GSMOON KD260-1, KD260-3, KD260-2 Repair Manual
GO-KART [XYKD260] Repair Manual
1
1 Service Notice
Position of Identification Number Lubrication diagram
Main Features Structure Drawing
Standard Torque Rating Troubleshooting
Position of Identification Number
Vehicle Identification Number
Engine Identification Number
2
Main features
Vehicle Dimensions [mm] KD260-1 KD260-2 KD260-3
Overall Length………………………….………………………………………………..2470 2690 2550
Overall Width……………………………………………..……………………………..1570 1510 1670
Overall Height……………………………………………………………………………1535 1460 1440
Wheelbase………………………………………………………………………………..1870 1950 2010
Front Track……………………………………………………………………………….1345 1270 1485
Rear Track……………………………………………………………………………….1250 1250 1263
Ground Clearance…………………………………………………………………………200 220 200
ENGINE
Type…………………………………………………………………….……………..Water cooling, four stroke
Engine capacity……………………………………………………………………….260cc
Bore *Stroke…………………………………………… ……………… ……… …… .70m m*66.8m m
Displacement………………………………………………………………………….257cm³
Corrected compression ratio…………………………………………………………9：1
Max output power…………………………………………………………………..11kw/7000rpm
Max T or que……………… ……………………… ……………… …………… ……..17Nm/5000N.m /r/m in
Starting………………………………………………………………………………..Electric Start
Ignition………………………………………………………………………………..C.D.I
Lubrication…………………………..………………………………………………..pressure splash
Transmission………………… ………..………………………………………………. Autom atic C.V .T System
Spark plug…………………………..……………………………………………….DPR5EA-9（NGK）
Plug gap…………………………..………………………………… ……… …….0. 6-0.8mm
Fuel type…………………………..……………………………………………… .RQ 90 (leadless)
Lubricate oil…………………………..……………………………………………….SAE15W-40/SF
Capacities
Maximum load…………………………..………………………………… …………….Two seats/200Kg
Fuel tank…………………………..……………………………… ……………… ……...9.5L
Engine oil…………………………..……………………………………………………..1180mL
Starting Tim e…………………………..…… …………………… …………………………..<10s
Climbing…………………………..……………………………………………………..20º-25°
Battery…………………………..………………………………………… …………..12V 14Ah
Head Light…………………………..……………………………………………………..12V 35W
Tail Light…………………………..……………………………………………………..12V 21W/5W
Fuse…………………………..……………………………………………………..10A
Brake Track…………………… ……..……………… ……………… ……………… …….. 7m at 30KM/h
Top speed…………………………..…………………………………..75KM/h (
CHASSIS
Front/Rear brake ………………………………Hydraulic disc brake/ Left leg control
Front tire ……………………………………………… AT21X8-10
Rear tire ………………………………………………AT22X11-10
Front Suspension …………………………………………
Rear Suspension …………………………………Independent swing arm/ Double hydraulic shock
Independent dual-A arm
Or as customer requirement)
3
Restraint System ……………………………………… Double quincunx safety belts
Final Drive ………………………………………………… shaft drive
TIRE PRESSURE[kPa] off-road Tire Road Tire
Front …………………………………………………… 25 200
Rear …………………………………………………… 30 225
WEIGHT[KG] KD260-1 KD260-2 KD260-3
Net W eight …………………………………355 346 365
G.W. …………………………………… 380 370 380
4
Standard Torque Rating
XYKD
SER
NUM
1 Screw used between Exhaust pipe and Front Cylinder 8 20-26
2 Igniter plug 10 18-20
3 Screw used between Front wheel hub and front universal
joint
4 Screw used for Rear wheel hub and Constant-velocity joint 18 120-140
5 Universal joint fastening bolt 8 20-26
6 Bolt of protective parts of steering mechanism 8 30-40
7 Screws between handle ball and gimbal 10 50-60
8 Screws of wheel and wheel rim[Front and rear] 10 50-60
9 Screws of support parts[Front wheel] and vehicle body 10 50-60
10 Connection of brake pump parking brake and front gimbals,
elevation
11 Screws of handle adjusting line 10 30-40
12 Screws exhaust pipe and engine rear support part 8 20-26
13 Screw used on Front Vibration Damper 10 30-40
14 Screw used on Rear Vibration Damper 12 50-60
15 Connecting screws between rear support part and vehicle
body
16 Screws of rear support parts of engine 10 30-40
17 Screws of front support parts of engine 10 30-40
18 Screws of back brake disc and back wheel rim 8 30-40
19 Screws of front brake disc and front wheel rim 6 20-26
Position
Diameter of screw
（mm）
14 80-100
8 20-26
16 110-130
Torque（N.m）
5
g
Lubricating oil and How to do lubrication
1、Engine
Position Description of Lubricating Oil Remark
Crankcase Only 15W/40SF
Gear case Only 15W/40SF or 85W/140
Parts of Clutch
Li oil ZL-3H（SY 1413）
Full capacity：1.0L
Full capacity：0.22L
4.5~5.0g
2、Vehicle Body
The parts, described [not limited] as following, should be added lubricating oil.
If no special requirement, please use the multiple functions lubricating oil.
In order to prevent the unusual sound and improve the durability, lubricating oil also should be used in
other transmission parts.
