TrailMaster MINI XRX, MINI XRX-R, MID XRX, MID XRX-R Assembly Manual

GOKARTMASTERS.COM

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

1

GOKARTMASTERS.COM

Remove outer cardboard from crate.

2

Remove metal crating and unpack all parts.

4

GOKARTMASTERS.COM

Place parts out on the floor and take inventory making sure of proper quan-

5

tities. At this time, if missing or damaged parts, call or email us.

GOKARTMASTERS.COM

Remove all bolts from metal crate with 9/16” wrenches or socket.

3

GOKARTMASTERS.COM

Remove bolts and nuts at lower front Aarms

6

GOKARTMASTERS.COM

Remove axle straps and discard.

7

GOKARTMASTERS.COM

Locate white box with battery.

8

Lay out all hardware on a clean work

10

bench. Take inventory per hardware list.

GOKARTMASTERS.COM

Locate one of the long cage bars.

11

GOKARTMASTERS.COM

See Battery Fill Procedure Instruction Sheet. Fill battery according to Instruc-

9

tion Sheet . Let sit.

GOKARTMASTERS.COM

Place bar on front pin above head-

12

light.

GOKARTMASTERS.COM

Place rear of bar onto pin at rear be-

13

14

hind seat.

GOKARTMASTERS.COM

Locate 2 long bolts, 4 nuts & 8 chrome cup washers.

It may be necessary to align the hole

16

17

NOTE: DO NOT TIGHTEN AT THIS TIME.

in the bar with a screwdriver.

GOKARTMASTERS.COM

Install a second cup washer and the nut.

GOKARTMASTERS.COM

Install with washer into front of bar

15

from the outside.

GOKARTMASTERS.COM

Install bolt, washers and nut at rear of

18

bar.

GOKARTMASTERS.COM

Repeat steps 16-19 for the other top

19

bar.

GOKARTMASTERS.COM

Locate the passenger side bar.

20

Place the side bar onto the passen-

22

23

ger’s side of the go-kart.

GOKARTMASTERS.COM

Turn the plastic cap with a pair of pliers to align the side bar to the top bar.

GOKARTMASTERS.COM

Locate 4 large bolts, 6 cup washers

21

and 2 nuts.

GOKARTMASTERS.COM

It is necessary to tap the plastic cap

24

or rubber mallet or a block of wood with a standard hammer.

all the way onto the bar. Use a plastic

GOKARTMASTERS.COM

Install the top bolt & washer first.

25

26

Start the threads but do not tighten.

GOKARTMASTERS.COM

Now, install the bottom bolt and washer from the front.

Repeat steps 20-27 for the driver’s

28

29

side bar.

GOKARTMASTERS.COM

Locate the top bar weldment assembly.

GOKARTMASTERS.COM

Install the second washer and nut on

27

NOTE: DO NOT TIGHTEN THE HARDWARE.

the bottom bolt.

GOKARTMASTERS.COM

Locate 4 large bolts and 4 chrome

30

cupped washers.

GOKARTMASTERS.COM

Install the top bar assembly.

31

GOKARTMASTERS.COM

Start each of the 4 bolts with cupped

32

NOTE: DO NOT TIGHTEN HARDWARE .

washer into the threads of the top bar.

Locate 2 long bolts and 2 chrome

34

35

cupped washers.

GOKARTMASTERS.COM

Install the short bar behind the seats. Start the bolts with washers into the threads.

GOKARTMASTERS.COM

Locate the short rear bar.

33

GOKARTMASTERS.COM

Tighten ALL of the bar bolts previ-

36

ously installed with a 10mm & 12mm wrenches.

GOKARTMASTERS.COM

Locate the fuel tank.

37

is already installed on the engine. Check tank mounting hardware to insure tight. Proceed to Step 46.

38

NOTE: On some models, the fuel tank

GOKARTMASTERS.COM

Locate 4 long bolts and nuts and fuel hose clamp.

Install the 4 bolts and nuts into the

40

41

tank.

GOKARTMASTERS.COM GOKARTMASTERS.COM

Tighten with a 10mm & 12mm wrenches.

GOKARTMASTERS.COM

Place the fuel tank onto the rear rack

39

with decal to the rear.

GOKARTMASTERS.COM

Locate the end of the fuel hose on top

42

of the engine.

GOKARTMASTERS.COM

Place the fuel hose clamp onto the

43

filter that’s already attached to the fuel tank.

44

1/4” from the end of the hose.

hose and push the hose onto the fuel

GOKARTMASTERS.COM

Using pliers, place the fuel hose clamp on the filter approximately

Now, it’s time to install the rear

46

bar from the passenger’s side shock mounts.

