 1

Part 25
Seat Crossbar

PLYWOOD SHEET 3

Part 26
Seat Crossbar

PLYWOOD SHEET 3

Part 27
Seat Crossbar Bracket

PLYWOOD SHEET 3

Part 28
Seat Bolster Left

PLYWOOD SHEET 4

Part 21
Steering Wheel

PLYWOOD SHEET 2

Part 22
Seat Side Left

PLYWOOD SHEET 3

Part 23
Seat Side Right

‒ gas tank side

PLYWOOD SHEET 3

Part 24
Seat Crossbar

PLYWOOD SHEET 1

Part 29
Seat Bolster Right

PLYWOOD SHEET 4

Part 30
Seat Thigh Bolster Left

PLYWOOD SHEET 4

Part 31
Seat Thigh Bolster Right

PLYWOOD SHEET 4

Part 32
Seat Back

PLYWOOD SHEET 4

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PlyFly Go‑Kart Instruction Guide • 2015 Release

63

List of the wooden parts

DESCRIPTION

Part 33

Seat Bottom

PLYWOOD SHEET 4

Part 34
Brake Pedal

PLYWOOD SHEET 1

Part 35
Gas Pedal

PLYWOOD SHEET 3

reference image

List of the wooden parts

DESCRIPTION

Part 41

Frame Rail Inner Right

PLYWOOD SHEET 1

Part 42
Frame Rail Outer Left

PLYWOOD SHEET 1

Part 43
Frame Rail Outer Right

PLYWOOD SHEET 1

reference image

Part 36

Pedal Side

PLYWOOD SHEET 1

Part 37
Pedal Side

PLYWOOD SHEET 1

Part 38
Pedal Side

PLYWOOD SHEET 1

Part 39
Pedal Side

PLYWOOD SHEET 1

Part 40
Frame Rail Inner Lef t

PLYWOOD SHEET 1

Part 44
Frontend Bottom

PLYWOOD SHEET 2

Part 45
Fr o nte n d To p

PLYWOOD SHEET 2

Part 46
Frame Rail Bracket

PLYWOOD SHEET 2

Part 47
Sprocket Guard

PLYWOOD SHEET 3

1 50 7 1 8 P LY F LY r e v A_E M | August 7, 2015 5:06 PM

Part 48
Frame Rail Rear

PLYWOOD SHEET 2

11 Master List

64

List of the wooden parts

DESCRIPTION

Part 49

Frame Rail Engine Mount

PLYWOOD SHEET 1

Part 50
Engine Mounting Plate

PLYWOOD SHEET 3

Part 51
Floor Panel

PLYWOOD SHEET 4

Part 52
Frame Gusset

PLYWOOD SHEET 2

reference image

Part 53

Fairing Left

PLYWOOD SHEET 4

Part 54
Fairing Right

PLYWOOD SHEET 4

Part 55
Fairing Front

PLYWOOD SHEET 4

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PlyFly Go‑Kart Instruction Guide • 2015 Release

65

List of the wooden assemblies

DESCRIPTION REFERENCE

List of the wooden assemblies

DESCRIPTION REFERENCE

1

Steering rack

Assembly

Pa r t s 9 ‑12

2

Fixed steering column

Assembly

Pa r t s 13‑18

3

Steering column

Assembly

Par ts 19‑21

6

Brake Pedal

Assembly

Parts 35, 38‑39

7

Left Spindle

Assembly

Parts 1, 3, 5, 7

8

Right Spindle

Assembly

Parts 2, 4, 6, 8

4

Seat

Assembly

Parts 22‑33

5

Gas Pedal

Assembly

Parts 34, 36‑37

Note If you received a 1/4” plywood sheet that is nished on one side and you

intend to paint the Plyy go-kart seat or fairings; reverse wooden parts 28-33 and
parts 53-55 (so the unnished side is outward facing and ready to receive paint). For

a complete list of wooden parts, go to “List of the wooden parts” on page 62.

