TrailMaster 150 Assembly Manual

Move carton to a clean location with 3
or more feet of room around the unit.

1

Lay out ALL hardware on a clean sur­face and count.

4

Remove strapping and outer container.

2

Unpack parts and place near where
they are to be installed.

3

Remove battery box from kart. Read all
precautions, filling instructions and

5

safety instructions. Make sure to wear safety
glasses and protective gloves.

Place the battery in a sink.

6

Remove the battery cell seal.

7

Place the battery acid container on

10

align the container with the battery cells.

top of the battery. Be sure to properly

Carefully open the package containing
the battery acid and hardware. Set the

8

hardware package aside for later use.

Remove the plastic cap from the battery
acid container. IMPORTANT: DO NOT

9

DISCARD THE PLASTIC CAP. Set the plastic
cap aside for later use.

Gently press the battery acid con-

11

puncture the foil caps and allow the battery
acid to flow.

12

from the container easier. With a sharp knife
or thumbtack, poke a hole in the TOP of each
of the battery acid container’s cells.

tainer into the battery cells. This will

The battery acid container needs to
be vented to allow the acid to flow

Allow the battery acid to fill the bat-

13

er or at least for 30 minutes. This will also al­low the battery to absorb the acid and vent
properly.

tery while putting the go kart togeth-

Remove the hose from the frame be-

16

will connect to the fuel petcock on the fuel
tank later.

hind the driver’s seat. This fuel hose

14

15

Select the two short 8mm bar bolts.
These will be used to install the rear
rack.

Install 1 each of the cupped washers
to each bolt.

17

18

This hole will be used to mount the
rear rack.

With an assistant, sit the rack in place
and align it with the holes in the
frame.

Insert the bolt with washer through

19

to tighten the threads (clockwise rotation)
into the rack. Do this procedure on both the
left and right sides. Then, tighten both bolts
securely with a 10mm wrench.

the hole in the frame and turn the bolt

22

Locate the vacuum hose that is al­ready connected to the fuel valve.

Now, it is time to mount the fuel tank

20

tank into place with the fuel cap on the driv­er’s side.

21

of the short bolts. Do not install 8mm yet.

and install the fuel hoses. Sit the fuel

The hardware necessary to mount
the tank. These are the (4) four longer

23

24

Attach the vacuum hose to the ‘Y’
connector near the carburetor.

Push hose on completely and slide

the hose clamp to 1/4” from end of

hose.

Locate fuel hose with the fuel filter

25

the carburetor.

and spring that is already attached to

Start all four bolts into the threads by

28

ing is inserted into each rubber bushing.

hand. Make sure that the steel bush-

Push the hose onto the top fitting of

26

1/4” from hose end.

27

hardware. The tank should be mounted with
the curve of the tank towards the rear of the
go kart.

the fuel valve and slide the clamp to

After properly connecting the fuel
hoses, it is time to install the tank

This is the rear support for the rear

29

rack. One on each side of the go kart.

30

10mm and 12mm wrenches.

rack. There are two supports on the

Install the 4 shortest 8mm bolts with
nuts. Then, tighten all 4 bolts with a

It is time to install the main bars on

31

nuts and 8 cupped washers.

the cage. This step require 4 bolts, 4

Insert the bolt, washers and nuts

34

and front right side. Nut should be to the in­side.

NOTE: DO NOT TIGHTEN HARDWARE YET.

through the bars at the front left side

Place the 2 long top bars into place.

32

The left and right bars are the same.

33

NOTE: May be necessary to use a medium
size Phillips screwdriver or punch to align the
mounting holes.

Install the right side rear bolt, wash-

35

NOTE: DO NOT TIGHTEN HARDWARE YET.

36

NOTE: DO NOT TIGHTEN HARDWARE YET.

ers, and nut. Nut should be to the in­side.

Install the left side rear bolt, washers,
and nut. Nut should be to the inside.

37

Four (4) 8mm bolts and washers will
be used for the top weldment.

40

Install the bolt with washer in the top
of the bar first.

Two (2) long bolts, nuts and four (4)

38

with washers only will be used to install the
side bars.

39

washers along with two (2) long bolts

Side bar installation. Fit the left side
and right side bars into place.

Make sure the threads start into the

41

NOTE: DO NOT TIGHTEN HARDWARE YET.

42

Repeat Steps 38-42 for other side bar.

bar.

Install the bolt, 2 washers and nut at
the bottom of the bar.

NOTE: DO NOT TIGHTEN HARDWARE YET.

43

Place the rear cross bar into place
and align holes.

46

Use the remaining four (4) long 8mm
bolts and washers to install the top
weldment.

Start 8mm bolts with washers.

44

NOTE: DO NOT TIGHTEN HARDWARE YET.

45

.

With an assistant, hold the top weld­ment in place.

Plastic end caps may need to be ro-

47

48

NOTE: DO NOT TIGHTEN HARDWARE YET.

tated with pliers to fit properly

Start the four (4) bolts with washers
into the top weldment.

Tighten ALL of the hardware previ-

49

time with a 10mm wrench and a 12mm
wrench.

ously installed into the cage at this

Align the shock.

52

It is time to install the lower shock

50

move the bolt and nut from the frame at the
shock mount.

51

bolts at the rear of the go-kart. Re-

Have an assistant lift up on the rear
rack to align the shock with the
mount.

Insert the bolt and nut.

53

Tighten the bolt and nut with two (2)

54

NOTE: Repeat Steps 50-54 for the other side.

14mm wrenches.