Steering wheel nylon bushing
Sub seat slide rail
Constant speed
imbal
Front Wheel Support Part
Connection part
between Steering gear
parts and handle ball
Brake pedal
Accelerator pedal
Accelerator cable
Parking brake cable
Front lower swing arm
Main seat slide rail
Front wheel axle
6
Rear wheel rim axle
Rear swing arm axle
Pipe of
cooling liquid
kettle
Temperature
Control
Switch
Structure Drawing
Water tubing
Brake cable
Rear brake oil
tube
7
Fuse 15A
y
r
Rela
Flash apparatus
BATTERY
CDI
Electric parts
case
rectifie
Ignition coil
Throttle cable
Quadric air-intake
mechanism
Parking
brake cable
Reverse cable
8
Main cable
Can not or difficult to start
Speed Sensor cable
Troubleshooting
Description
Whether oil run in carburetor. Take
●
Yes
No
Take off spark plug to check
Yes No or not enough
Adjustment Reasons
● No oil in oil tank
down vent bolt to check.
sparkle or not
● Jam between oil tank and carburetor
● Oil tank hole jammed
● Oil filter jammed
● Oil cleaning net jammed
● Pressure oil switch not work
● Spark plug not work
● Spark plug not clean
● CDI parts not work
● Trigger not work
● Spark plug coil broken or short-circuit
● Ignition coil broken or short circuit
● Igniter switch not work
● Magneto coil not work
Pressure Value
● Valve gap not enough
9
OK No or not enough
● Valve socket not good
● Damage of cylinder, piston rings
● cylinder head gasket works not well
Start accordingright method
No explosion No start with explosion
Take off spark plug again
火花塞是干的 火花塞湿
Dry Wet
◆
Power is not strong, not speed up
Description Routine
●
Yes
No
Let engine work
at high speed
● Valve is damaged
● Mixing air time not good
●EEV of carburetor not work
●Air leakage of minus pressure tube
●Ignition time not good
●Vent bolt of carburetion not work
●Too many oil in carburetor
● 化油器过满溢出
●EEV of carburetor not work
●Value of throttle is unusual.
Reasons
● Battery connection badness
● Air filter jammed
● oil tube jammed
● minus Pressure line not connected well
Yes No
Yes No
● Vent hole of oil tank cover jammed
● Carburetor jammed
Check Ignition
time [Ignition le d]
● CDI parts not work
● Trigger not work
Check Valve Gap
● Valve gap not good
● Shape of valve changed
Check Compress pressure Value in Plunger
10
Yes No or Lower
● Valve socket not work well
● Plunger ring is damaged
● Air leakage from gasket position
No Yes
Clean Dirt
◆
Description Routine
●
Check Carburetor jammed.
Check spark plunger
Check oil quantity
level and quality
● Mix air time not good
● Parts of Carburetor jammed
● Spark plunger polluted/damaged
● Temperat ure of spark plunger wrong
Reasons
● Too many oil
OK
No Yes
● Oil is not enough No
● Oil is not replaced
Engine is too hot or not
● Cooling liquid not enough
● Plunger or Cylinder damaged
● Mix air rare
● Quality of oil bad
● Too many carbon powers in firebox
● Ignition time wrong
Speed up or work at high
speed
● Too many carbon powers in firebox
● Quality of oil is bad
11
● Mix air rare
● Ignition time wrong
No sound Unusual
sound
Egine works unusually（such as idle and low speed）
Description Routine
●
Yes
No
Yes No
Reasons
Ignition Time OK?
● CDI parts not good
● Magnetor not good
Vent screw of
carburetor OK?
● Mixed air is rare[Take screws down]
● Mixed air is thick[Take screws up]
Air leakage in
carburetor gasket?
● “O” gasket not good
No Yes
● Carburetor is loosed
● Airproof parts not good
● Air leakage in vacuum parts
Sparks OK?
12
OK No or less spark
● Spark plunger not good or polluted
● CDI parts not good
● Ignition coil not good
● Ignition coil is broken or in short
Cut Air V alve OK?
Yes
No
◆
Engine works unusually [High speed]
Description Routine
●
Ignition time OK?
● Ignition trigger not good
● Cut Air Valve not good
● Vacuum line jammed or damaged
● Air tube jammed or damaged
Reasons
Yes
No
Yes No
OK Unusual
Carburetor socket jammed?
● CDI parts not good
● Magnetor not good
Handspike gap OK?
● Adjustment not good
● Value socket damaged
Check oil automatic
screw function?
● Not enough oil in oil tank
● Oil line or oil filter jammed
● Vent hole is jammed
● minus Pressure line switch not work
No Yes
● Clean carburetor socket
13
Yes No
◆
Not move with high speed
Description Routine
●
Engine works at high
speed or easy to stop?
Mixed time right?
Spring of valve good？
● Protruding sprocket wheel and magneto
flywheel position not match
● Spring not good Yes No
Reasons
Engine works at
high speed
reverse gear OK
No high speed or easy to
stop
Check reverse operation system
reverse position wrong
Any unusual sound of engine
gear case
● Ignition coil wrong connection
● Spark plug bad connection
● Connection of battery not good
● Oil line not good
●Length of reverse cable is not suitable
●reverse gear damaged
No Yes
14
●Connector sheath of reverse gear damaged
●Differential gear damaged
●Differential damaged
Open side cover of engine and check
◆
No power in battery
Description Adjustment
●
Start engine and check
voltage of battery
clutch strap broken or not
Reasons
Battery can not charging
Normal
Yes
Unusual
No
Normal
●Check battery whether out of usage
●Battery not good
Resistance value
of coil
● Stator not good
● Yellow line is broken
● Connection of line is not good
Voltage between Blue/yellow and Green
● Blue/yellow or Green line is broken
Whether any looseness of booster and connection-peg？
Yes
No
15
● Booster not good
● connection-peg not good
● Magneto not good
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