9

Frame

Assembly

Par ts 21‑2 8

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11 Master List

66

List of the tools needed

DESCRIPTION REFERENCE IMAGE

List of the tools needed

DESCRIPTION REFERENCE IMAGE

Chisel

Hammer

Dead blow Hammer

or mallet

Sandpaper

Screwdriver

Allen Wrench

or ratcheting allen wrench

Metric Allen Wrench
included with mounted bearing

Socket Wrench

Orbital Sander

(optional)

Jigsaw or
Reciprocating Saw

(optional)

Electric Driver

Impact Driver

(optional)

Wrench

Needle Nose Pliers

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PlyFly Go‑Kart Instruction Guide • 2015 Release

67

List of loose contents

KIT DESCRIPTION 10” WHEELS 10” WHEELS 12” WHEELS 10” WHEELS 12” WHEELS

№

12576

Clutch

#35 Chain, 11 Tooth Pulley for 5/8” D

2.5 HP MODEL

1257 7

Clutch

#35 Chain, 12 Tooth Pulley for 3/4” D

4.0 HP MODEL

1252 2

Sprocket

#35 Chain, 60 Tooth, 5/8” D bore

1252 4

Roller Chain

#35 Chain, 29‑5/8” L

12534

Master Chain Link

#35 Roller Chain connector

Part 56

120 05

Clutch Guard Side

Engine Mounting Plate

Part 57

120 06

Clutch Guard Top

Top C o ver

Part 58

120 07

Clutch Guard Cover

Outside Cover

2.5 HP 4.0 HP 4.0 HP 4 .0 HP 4.0 HP

SINGLE WHEEL SINGLE WHEEL SINGLE WHEEL LIVE AXLE LIVE AXLE

1

―

― ― ― ―

1 1 1 1

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

12525

Control Cable

1/16” D, throttle & brake control cable

1252 7

Red Throttle Cable

Brake conduit, 5’ L

1252 8

Green Throttle Cable

Gas conduit, 6’ L

1252 1

VXB Mounted Bearing

5/8” ID

12531

Brake Caliper

12532

Brake Disc

12533

Brake Disc Hub

12502

Long Hex Bolt

Grade 5, 5/8”‑11, 11” L

SINGLE WHEEL KIT

12503

Shor t Hex Bolt

Grade 5, 5/8”‑11, 6.5” L

2 2 2 2 2

1 1 1 1 1

1 1 1 1 1

3 3 3 3 3

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

1 1 1

― ―

4 4 4 4 4

1 50 7 1 8 P LY F LY r e v A_E M | August 7, 2015 5:06 PM

11 Master List

68

List of loose contents

KIT DESCRIPTION 10” WHEELS 10” WHEELS 12” WHEELS 10” WHEELS 12” WHEELS

№

12507

Precision Rod

1/4” D, 18” L

12580

Drive Shaft

Steel, Keyed, 5/8” D, 18” L

SINGLE WHEEL KIT

12581

Drive Shaft

Steel, Keyed, 5/8” D, 33” L

LIVE A XLE KIT – 10” WHEELS

12582

Drive Shaft

Steel, Keyed, 5/8” D, 36” L

LIVE A XLE KIT – 12” WHEELS

12508

Drawer Slide

Hardware included, 10” L

125 17

Green Elastic Cord

3/16” OD, 18” L

12519

Spax Screw

1 Box, #8, 1‑1/2” L

2.5 HP 4.0 HP 4.0 HP 4 .0 HP 4.0 HP

SINGLE WHEEL SINGLE WHEEL SINGLE WHEEL LIVE AXLE LIVE AXLE

1 1 1 1 1

1 1 1

― ― ―

― ― ― ―

― ―

1

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

―

1

12590

10” D Wheels

Rear driven wheel

12591

10” D Wheels

Undriven wheel

12592

12” D Wheels

Rear driven wheel

12593

12” D Wheels

Undriven wheel

12535

Flatworks Flag

Plyy safety ag

1 1

3 3

― ―

― ―

―

―

1

3

2

2

―

―

―

―

2

2

1 1 1 1 1

1 50 7 1 8 P LY F LY r e v A_E M | August 7, 2015 5:06 PM

PlyFly Go‑Kart Instruction Guide • 2015 Release

69

List of the packaged contents

KIT DESCRIPTION 10” WHEELS 10” WHEELS 12” WHEELS 10” WHEELS 12” WHEELS

№

12504

Large Metal Bushing

Flanged, 3/4” OD, 5/8” ID

12505

Flat Washer

5/8” ID, 1‑3/8” OD

12506

Lock Nut

5/8” ID

12509

Plastic Bushing

Flanged, 1/4” ID, 3/8” OD

12510

Small Tee Nut

Zinc Plated, 5/16”‑18

12513

Shor t Shoulder Screw

5/16”‑18, 3/8” D, 1.00” L,

12514

Long Shoulder Screw

5/16”‑18, 3/8” D, 2.25” L

2.5 HP 4. 0 HP 4.0 HP 4 .0 HP 4 .0 HP