NOTE: SAVE THE BOLTS & NUTS.

shocks. Remove the metal shipping

GOKARTMASTERS.COM

Discard this bar.

47

.

GOKARTMASTERS.COM

Turn fuel valve to ‘ON’ position.

45

GOKARTMASTERS.COM

Locate one (1) shock.

48

GOKARTMASTERS.COM

Place the top shock eye into the

49

bolt and washer that was removed in Step 46.

50

the rear swing arm.

bracket with the spring up. Reinstall

GOKARTMASTERS.COM

Lift up on the rear rack and align bottom shock eyelet with the bracket on

Tighten top and bottom shock bolts

52

53

with wrenches.

GOKARTMASTERS.COM

Repeat Steps 48-52 for the driver’s side rear shock.

GOKARTMASTERS.COM

Install bottom shock bolt and nut.

51

GOKARTMASTERS.COM

At this time, lift the rear of the go-kart

54

kart on a jackstand. Be safe. Use caution.

with the help of an assistant. Place the

GOKARTMASTERS.COM

Place the battery pad into battery tray

55

located behind the passenger’s seat.

GOKARTMASTERS.COM

Install the battery in the cart with the ter-

56

cable (red) to the ‘+” on the battery. Next, install the negative cable (black or green) to the ’-’ on

the battery. NOTE: Use pliers to hold the nut while using a Phillips head screwdriver to tighten the screw.

minals to the rear. First, install the positive

Place rubber battery strap over bat-

58

tray first. Then, pull the strap over the battery and place it on the rear hook of the battery tray. If necessary, use pliers.

tery hook to the front of the battery

GOKARTMASTERS.COM

Locate the set bolt on the sprocket

59

hub and tighten securely.

GOKARTMASTERS.COM

Place gray plastic cover over bat-

57

tery.

GOKARTMASTERS.COM

Locate the rear passenger’s side

60

wheels. The tread on top of the tire will point towards the front of the go-kart & the air valve stem will be facing towards the outside.

wheel. This is one of the larger

GOKARTMASTERS.COM

Place the wheel onto the rear axle.

61

GOKARTMASTERS.COM

Place the largest washer and castle

62

nut onto the axle.

Install the cotter pin into the axle nut.

64

the end of the axle. Clip off other end with cutters.

65

Bend one end of the cotter pin over

GOKARTMASTERS.COM

Install rubber hubcap over axle nut.

GOKARTMASTERS.COM

Tighten the castle nut securely and

63

align the holes in the axle with the nut.

NOTE: Repeat Steps 60-65 for the driver’s side rear wheel.

GOKARTMASTERS.COM

Lift front of go-kart and support with

66

jack stands.

GOKARTMASTERS.COM

Locate passenger’s side top spindle

67

NOTE: Save cotter pin.

68

NOTE: Save cotter pin.

nut and remove cotter pin.

GOKARTMASTERS.COM

Locate passenger’s side bottom spin- dle nut and remove cotter pin.

Make sure the hole in the spindle

70

71

driver’s side spindle.

lines up with the castle nut.

GOKARTMASTERS.COM

Reinstall cotter pins. Bend and cut off excess. Repeat Steps 67-71 on the

GOKARTMASTERS.COM

Tighten both nuts securely with a

69

17mm wrench.

GOKARTMASTERS.COM

Locate outer steering joints and tight-

72

socket on the nut and a 12mm wrench on the top.

en the nut securely using a 12mm

GOKARTMASTERS.COM

Locate the front passenger’s side

73

side front axle. The tread on top should point forward with the air valve stem to the outside.

74

wheel and place it on the passenger’s

GOKARTMASTERS.COM

Locate 2 castle nuts, 2 washers and 2 cotter pins.

Check tire pressure in all 4 tires. Set

76

sure gauge to check the tire pressure.

77

NOTE: Lowering this bolt will restrict the top speed of the go-kart.

to 10 PSI. You will need a low pres-

GOKARTMASTERS.COM

Locate the throttle stop and tighten the jam nut securely.

GOKARTMASTERS.COM

Install cotter pin and bend. Cut off

75

on the driver’s side.

excess cotter pin. Repeat Steps 72-75

GOKARTMASTERS.COM

Locate the steering box clamps and

78

curely with 8mm & 10mm wrenches.

NOTE: Plastic connector should be next to the metal clamp.

tighten all four (4) bolts and nuts se-

GOKARTMASTERS.COM

Locate the three (3) small bolts and

79

nuts.

GOKARTMASTERS.COM

Locate the steering wheel.

80

Tighten bolts securely with two (2)

82

83

10mm wrenches.

GOKARTMASTERS.COM

Install the plastic steering wheel cap by snapping it into place.

