GK125 PGO MANUAL - Brilliantstone.us
Contents
1. 1 1 Refueling Screw off the fuel tank cap counterclockwise refuel until reaching to the position as shown in fig 2 10 4 1 2 Adding engine oil Using premium four stroke engine oil recommended oil SAE 15W 40 Warm the engine up for about 5 minutes remove to oil drain screw to let all oil flow out Clean the oil screw and mount it Remove the oil gauge and the oil to the upper limitation position of the oil to the upper limitation position of the gauge Reinstall the oil gauge After adding fuel or engine oil the tank cap must be screwed on tightly Do not permit anyone except adult to add fuel or engine oil Add fuel in well ventilated area only The engine must be stopped when adding fuel and prevent fuel from spurting out onto the warm engine No smoking and fire when adding fuel The children should be far away when the adult is adding fuel Avoid contacting skin with the gasoline and breathing in gasoline vapors 4 2 Front and rear brakes 4 2 1 Brake and rear pedal Check for correct free play in the brake levers and brake pedal If the free play is incorrect adjust it Check operation of the brake levers and brake pedal They should move smoothly and there should be a firm feeling when the brakes are applied If not have the GO KART checked by the sales dealer 4 2 2 Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provid2. 3 2 Tire Mainly check the surface of tire and air pressure gauge Inspect if there are cuts in surface of tire and nails or stones bedded in the tire tread Check whether the depth of the tire tread is enough please replace the tires when the depth of the tire tread is less than 0 16 inch 4 0mm Air pressure in tire should be about 0 25kg cm 3 6psi Never under inflate or over inflate WARNING Operating the vehicle with excessively worn tires can cause skidding due to reduced traction Improper air pressure can affect handling characteristics under inflation could cause slip or skid off the tire bead over inflation can cause the tire to burst or tire serious damage Be sure to use equal air pressure in left and right tires Unequal air pressure may be adversely effect riders CONTROL Please replace the tire if they are extremely worn out It is very important to replace the tires we recommend that you let the dealer completes this work leaks due to a puncture should also be repair by dealer 8 3 3Braking system Inspect for brake travel The brake level travel should be between 5mm and 8mm to adjust the Brake level travel please use following procedure Loose the adjusting nut and adjust the brake level travel 27 After adjustment Hold the brake level and check whether the brake level travel is between 5mm and 8mm Periodically inspect the thickness of the brake pads When its warness more than Imm it shou
3. 6 4 Braking Release the throttle and hold the brake lever then force gradually the vehicle will decrease gradually until stop Avoid braking during turns Whenever possible use the brake to slow down before entering turns If the vehicle has to be braked while turning the brake lever should be used gently otherwise could cause the vehicle to slide or tip over easily Avoid braking quickly Use brakes for advance when riding in a rainy day 6 5 Stopping If the rider need to stop the vehicle while riding he she should first release the throttle Hold the brake lever to decelerate then put the engine cutoff switch to off position Shift into neutral WARNING After shutting off engine do not touch the engine and exhaust pipe so as to avoid being burned 6 6 Parking brake When parking the vehicle on a slope the parking brake should be used Hold the front brake lever and press the parking brake plate After releasing the brake lever the parking brake plate should not leap up This means that he parking brake plate has taken effect If you want cancel the parking brake You only need squeeze the front lever then the parking brake plate will pop out 7 Instructing the young rider To make your child ride this vehicle safely and familiarly you must take certain time to instruct him her The instruction includes the instruction before your child begins to ride and instruction and supe