SINGLE WHEEL SINGLE WHEEL SINGLE WHEEL LIVE AXLE LIVE AXLE

11

11 11 10

4 4 4 4 4

5 5 5 4 4

4 4 4 4 4

12 12 12 12 12

1 1 1 1 1

1 1 1 1 1

10

12515

Button Socket Head Cap Screw

Zinc Plated, Steel, M8, 12mm L

12516

Flat Washer

5/16” ID, 7/8” OD

1252 0

Thin Nut

Grade 5, 5/16”‑24

12537

Throttle Cable Clamp

12538

Small Metal Bushing

Flanged 3/8” ID, 1/4” L

12539

Key
3/16” square, 1”L

12540

Shaf t Collar

5/8” ID

12542

T‑Handle Pin

Quick Release Pin

12543

Hex head cap screw

5/16”‑18, 1.25 L

4.0 HP MODEL

5 5 5 5 5

15 15 15 15 15

4 4 4 4 4

1 1 1 1 1

4 4 4 4 4

3 3 3 4 4

1 1 1 2 4

1 1 1 1 1

8 8 8 8 8

1 50 7 1 8 P LY F LY r e v A_E M | August 7, 2015 5:06 PM

12544

Socket Head Cap Screw

Black Oxide Alloy Steel, 3/8”‑16, 1.25 L

12545

Large Tee Nut

Zinc Plated, 3/8”‑16

11 Master List

70

6 6 6 6 6

6 6 6 6 6

List of the packaged contents

KIT DESCRIPTION 10” WHEELS 10” WHEELS 12” WHEELS 10” WHEELS 12” WHEELS

№

12546

Nylon Spacer

3/4” OD, 3/8” ID, 1‑1/4” L

12547

Shor t Aluminum Spacer

1/2” OD, 1/4” ID, 7/8” L

12548

Long Aluminum Spacer

1/2” OD, 1/4” ID, 1‑1/16” L

12549

Oversized Flat Washer

Zinc, M6

12550

Socket Head Cap Screw

Black oxide, M6, 55mm L

12551

Sheetmetal Screw

Galvanized, #6

12553

Fillister Head Screw

5/16”‑18, 3/4” L

2.5 HP 4. 0 HP 4.0 HP 4 .0 HP 4 .0 HP

SINGLE WHEEL SINGLE WHEEL SINGLE WHEEL LIVE AXLE LIVE AXLE

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

2 2 2 2 2

2 2 2 2 2

8 8 8 8 8

2 2 2 2 2

12558

Zip Tie

10lb Nylon, White, 7/8” D, 4” L

12559

Button Socket Head Cap Screw

Zinc Plated, Steel, 5/16”‑24, 1/2” L

12560

Extension Spring

Black‑Oxide, Precision

12554

Hex Cap Screw

1/4”‑20, 1” L

2.5 HP MODEL

12555

Fender washer

5/16” ID, 1‑1/8” OD

12556

Lock washer

5/16” ID

12557

Clutch Key
3/16”, 1/2” L

12561

Throttle Return Clip

4.0 HP MODEL

12562

Button Head Cap Screw

5/16”‑24, 3/4” L

6 6 6 6 6

4 4 4 4 4

1 1 1 1 1

1

― ― ― ―

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

―

―

1 1 1 1

1 1 1 1

12563

Set Screw

Clutch

125 64

1 50 7 1 8 P LY F LY r e v A_E M | August 7, 2015 5:06 PM

Pan head
M6, 12 mm L

4.0 HP MODEL

2 2 2 2 2

―

1 1 1 1

PlyFly Go‑Kart Instruction Guide • 2015 Release

71

12

Legal

1 5 0 7 1 8 P L Y F L Y r e v A _ L e g a l | August 5, 2015 10:38 PM

72

Legal

Assumption of Risk, Waiver and Release of Liabilities and Indemnity
Agreement

I, the undersigned, on behalf of myself, (and, if applicable, my minor
child or ward listed below), as well as my spouse, heirs, estate, insurers
and assigns (all collectively hereinaf ter referred to as “I” or “me” or “my”,
as the case may be), in consideration of being permitted to use and
operate (whether via a test drive prior to purchase or otherwise) the go
kart equipment of The Flatworks, LLC, a Rhode Island Limited Liability
Company (hereinafter “Flatworks”), at its premises and facilities located
at 11 Waites Wharf, Newport, Rhode Island or at any other locale, and for
other good and valuable consideration, do hereby covenant and agree as
follows:

1. I fully understand and acknowledge that I, like all potential customers of
Flatworks and others desiring to test drive or other wise use and operate

its go-kart equi pme nt, as a condition of such use and operation, must rst:

a) read, understa nd, and agree to this Assumption of Risk, Waiver and

Release of Liabiliti es and Indemnity Agre ement (the “Agre eme nt” ); and b)