At this time, the go-kart must be lift-

55

You may need an assistant or two. Place a
sturdy support under the kart frame i.e. jack­stands. Be safe. Use caution. Make sure the
unit is stable and secure so that it doesn't fall.

ed approximately 12” from the crate.

Steps 58 & 59 are not necessary,

58

quality lubricant with straw.

however, we recommend using a

56

57

Locate the rear axle.

Apply multi-purpose grease on the
spline of the axle. Remove nut and
washer.

Carefully push the straw between the

59

about 1 second.

60

bracket with a 10mm wrench.

seal and axle. Spray lubricant for

Mounting rear fenders. Remove
mounting bolt from rear fender

61

Place bolt through rear swing arm
located just in front of rear shock.

64

Install large washer and castle nut on
axle.

Start bolt into fender bracket by

62

NOTE: Repeat Steps 60-62 for the other side.

63

tread on top of the tire should be pointing
forward.

hand. Then, tighten firmly with a
10mm wrench.

Slide rear wheel onto rear axle with
the valve stem to the outside. The

Tighten nut making sure to align with

65

66

Repeat Steps 63-66 for the other side.

holes in axle.

Install cotter pin. Bend and clip off
excess clip.

Locate front passenger side spindle.

67

washer are installed.

Make sure rubber boot and square

Install stud in hole.

70

68

69

Align square stud with hole in A-arm.

Align square stud with lower A-arm.

Make sure stud square is seated.

71

Install washer and castle nut.

72

73

Tighten nut. Align with hole in spin­dle stud.

Check castle nut for tightness.

76

74

75

Install cotter pin in lower spindle nut.
Bend and clip excess.

Remove cotter pin from top of spin­dle.

77

78

Install cotter pin in upper spindle
nuts. Bend and clip excess.

Remove cotter pin from ball joint.

79

Tighten nut. Align hole with stud.

Install fender and tighten bolts with

82

Repeat 81-82 for driver’s side.

10mm wrench.

Reinstall cotter pin. Bend and clip off

80

Repeat steps 67-80 for driver’s side.

81

excess.

Remove fender mounting bolts from
passenger side spindle.

83

84

Remove wheel nuts from passenger
side hub.

Install front wheel with valve stem
facing out and tread pointing forward
on top of tire.

85

Tighten lug nuts securely.

Tighten all valve stem cores.

88

Bend and cut cotter pin in wheel hub.

86

Repeat Steps 83-86 on driver’s side.

87

can be purchased at an auto parts store.

You will need a valve stem tool to
tighten all valve stem cores. This tool

Using a low pressure tire gauge, set

89

rear. Install valve stem caps.

90

card. Set the plastic cap (from Step 9 ) into
the top of the battery making sure that ...

tires at 10 psi for front and 8 psi on

Remove the acid container from the
top of the battery and properly dis-

Make sure cap lines up correctly. If

91

come damaged and it will not fit properly.
Firmly press cap into top of battery.

92

into place. Make sure to work your way from
one end to the other and the repeat until the
battery is flush to the top of the battery.

not properly aligned, the cap can be-

After making sure that the cap is
properly inserted, gently tap the cap

The rubber … will lay flat in the bot-

94

ducing battery movement and noise.

95

SWITCH IS TURNED TO THE OFF POSITION.
Place battery in tray with terminals towards
the rear of the go kart.

tom of the tray and will help with re-

BEFORE YOU BEGIN BATTERY IN­STALLATION: MAKE SURE KEY

Insert the rubber … into the battery

93

tray located behind the driver’s seat.

Locate battery bolts and nuts.

96

97

First, insert one square nut into the
‘+’ terminal.

Place rubber cover over terminal.

100

Locate the positive battery cable

98

99

‘+’ terminal on the battery.

(red).

With a Phillips head screwdriver,
mount the positive (red) cable to the

101

102

Repeat Steps 97-100 for negative
battery cable (black).

Battery installation is complete.

103

Install battery cover.

Find the 3 wire connectors from

106

at the wiring harness and connect.

the tail light and top of the engine

Install rubber strap using a pair of

104

*NOTE: WD40 sprayed on the rubber strap
will make this step easier.

105

pliers to stretch .

Completed battery cover and
strap.

107

108

Remove bolts from steering
wheel mount.

Install steering wheel with center
spoke down.

109

Install and tighten bolts.

Install hub caps on front wheels.

112

110

111

Install plastic cover.

Snap cover into place.

113

114

Install hub caps on rear wheels
and check mounting nuts.

Make sure seat belts are to cen­ter of seatback.

115

Install headrest into holes on
seat.

Use electrical tape to secure top

118

*NOTE: May also use spray adhesive on all
padding and foot pads.

padding.

116

117

Push headrest all the way down.

Peel protective film from decals,
reflectors and seats.

Install fabric top starting at front.

119

Secure and attach with Velcro.

120

TrailMaster 150 Startup

1. READ owner’s manual carefully.

2. Fill fuel tank with 93 octane gasoline.

3. Make sure operator is seated in seat and seatbelt in fastened.

4. Place foot on brake or apply parking brake.

5. Turn key to ‘ON’ position.

6. Turn key to start position in 4-5 second intervals.

7. May need to repeat Step 8 several times to make engine start up and run.

8. If engine does not start, have another person place their hand over the in­take pipe snorkel hose (corrugated, flex hose). Hose is located behind the

driver’s seat near the headrest at the seatbelt bracket (See pictures below).

While holding their hand over the intake pipe, turn the key to the start po­sition again in 4-5 second intervals. This procedure chokes the engine and
should be used in colder weather or if the go-kart has been sitting for a
while.

Manually Choke Engine Procedure

Intake Pipe

Place Hand Over Intake Pipe