4. GASOLINE ONLY Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston 3 Charging and Installation of Battery Before starting the vehicle install the battery first Before installing the battery pour in the electrolyte first Then press eh strip seal on the top cap firmly Charge the battery according to the battery service manual This will achieve the best starting effectiveness And prolong to the battery s life After charging install the battery into the battery case and tighten it firmly with tighten belt Never take out the seal plug so as to avoid causing danger such as the water entering into the battery and electrolyte leaks The battery should installed firmly no looseness Do not to connect the electrodes reversed Check red to red black to black Do not place the battery near high temperature fire and smoke 4 Checking before riding Before operating this GO KART be sure to check the items listed in the following table ITEM ROUTINE Fuel e Check fuel level in fuel tank and add recommended fuel if necessary e Check fuel line for leakage Correct if necessary Engine oil e Check oil level in engine and add recommended oil to specified level if necessary Check GO KART for oil leakage Correct if necessary Final gear oil Check GO KART for oil leaka
5. System Ignition switch OTE OFF s ee R Horn switch Flash oe A Turning switch brake switch Dy Horn oH 2v ath Bat tery Pe Brake lights rear Light lt 8 Left turn signal Left to li D Right to light ght Right turn signal 41
6. according to the introduction on the above chapter of the manual let the child practice the exercise of starting and parking Step 4 turning Explain the skill of turning to the child on a open and wide ground let your child practice first with the engine off as you push the vehicle from behind After your child is familiar with it she he can practice under power 21 Step 5 Putting all together When your child has mastered above steps you can let your child practice putting them all together until he she is familiar with them The above steps will help you guide your child master the most basic technique Your child will need a great deal of practice after these steps have been completed During this period guiding your child you must be patient and careful then you can realize the aim of the guide 8 Inspection and Maintenance It is very important to inspect and maintain your Go kart regularly If you have proper tools and are qualified you can perform the maintenance yourself according to the instructions in this section If you are not sure whether you can complete it please consult your sales dealer WARNING Keep the child far away when you perform inspection and maintenance to avoid injury 22 8 1 Periodic maintenance chart for the emission control system INITIAL EVERY CHECK OR Whichever month 1 3 6 6 12 No ITEM MAINTENANCE comes first Km 320 130
7. close to touch any moving parts or any heated areas such as the engine and exhaust pipe yx Do not allow the vehicle to be ridden at night because this vehicle is not equipped with a headlight IMPORTANT Please read this manual carefully You should pay special attention to these items wit WARNING and CAUTION words and must review the contents for the items Failure to follow WARNING instructions could result in severe injury or death to the GO KART operator a bystander or a person inspecting or repairing the GO KART CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the GO KART POTENTIAL HAZARD Improper handling of gasoline WHAT CAN HAPPEN Gasoline can catch fire and you could be burned HOW TO AVOID THE HAZARD Always turn off the engine when refueling Do not refuel right after the engine has been running and is still very hot Do not spill gasoline on the engine or exhaust pipe muffler when refueling Never refuel while smoking or in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock isinthe OFF position Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you
8. ea ene EEEE E A TT 20 INSPECTION AND MAINTENANCE 0 cceeeeceeneceeeeee cence en eeeeeeeeeeeeeeeaecees 22 Periodic maintenance chart for the emission control system cececeeeeeeeeeeeeeeees 23 General maintenance and lubrication chart ccececeeeec scene eeeceeeeeeeeesteseees 24 26 Toolkits ceee ng oidailh deep E da saue daveubs babs de bdebdadedde Vest dang crea demecte 27 PPG pgs tinier Stave eae e Ta E E eE E A ea ek ee wee teeta 27 Bralan SyStemtiessvcecievs canted secede nent EE E Supe valor eaciten ese ciowed OERE A N EEEN 27 28 Lubrication driven chain 0 ccece cence cence eee e eee ene eee e nee cent ea TE 28 Gear box lubricating oilen n o aaa eA E ESERE Sii 29 Inspection of battery anneer heken e E E EA A EE AA E N 29 Troubleshootitigichartss lt 3 scce ccte aen a a E Bases E RE 30 CLEANING AND STORAGE 0 cccececececeeeneeeceeeceeeeneneceeneceeeeeeneaeeneneneanees 31 CSA ear tk ich cra sire oe ath ae one teehee A Cle Sereda ot le EA E get Ua 31 SOTA Bes cies ca ciieasaave ced EUREI EEEN od Gua oies sega EEUE TECON SANESA AEAEE NEARNE TEARS 32 SPECIFICATION sern manatan n e a e cits cei aaerangaaeay EA E EAS 33 MAINTENANCE RECORD roeiers ana i ai a a a aiaia 33 WARRANTY etilar seata r a E r o R A Ea E E DLE 34 37 SPECIFICATIONS isis eerie ieee piae aI E EE onstage EE mc aea 38 40 AN IMPORTANT NOTE TO PARENTS This Go kart is not a toy Before you let your child ride this Go kart