read, understand, adhere to, and abide by the safet y rules and instructions
of Flatworks related to the use a nd operation of its go‑kart equipment.

2. I fully understand and acknowledge that: a) using and operating a
motorized go‑kart is an inherently dangerous activit y and that participation
in this activity involves risks of damage to or loss of my property or the
proper ty of others and risks of bodily injury to me or others, including
injuries such as bruises, lacerations, sprains, fractures and, in extreme

cases, disabili ty, paralysis and death; b) such danger s and risks may b e

caused, in whole or in par t, by my own actions or inactions, the actions
or inactions of others, the condition of the go‑kart equipment and the
condition and the layout of the facilities on which they are used, and/or
the negligence of others, including the Protected and Released Parties (as

dened below); and c) there may b e other dangers an d risks assoc iate d

with this activity which at this time are unknown or that are not readily
foreseeable by me or others.

3. I fully understand and ack nowledge the demands of this inherently
dangerous and risky activity relative to my personal knowledge, experience,
skills, aptitude and abilities, as well as my current physical and medical

conditi on and level of  tness, and nevertheless knowingly and voluntarily

accept and assume such dangers and risks, and further assume f ull
responsibility for any and all liabilities, losses or damages, including
any direct or consequential damages, resulting from or related to my
participation in this activity, including, but not limited to: any and all damage

to or loss of my proper ty or the prop erty of others; pe rso nal i njuries to me
or oth ers of any t ype, inc luding disability a nd death; a nd any leg al fe es,

costs or other expenses related to such damages and/or injuries, expressly
including, but not limited to, those alleged to be caused, in whole or in part,

by the neglige nce of the Protected a nd Re leased Parties (as dene d below).

4. I hereby agree to waive, re lease, discharge and covenant not to sue

Flatworks or any other person or entity associated or aliated with these

entities, including, but not limited to, their owners, shareholders, directors,

ocers, members, partners, employees, volunteers, agents, subsidiaries,
related and aliated entities, and succe ssors an d assign s (all hereinafte r

referred to as the “Protected and Released Parties”) from liability for any
and all claims, suits, demands, liabilities, losses or damages a rising from
or relating to my use and operation of Flatworks’ go‑kar t equipment, my
participation in any related activities, and my pre sence on the premises
and facilities of the Protected and Released Parties. This waiver, release,
discharge and covenant not to sue applies, but is not limited to, any and
all liabilities, losses or damages, including any direct or consequential
damages, resulting from or related to my participation in this activity,
including, but not limited to: any and all damage to or loss of my property

or the proper ty of others; personal inju rie s to me or others of any t ype,
includi ng di sab ili ty and de ath; and any legal fees, costs or other expenses

related to such damages and/or injuries, expressly including, but not limited
to, those alleged to be c aused, in whole or in part, by the negligence of the
Protected and Released Parties.