GOKARTMASTERS.COM

Install the steering wheel with the center

81

NOTE: If the steering wheel does not line up correctly with the front wheels, continue mounting the steering wheel as close as possible.

spoke facing down & the front wheels straight forward.

GOKARTMASTERS.COM

If the steering wheel is not straight

84

straight, locate the plastic gearcase on the steering box.

when the front wheels are pointing

GOKARTMASTERS.COM

Remove plastic cap from the bot-

85

driver.

86

way the steering wheel needs to be turned to align correctly.

tom of the plastic case with a screw-

GOKARTMASTERS.COM

Make sure the front wheels are straight ahead and determine which

Pull steering wheel and shaft out of

88

steering wheel gently.

89

the gear. You may need to bump the

GOKARTMASTERS.COM

Hold the gear in place with your finger.

GOKARTMASTERS.COM

Remove steering shaft nut with

87

17mm socket.

GOKARTMASTERS.COM

Turn the steering wheel straight and

90

gear.

push the shaft back down into the

GOKARTMASTERS.COM

Reinstall the nut securely. Reinstall

91

into place.

92

ahead.

the plastic cap by simply pushing it

GOKARTMASTERS.COM

Now, it’s time to align the steering. Turn the steering wheel to straight

The front wheel should be in a

94

parallel.

NOTE: The front of the go-kart is wider than the rear.

95

straight line with the rear wheel or

GOKARTMASTERS.COM

The measuring tape in the pictures is for sight reference ONLY!

GOKARTMASTERS.COM

Stand approximately 10 feet in front

93

passenger wheel in relationship to the rear passenger wheel.

of the go-kart and look at the front

GOKARTMASTERS.COM

Adjust the passenger tie rod ac-

96

cordingly to align the wheel.

GOKARTMASTERS.COM

Hold the rod with a 10mm wrench

97

(standard thread).

98

and loosen the outer jam nut

GOKARTMASTERS.COM

No w, lo osen the i nner nut (backwards thread).

Hold the rod with a wrench and

100

GOKARTMASTERS.COM

101

tighten the jam nuts securely.

Repeat Steps 92-100 for the driver’s side.

GOKARTMASTERS.COM

Now, adjust the wheel in or out by

99

turning the rod.

GOKARTMASTERS.COM

For final front end alignment pro-

102

turn toward each other approximately 1/4” to 1/2”.

cedure, the front wheels should

GOKARTMASTERS.COM

Measure across the front wheels

103

rear of the tires and adjust accordingly according to the procedures in Steps 92-100.

104

the go-kart.

that the front of the tires and at the

GOKARTMASTERS.COM

Locate the foam padding and place it on the top outside bars of

Tighten inner air filter nut secure-

106

and nut.

GOKARTMASTERS.COM

107

NOTE: This is ONLY on the Mini XRX-R

ly with fingers. Reinstall cover

Locate the shift cam. Tighten both cables with a 12mm wrench.

GOKARTMASTERS.COM

Remove air filter nut and cover.

105

GOKARTMASTERS.COM

Cut and remove all strings on can-

108

opy top and pad covers and dispose.

GOKARTMASTERS.COM

You’re almost done! Just a few

109

you will be ready to ride your new go-kart.

pre-drive items to inspect, and

GOKARTMASTERS.COM

Locate oil dipstick on front of en-

110

With the go-kart sitting on level ground, the oil level should be to the top of the threads. If not, fill with 10W30 oil.

gine behind the driver’s seat.

It is highly recommended to use

112

such as Seafoam or Stabil. Follow manufacturer's instructions on the bottle.

a fuel additive or fuel stabilizer

GOKARTMASTERS.COM

If there is no passenger in the go-

113

keep it from dragging the ground or from being run over by the rear tire.

kart, keep the seat belt buckled to

GOKARTMASTERS.COM

Fill fuel tank 3/4 full with premi-

111

NOTE: Follow all gasoline handling precautions and fuel can.

um high octane fuel.

GOKARTMASTERS.COM

Make sure the fuel valve is on.

114

GOKARTMASTERS.COM

There should ALWAYS be some-

115

before starting the go-kart.

GOKARTMASTERS.COM

116

one seated in the driver’s seat

ALWAYS engage the parking brake before starting the go-kart.

Pull the choke control out firmly

118

GOKARTMASTERS.COM

119

and hold.

Push the red Start Button.

GOKARTMASTERS.COM

Insert ignition key and turn to the

117

‘ON’ position.

GOKARTMASTERS.COM

It may be necessary to run the

120

(halfway pulled out) for 30 seconds to 1 minute to warm up the engine.

engine on choke or partial choke

GOKARTMASTERS.COM

Turn the key to ’OFF’ or push the

121

go-kart engine off.

stop button and hold to turn the