9. on any public street road or highway even a dirt or gravel one This GO KART is designed and manufactured for use only off public roads yyNever operate an GO KART without wearing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots a long sleeved short or a jacket and long pants yy Never consume alcohol or drugs before or while operating this GO KART yx Never operate the GO KART on hills too steep for the GO KART or for your abilities Practice on smaller hills before attempting larger hills yx Never modify an GO KART through improper installation or use of accessories yy Never attempt wheelies jumps or other stunts yx Always inspect your GO KART each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual yxAlways keep both hands on the handlebars and both feet on the footrests of the GO KART during operation yx Always follow proper procedures for turning as described in this manual Practice tuning at low speeds before attempting to turn faster speeds and never turn at excessive speeds yx Never permit vehicle refueling by anyone other than an adult yx Never permit anyone other than an adult to start the GO KART yx Drain gasoline form the fuel tank and carburetor prior to transporting the GO KART yxCaution the child and others near the vehicle not to get
10. should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes seek medical help immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes Contents AN IMPORTANT NOTE TO PARENTS 0 c0cceceece ence eee ene eee ses e eeeeeeeeeeenees l LOCATION OF THE WARNING AND SPECCIFICATION LABELS 0 00ee 2 DESCRIPTION cAr A emus A E E tate ates a E O S 3 Serial number locatiotice a a EE a R E A ERRER 3 Location and function Of parts 00 ccc ccc cc ence ence ERa T AE rE Eai 4 TOMILOMIS WITCH ais s c okie ashes A stad cameneueine eee e eae mee a eancon Gans Neate abate atten Denia Ta 5 Remote engine stop SWItCh 0c s aea eee eee ea ease ea E O Parking brake Pleyer an orane aona ssw EEA AEE AET ASEA S EENAA a AAS 6 Throttle levet censo a dy E a N La Sais Vou E A EE EE A E eae gaa vale ees 6 Throttle limiter Screw ssccveus etecesend deugatiens denned aa ie EE ae ned pa Teenaa Eee 7 Fuel p tcock 2 te ete eth ee ee ee ee eg es 8 Chock leven arauan iai at EE Races Bene WWE ot Behe eh ES TEs HG Dat She ON 8 Shittt Pedals oy cevcwvarsayacensa esis dation sews ebavan es vice en seh gases egw NRE EE E otoes Dee 9 Fuel tank Cap ccistacniisaciectactatyehiinaghiaeniatiehdimieidurin EERE EEEREN 9 UG AEE T A A ka EN E EE E aon ne 9 Charging and installation of battery 0 0 ccecc cece e cece ee ee
11. you should understand the instruction and warming in this Owner s manual Then be sure your child understands and will follow them Children differ in skills physical abilities and judgment Some children may not be able to operate an Go kart safely Parents should supervise their child s use of the Go kart at all times Parents should permit continued use only if they determine that the child has the ability to operate the Go kart safely Your Go kart was delivered with an adjustable speed limiter and also with an air intake restrictor We Recommend that all beginners start off with the speed limiter screw turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn The limiter screw may be gradually turned out to increase maximum speed as the beginner becomes more familiar with operating the Go kart Parents should decide when to adjust the Go kart for more power as their youngster s riding skills improve Once the Go kart rider can operate with skill at the top speed permitted by adjusting the speed limiter alone the air intake restrictor plate can be removed Since removal of this plate will result in a significant increase in power turn the speed limiter back in again adjust it out in stages as you did before If you child is a beginner or is inexperienced he or she should take a training course See the previous page for information about the free training available to purchaser of new G Go k