5. If, despite my aforesaid express assumption of risk, and my aforesaid
express waiver, release, discharge and covena nt not to sue, I, or anyone
acting on my behalf, brings a claim or suit, or takes any other action,
against any of the Prote cted and Released Parties for any and all liabilities,
losses or damages, including any direct or consequential damages,
resulting from or related to my participation in this activit y, including, but not

1 5 0 7 1 8 P L Y F L Y r e v A _ L e g a l | August 5, 2015 10:38 PM

limited to: any and all damage to or loss of my propert y or the property of

othe rs; personal inju rie s to me or others of any t ype, including disabili ty and
death; and any legal fees, costs or other expenses related to suc h damage s

and/or injuries, expressly including, but not limited to, those alleged to
be caused, in whole or in par t, by the negligence of the Protected and
Released Par ties, I, for myself and for anyone acting on my behalf, further
agree to hold harmless, defend, and indemnify the Protected and Released
Parties from any such claims, suits, actions, liabilities, losses, damages,
fees, costs or expe nses.

6. In the event of a medical emergency, I hereby authorize Flatworks and
any other Protected and Released Par ties to, if deemed necessary in their

discretion, to admi nister emerg enc y rs t aid, CPR, and use an A ED, and

to secure emergency medical care or transportation (i.e., EMS). I agree to
assume all costs of such emergency medical care and transportation.

7. I acknowledge that this Agreement constitutes the entire agreement
by and among me and the Protected and Released Parties pertaining
to the subject matter hereof and supersedes all prior agreements and
understandings pertaining thereto, and agree that this Agreement may not

be changed, modi ed or amended in whole or in part except in writing,

signed by all of the partie s hereto.

8. I agree that this Agreement and the rights of the par ties hereunder shall
be interpreted in accordance with the laws of the State of Rhode Island,
as broadly and inclusively as permitte d under such laws, a nd all rights and
remedies shall be governed by such laws without regard to principles of

conict of laws. I furth er ag ree that if any portion of this Agreement is held

invalid, the balance shall, notwithstanding, continue in f ull legal force and

eect.

9. I agree that if any disputes or controversies shall arise from this Agreement
or otherwise in connection with my use and operation of Flatworks’ go‑kart
equipment, my par ticipation in any related activities, or my presence on
the premises and facilities of the Protected and Released Par ties, I shall

rst engage in good faith eorts to mediate such dispute. Should the

issue not be resolved by mediation, I further agree that all such disputes or
controversies shall be submitted to binding arbitration in accordance with
the Commercial Arbitration Rules of the American Arbitration Association

then in ee ct.

10. I hereby acknowledge, by signing below and by writing my initials in
the margin of all of the pages, that I have read this Agreement and fully
understand all of its terms and conditions. I understand that I am giving up
substantial legal rights, including rights that I may other wise have to sue for
damages in the event of my death, or injur y or loss occasioned by my use
of the go‑kart equipme nt of Flatworks. I acknowledge that I am signing
this Agreement freely and voluntarily, and intend by my signature, that this
Agreement constitute a complete and unconditional waiver, release, and
discharge of the Protected and Released Par ties from any and all manner of
claims, suits, actions, liabilities, losses, damages, fees, costs or expenses
arising from or related to the inherent risks of this activity, to the greatest
extent allowed by laws of the State of Rhode Island.