12. 0 2500 2500 5000 JOB mi 200 800 1600 1600 3200 hours 20 80 160 160 320 Fuel line e Check fuel hoses for cracks or other damage J J J and replace if necessary Spark plug e Check condition and clean the gap or replace if y y J y J necessary Valves e Check valve clearance and adjust if necessary Vv J v Carburetor e Check choke operation and correct if necessary J J J J check engine idling speed and adjust if necessary Crankcase e Check breather hose for cracks or other damage d J J breather system and replace if necessary e Check for leakage and replace gasket s if J y J Exhaust system Pecessary eCheck for looseness and tighten all screw clamps and joints if necessary Spark arrester e Clean v 23 Let your sales dealer maintain the item with If you are not qualified it is better not to perform maintenance yourself or you may damage your vehicle The engine stop switch usually on the off position unless the engine be running to perform the required maintenance Keep Go kart far away form children when you do maintenance to avoid injury 8 2 General maintenance and lubrication chart INITIAL EVERY CHECK OR Whichever month 1 3 6 6 12 No ITEM MAINTENAN comes first Km 320 1300 2500 2500 5000 CE JOB mi 20200 800 1600 1600 3200 hours 20 80 160 160 320 1 x Timing chain e Check chain tension J J J J e Adjust if nec
13. 00km whichever comes first provided there has been no abuse neglect or improper maintenance of your vehicle Where a warrantable condition exists the Distributor will repair your vehicle at no cost to you Including diagnosis parts and labor if an emission related part on your vehicle is defective the part will be repaired or replaced by the distributor This is your emission control defects warranty OWNER S WARRANTY RESPONSIBILITIES As the vehicle owner you are responsible for the performance of the required maintenance You should maintain a record of all maintenance performed on your vehicle and retain all receipts covering maintenance on your vehicle You may not be denied a warranty claim solely because of your failure to ensure the performance of all scheduled maintenance or lack of maintenance records or receipts You are responsible for presenting your vehicle to an authorized dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30days as the vehicle owner you should be aware that you may be denied your warranty coverage if your vehicle or a part has failed due to abuse neglect improper maintenance or unapproved modifications 34 WARRANTY COVERAGE The distributor warrants that each new 2009 and later vehicle is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Enviro
14. 8 6928 INTRODUCTION Congratulations on your purchase of the Go kart This GO KART represents the result of many years of the factory experience in the production of fine sporting touring and pacesetting racing machines This manual will provide you with a good basic understanding of the features and operation of this GO KART This manual includes important safety information it provides information about special techniques and skills necessary to ride the Go kart it also includes basic maintenance and inspection procedures If you have any questions the operation or maintenance of your Go kart please consult the sales dealer SAFETY INFORMATION XAN GO KART IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE READ THIS MANUAL TOGETHER WITH TIPS FOR THE GO KART RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR GO KART MAKESURE YOU UNDERSTAND ALL INSTRUCTIONS amp PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE GO KART NEVER OPERATE AN GO KART WITHOUT PROPER TRAINING OR INSTRUCTION THIS GO KART AND ANY OTHER GO KART OVER 90cc SHOULD NOT BE OPERATED BY A CHILD UNDER 16 YEARS OF AGE THESE CHILDREN MAY NOT BE ABLE TO OPERATE THIS VEHICLE SAFELY DUE TO PHYSICAL OR MENTAL LIMITATION yx Always avoid operating an GO KART on any paved surfaces including sidewalks driveways parking lots and streets yx This GO KART is designed for operation by a single person or with one passengers only yx Never operate an GO KART
15. GK125 PGO MANUAL READ THIS MANUAL CAREFULLY BEFORE YOU USE THIS VEHICLE It contains important safety information Operating this ATV if you are under the age of 16 increases the chances of severe injury or death to both Operator and passenger NEVER operate this vehicle if you are under age 16 PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERATING THIS VEHICLE This GO KART should not be ridden by anyone under 16 years of age Improper use can result in SEVERE INJURY or DEATH ALWAYS USE NEVERUSE NEVER CARRY NEVER USE AN APPROVED ONPUBLIC MORE THAN WITH DEUGS HELMET AND ROADS 1 PASSENGER OR ALCOHOL PROTECTIVE GEAR FOR DRIVER AND PASSENGER NEVER operate without proper ATV teaining or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger unless pasenger seat is securely in place THE OPERATOR MUST ALWAYS e use proper riding techniques to avoid overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control reduce speed and use ectra caution at all times when carryig apassenger dismount passenger when conditions require make sure passenger reads and understands this label and passenger safety label LOCATE AND READ OPERATOR S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS ADD 12851 Reservoir St Chino CA91710 TEL 888 90
16. art s 01 LOCATION OF THE WARING AND SPECIFICATION LABELS XK Read and understand all of the labels on your Go kart These labels contain important information for safe and proper operation XK Never remove any labels form your Go kart If a label becomes difficult to read or comes off request a replacement label from your ales dealer 02 DESCRIPTION 1 serial number location Engine serial number and frame serial number VIN number are used to mark the motor vehicle if some parts need special service these marks can provide you or maintenance man some information Engine serial number is stamped on the topside of the engine transmission case Frame serial number VIN brand is located on the frame head pipe Please write down the engine serial number VIN number in the following blanks in the future Engine Serial Number Frame Serial Number 03 2 Location and Function of parts 2 Ignition switch 1 Brake pole 3 Pedal of the braking 4 Oil tank 5 Accelerograph 6 The cover of the oil tank 7 Luggage rack 8 Battery 10 Instrument and indicator light 9 Fuse 11 Shaft lever 04 2 1 Ignition switch Ignition switch is located at right side of the body which has two positions NO OFF and ST 0 NO Turn on power the vehicle is started the key amp Sy can be pulled out OFF Cut off power the vehicle could not be started the key can be pulle
17. cements as a result of e Accident e Misuse e Use of replacement parts or accessories not conforming to the original specifications which adversely affect performance 36 Physical damage corrosion or defects caused by fire explosions or similar causes beyond the control of the Distributor Failures not caused by a defect in material or workmanship Use of the vehicle in any type of competitive racing or related events immediately and completely voids this and all other warranties LIMITED LIABILITY The liability of the Distributor under this Emission Control System Warranty is limited solely to the remedying of defects in material workmanship by an authorized dealer at its place of business during customary business hours This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to from the authorized dealer The distributor is not liable to any person for incidental consequential or special damages of any description whether arising out of express or implied warranty or any other contract negligence or other tort or otherwise No express emission control system warranty is given by the Distributor except as specifically set forth hereon Any emission control system warranty implied by law including any warranty of merchantability or fitness for a particular purpose is limited to express emission control system warranty terms stated in this warranty the foregoing statements of warran
18. d out ST the switch is twisted to this location can start the engine brake pedal in the braking state Pulling the key out can prevent non owners from operating the vehicle 2 2 Rear Brake pedal Hold the rear brake lever with right foot The rear brake is in action the vehicle speed will decrease until the vehicle stops In addition hold the rear brake lever firmly start clutch engages then you can use the pedal lever to start the engine Brake pedal 05 2 3 Parking brake plate In addition hold the front brake lever firmly and press the parking brake plate It is used to prevent from slipping of itself Method firstly hold front brake lever Then press down parking brake plate to achieve parking brake 1 Parking brake plate 2 4 Throttle lever Used to control the vehicle speed Push the throttle lever forward throttle up accelerate the vehicle release the lever and reduce the speed until the vehicle is idle 2 Throttle lever 06 2 5 Throttle limiter screw The throttle limiter screw can restrict maximum engine power by limiting throttle lever travel thus restricting the vehicles maximum speed Adjust the throttle limiter screw according to the riders skill and experience Method loosen the lock nut Turn the throttle limiter screw clockwise to decrease the maximum speed or counterclockwise to increase the maximum speed after adjusting tighten the lock nut 1 Locknut 2 Ad