PlyFly Go‑Kart Instruction Guide • 2015 Release

73

Terms &

13

Conditions

150718 PLYFLY rev A_Terms & Conditions | August 5, 2015 10:38 PM

74

THE FLATWORKS, LLC

Terms & Conditions of Purchase and Use

THE FOLLOWING TERMS AND CONDITIONS APPLY TO ALL PRODUCTS
DESIGNED, MANUFACTURED AND SOLD BY THE FL ATWORKS,
LLC. THESE TERMS AND CONDITIONS INCLUDE PROVISION WHICH
ALLOCATE THE RISKS ASSOCIATED WITH THE USE OF THE PRODUCTS
AND LIMIT MY LEGAL RIGHTS TO RECOVER DAMAGES IN THE EVENT
OF INJURY OR LOSS OCCASIONED BY SUCH USE, INCLUDING
DISCLAIMERS, EXCULPATORY PROVISIONS (ASSUMPTIONS OF
RISK AND RELEASES), WAIVERS, INDEMNIFICATION PROVISIONS,
LIMITATIONS OF LIABILITY, LIMITED WARRANTIES, A COVENANT NOT
TO SUE, AN ABBREVIATED LIMITATIONS PERIOD FOR CLAIMS, AND AN
ARBITRATION PROVISION.

1. Denitions. As used herein, the following terms shall have the following
meanings:

a) “Flatworks”, shall mean The Flatworks, LLC, a Rhode Island Limited

Liability Co mpany and any and all of i ts aliates, subsidi ar ie s, ass oc ia tes,
owne rs, m emb ers, ocers, agents, employees, and volu nteers, and its

successors and assigns.

b) “Original Purchaser” shall me an the person to whom the Product was

originally sold as evidenced by the sales invoic e from Flatworks.

c) “Products” shall mean all products and related accessories designed,

manufactured and sold by Flatworks.

d) “User” shall mean the purchaser and/or the end user of any Product.

2. Acknowledgement of High Risk Activity. Products sold by Flatworks
include motorized go‑karts and related accessories. User hereby
acknowledge s that: a) using and operating a motorized go‑kart is an
inhere ntly dangerous activity and that participation in this activity invol ves
risks of damage to or loss of my property or the property of others and
risks of bodily injury to himself, herself, or others, including injuries such
as bruises, lacerations, sprains, fractures and, in extreme cases, disability,

paralys is and death; b) such dangers a nd risks may be caus ed, in whole

or in par t, by User’s own actions or inactions, the actions or inactions of
others, the condition of the go‑kart equipment and the condition and the
layout of the facilities on which they are used, and/or the neglige nce of

othe rs; and c) there may be other dang ers and risks associated with this

activity which at this time are unk nown or that are not readily foreseeable by
User or others.

3. Assumption of Risk. User fully understands and acknowledges the
dangers and risks involved with the use of the Products relative to his or her
personal knowledge, experience, skills, aptitude and abilities, as well as his

or he r physical and medica l con dition and level of tne ss, a nd ne ver the les s

knowingly and voluntarily accepts and assumes such dangers and risks,
and fur ther assumes full responsibility for any and all liabilities, losses or
damages, including any direct or consequential damages, resulting from or
related to his or her use of the Products, including, but not limited to: any

and all da mage to or loss of his o r her prop erty or the prope rt y of others;

personal injuries to User or others of any type, including disability and

death; and any legal fees, costs or other expenses related to suc h damage s

and/or injuries, expressly including, but not limited to, those alleged to
be caused, in whole or in par t, by equipment malfunction from whatever
cause, or any other negligence or fault of Flatworks.

4. Release and Waiver of Liability, Covenant Not to Sue. Other than the
liability assumed under the limited warrant y set for th herein below, which

liabili ty is conned to the repa ir or repl ace ment of its Prod ucts under li mite d

circumstance s, User he reby waives, releases, discharges and covenants
not to sue Flatworks from liability for any and all claims, suits, demands,
liabilities, losses or damages arising from or relating to his or her use of the
Products. This waiver, release, discharge and covenant not to sue applies,
but is not limited to, any and all liabilities, losses or damages, including any
direct or consequential damages, resulting from or related to the use of
the Products, including, but not limited to: any and all damag e to or loss of

his or her property or the prope rt y of others; per sonal injuries to the User
or oth ers of any t ype, inc luding disability a nd death; a nd any leg al fe es,

costs or other expenses related to such damages and/or injuries, expressly
including, but not limited to, those alleged to be caused, in whole or in part,
by equipment malfunction from whatever cause, or any other negligence or

150718 PLYFLY rev A_Terms & Conditions | August 5, 2015 10:38 PM

fault of Flatworks.