19. e proper braking performance check the brake linings for wear 5 Ride with care and good judgment 5 1 Get training if you are experienced Beginners should get training from a certified instructor Become familiar with this GO KART at slow speeds first even if you are experienced operator Do not attempt to operate at maximum performance until you are totally familiar with the GO KART s handing and performance characteristics 5 2 Not recommended for anyone under 16years of age OD 5 4 Apparel WARNING POTENTIAL HAZARD Operating this GO KART without wearing an approved motorcycle helmet eye protection and protective clothing WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or fact shield e golves e boots e long sleeved shirt or jacket e long pants 1 Protective clothing 2 Goggles 3 Gloves 4 Boots 5 Helmet 5 5 Do not operate after consuming Alcohol or drugs The operator s performance capability is reduced by the
20. eens ea eeeeeee senses eae eaeaens 10 Checkins before Tding oie secede ie e a dose dedeadedlsawieevaausaas eevee sislaasartned e S 11 Adding fuel and engine Oil 00 cece cece cece een e ec ecete teen eee eee eases snes ene eaeaenennenenens 12 Front and tear brakes ic setcaa ase a a ca daged a aeeeca taipihaiedai ihantesia haiti lo Ride with care and good judgment cece ccececee ec ence e eens eens eens eaeneneneeegened 14 Get training if you are inmexperienced 0 ccecece cence ene eee cee eens ea eneneneeneneenes 14 Not recommended for children under 16 years of age 0 0 ccecececeee eee ee eee enseestens 14 Apparel errare candy ara dhiectiaga ecs tees uiaeeG DE yea eB AESA ceva So ceph the 15 Do not operate after consuming alcohol or drugs cccececceeee ec eneee eee eneeeeeenens 16 Starting and tiding cc eierne Seen a aa wade daw yee dave oeden tage cts EE ESE 16 Starting the engine sass erer orots Orea segue aA RR gee pet AEO R Dea Er eer sron soent 16 RIGID E A E A aint AE E E A naa aea ieee co 17 PUTIN sk i A Me a ek E N E E hatin ie tae iat 18 PESTA hs aca tats hth c baa tle ee mate geet EEEE A N E tata ae 18 StOPPIN Gs dics ists tieatids waded a A E A tad ales Ret edu ada A E eb era neieaden bed ahetion 19 Parkin ge brake reset scenes silanes tite st tei Saalcds sh un diabetes ade a E doen aeaane E ORS 19 Instructing the young rider 0 cece cece cece nent cence eee EEEE ee
21. engine is running so as to avoid damaging the engine In order to save electricity in the battery don t press starting button more than 5 seconds at a time Intermittent time is less than 10 seconds If the engine fails to start after pressing the start button for 3 4 times or more than 15 seconds by pedal starting please check the vehicle In cold starting state the choke lever can t open too long after the engine is preheated otherwise the plug will deposit carbon and this will increase the oil consumption 6 2 Riding After the engine runs 30 40 seconds at idle speed and the riders is ready to ride While beginning to run just do not throttle up quickly When riding the rider should always pay his her attention to putting his her feet on the footrest Otherwise may cause the feet to touch the wheels or reduce the rider s ability to control the vehicle and could lead to an accident Step 1 apply the brake 2 push down shift from neutral to drive position if has the gear 3 throttle up gradually the vehicle begin to accelerate 6 3 Turning To turn the vehicle the rider should shift body weight forward and support weight on the outer foot Lean upper body into the turn and turn the handlebars in the direction of the turn The rider should first practice the turning technique in a wide open area until he she has mastered it then the rider and ride on the complicated road
22. essary 2 x An filter element e Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 3 Clutch e Check operation and adjust if necessary v v Ki e Check operation and correct if necessary 4 e Check brake lever free play and adjust if v J v Front brake necessary e Replace brake shoes Whenever worn to the limit 24 INITIAL EVERY CHECK OR Whichever month 1 3 6 6 12 No ITEM MAINTENANCE comes first Km 320 1300 2500 2500 5000 mi 200 800 1600 1600 3200 JOB hours 20 80 160 160 320 e Check operation and correct if necessary e Check brake lever and pedal free play and y y Ki J y 5 Rear brake adjust if necessary Replace brake shoes Whenever worn to the limit 6 Wheels e Check runout and for damage and replace if J Jj J J necessary e Check tread depth and for damage and 7 Tires replace if necessary af J J J e Check air pressure and balance and correct if necessary 8 Wheel hub bearings Check for looseness or damage and replace if J J J J necessary 9 Chassis fasteners e Make sure that all nuts bolts and screw are af of J J properly tightened 10 Shock absorber e Check operation and correct if necessary Check for oil leakage and replace if v v v assemblies necessary 11 Front knuckle pivots e Lubricate with lithium soap based grease 12 Steering shaft e Lub