5. Indemnication. In the event that User, or anyone acting on his or her
behalf, brings a claim or suit, or takes any other action, against any
Flatworks for any liabilities, losses or damages, including any direct or
consequential damages, resulting from or related to his or her use of the
Products, including, but not limited to: any and all damage to or loss of my

prop er ty or the propert y of others; person al injur ies to User or others of
any t ype, includi ng di sab ility and death; and any legal fees, costs or other

expenses relate d to such damages and/or injuries, expressly including, but
not limited to, those alleged to be caused, in whole or in par t, by equipment
malfunction from whatever cause, or any other negligence or fault of
Flatworks, User, for himself or herself, and for anyone acting on his or her
behalf, further agree to hold harmless, defend, and indemnify Flatworks
from any such claims, suits, actions, liabilities, losses, damage s, fees, costs
or expenses.

6. Limited Replacement Warranty. Flatworks warrants to any Original
Purchaser that the Products shall to be free from defects in materials and
workmanship for a period of one‑hundred eighty (180) days from the date of
purchase, provided that they have not been subject to apparent accident,
alteration, abuse, neglect or misuse. Flatwork’s sole liability under this
warranty is limited to the repair or replacement of Products that are
returned within this warranty period.

THE ABOVE STATED LIMITED WARRANT Y IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR A PARTICUL AR PURPOSE.
FLATWORKS NEITHER ASSUMES OR AUTHORIZES ANY OTHER
PERSON OR ENTITY TO ASSUME FOR IT, ANY OTHER LIABILIT Y
IN CONNECTION WITH THE DESIGN, MANUFACTURE OR SALE OF
ITS PRODUCTS, WHETHER FROM ITS WEBSITES, CATALOGS OR
OTHERWISE. THE LIMITED WARRANT Y SHALL NOT APPLY TO ANY
PRODUCT WHICH HAS BEEN SUBJECT TO ACCIDENT, NEGLECT,
ALTERATION, ABUSE OR MISUSE.

7. General Disclaimers. All Original Purchasers, as a condition of purchase,
agree to be bound by the following terms and conditions:

a) Inspection Prior to Use. All Products must be inspected upon delivery

for use to ensure that they have not been damaged in shipment or
otherwise. If any Product is damaged, such Product should not be
used and should be promptly returned to Flatworks for inspection,
replacement or repair, as the case may be.

b) Use of Products. Prior to the use and operation of any Product, the

Original Purchaser must read, understand, adhere to, and abide by
any instr uctions, manuals, directions and safet y rules related to the
Product, including, without limitation, those related to the assembly, use,
operation, and maintenance of the Product. Flatworks shall have no
responsibility whatsoever for the misuse or unauthorized and improper
use of its Products.

c) Duty to Inform O thers an d Ind emnicatio n. Prior to allowing othe rs to

use any Product, the Original Purchaser must require that such person
(or his or he r legal guardian, if a minor) reads, understands and agrees to
adhere to and abide by these Terms and Conditions and any instructions,
manuals, directions and safety rules re lated to the Product. The Original
Purchaser fur ther agrees, for himself or herself, and for anyone acting
on his or her behalf, to hold harmless, defend, and indemnify Flatworks
from any claims, suits, actions, liabilities, losses, damages, fees, costs or
expenses arising out of such person’s use of any Product.

8. Applicable Law. These Terms and Conditions and the rights of all aected
parties here under shall be interpreted in accordance with the laws of the
State of Rhode Island, as broadly and inclusively as permitted under such
laws, and all rights and remedies shall be governed by such laws without

regard to principles of conict of laws. If any por tion of these Terms

and Conditions shall be held invalid, the balance shall, not withstanding,

continue in full legal forc e and eect.

9. Resolution of Disputes. Any dispute, claim or controversy arising out of or
in connection with the purchase or use of the Products shall be resolved
by means of binding arbitration held within the State of Rhode Island
in accordance with the Commercial Arbitration Rules of the American

Arbitra tion Associatio n the n in eect. Any demand for arbitration must

be commenced within one (1) year after the dispute, claim or controversy
arises.

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