23. ge Correct if necessary Front brake e Check operation and correct if necessary Lubricate cable if necessary Rear brake e Check operation and correct if necessary e lubricate cable if necessary e check level and pedal free play and correct if necessary Throttle lever e Make sure that operation is smooth and check cable free play e Lubricate cable and lever housing if necessary Control cables e Make sure that operation is smooth lubricate if necessary Wheels and tires e Check wheel condition and replace if damaged e Check tire condition and tread depth Replace if necessary e Check air pressure Correct if necessary Brake and shift pedals e Make sure that operation is smooth lubricate pedal pivoting points if necessary Brake levers e Make sure that operation is smooth lubricate pedal pivoting points if necessary Chassis fasteners e Make sure that all nuts bolts and screws are properly tightened Instruments and switches e Check operation and correct if necessary Battery e Check electrolyte level Fill with distilled water if necessary 11 4 1 Adding Fuel and Engine oil Check before riding add it in time if you find fuel is not enough Spilling gasoline can harm your vehicle any gasoline can damage painted surface Be careful not to spill any gasoline when fill the fuel tank Wipe spilled gasoline up immediately 4
24. icle is hard to start during operation please remove the battery and charge battery according to the manual Never open top cap strip and seal plugs when charging 29 9 Troubleshooting chart 1 Fuel There is enough fuel Check the fuel level in the fuel tank There is no fuel 2 Compression There is compression Check the ignition Operate the electric Have a sales dealer check the Go kart Check the compression The engine dose not start Supply fuel Check the compression starter There is no compression 3 Ignition Wipe off with a cloth and correct Open the throttle the spark plug gap or replace the gt halfway and operate Remove the spark plug spark plug the electric starter and check the electrodes mN Have a sales dealer check the Go The engine does not kart start Check the battery 4 Battery The engine turns over quickly The battery is good The engine does not start Have a sales Operate the electric starter Check the electrolyte The engine turns level recharge Hie dealer check over slowly battery and check the the Go kart lead connections 30 10 Cleaning and storage 10 1 Cleaning Frequent thorough cleaning of your Go kart will not only enhance its appearance but will improve its general performance and extend the useful life of many components 1 Before cleaning the Go kart a Block off
25. influence of alcohol or drugs IWARNING POTENTIAL HAZARD Operating this GO KART after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause your to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this GO KART 6 Starting and riding Before riding please read this section carefully 6 1 Starting the engine Insert the key into the ignition switch Now it on the OFF position Turn the fuel petcock to the ON position the engine kill switch to the RUN position the remote engine stop switch to the installed position Shift to neutral 6 1 1 Starting in cold state 1 Pull the choke lever out Turn the key switch to ON position After the rider bestrides on the saddles set the parking brake plate press the staring button with the left thumb then the engine should start up 6 1 2 Starting in warm state 1 Don t pull the choke lever and let it in the original position 2 Start the engine following the step 2 3 in 6 1 1 WARNING Do not start the engine in doors or with little or no ventilation release the throttle temporarily after the engine has started Do not press the thumb continuously on the starting button after the engine has started Do not press the starting button while the
26. justing screw 3 No more than 20mm 0 8in 07 2 6 Fuel petcock The fuel petcock is rotary valve between the tank and carburetor it has three positions ON when the lever in on this position the fuel will flows to the carburetor normal 1 riding is done with this position RES if you run out of fuel while riding turn lever to this position then refuel at the first opportunity OFF when the lever is on this position the fuel line is cut out when the engine is not running the lever should be set to this position 08 2 7 Choke lever Choke lever is located in the right side of the body It is used to increase the fuel air mixing ratio when the engine start in cold state Pull the choke lever out a position the engine is in start state After the vehicle start preheat the engine for 2 3 minutes then push it back to the b position it is in run state this time Fully open ON Half open warming up position Closed OFF Chock PANS 2 8 Shift pedal This GO KART is equipped with a constant mesh 3 4 speed transmission The shift pedal is located on the left side of the engine 2 9 Fuel tank cap 1 Remove the fuel tank cap by turning it counterclockwise Fuel tank cap 2 10 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown 1 Fuel level 2 Filler tube Recommended fuel UNLEADED
27. ld be replaced Often inspect the liquid level of brake fluid in the oil cup When the brake fluid level is below the mark line drain out the remaining brake fluid and fill new DOT3 brake fluid Always keep the brake disc and the brake pads clean 8 3 4 Lubricating driven chain Lubricating the driven chain frequently as necessary please use the following procedures Remove the chain by taking off the chain joint clip Wash the chain in the solvent and lubricate it with chain lube Remount it after lubrication Must be carefully during use of solvent keep children away from solvent When reinstalling the driven chain be sure to position the chain joint clip so the slit end faces opposite the turning direction of the driven chain as illustrated The driven chain will come off if you installed it improperly 28 8 3 5 Gear box lubricating oil Using good quality SAE 15w 40 motor oil Add oil according to the following steps Remove the rubber plug in the gearbox and add 400 450m1 oil Tighten the plug after adding and check if it is leaking Keep children away from oil After the new vehicle breaks in 20 hours change the oil in gearbox Clean the box with kerosene and the add new oil Check the oil level frequently and add it quickly if is not enough Oil under level or over lever can affect engine performance and cause trouble 8 3 6 Inspection of battery If you find the veh
28. ngle cylinder Battery 12V 4AH 150cc 12V9AH Start type Electric start Catalytic converter 1Catalytic converter single configuration Max Power 110cc 4 5kw 75001 min 125cc 5 6kw 7000r min 150cc 7 0kw 7500r min Exhaust emission control system Three way converter TWC Ignition CDI Front Brake disc brake Rear brake disc brake 12 Maintenance record Copies of work orders and or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty The chart below is printed only as a reminder to you that the maintenance work is required it is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF MILEAGE SERVICING DEALER NAME REMARKS month Km mi hours SERVICE AND ADDRESS 1 320 200 20 3 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 22500 14400 1440 60 25000 16000 1600 33 EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS The emission control system warranty period for this vehicle begins on the date the vehicle is delivered to the first purchaser other than an authorized dealer or the date it is first used as a demonstrator lease or company vehicle whichever comes first and continues for 30 months after that date or 50
29. nmental Protection Agency and the California Air Resources Board and is free from defects in material and workmanship which cause such vehicle to fail to confirm with applicable regulations of the united states environmental protection agency or the California Air resources board for the periods specified above Your emission control system warranty covers components whose failure would increase an engine s emission including electronic controls fuel injection system carburetor the ignition system catalytic converter or any other system utilized in this vehicle to control emission if it is original equipped Also included may be hoses connectors and other emission related assemblies Replacing or repairing other components including part labor and other cost not covered by this emission control system warranty or the standard warranty is the responsibility of the owner Coverage of repairs under this warranty applies only when repairs are completed at an authorized dealer or repair facility except in an emergency situation The use of replacement parts not equivalent to the original parts may impair the effectiveness of your vehicle s emission control system If such a replacement part is used and an authorized dealer determines it is defective or causes a failure of a warranted part your claim for repair to bring your vehicle into compliance with applicable standards may be denied 35 If an emergency situation exists when a warra
30. nted part or a dealer is not reasonably available to the owner repairs may be performed at any available service establishment or by the owner using any replacement part The distributor shall reimburse the owner for the expenses including diagnostic charges not to exceed the distributor s suggested retail price for all warranted parts replaced and labor charges based on the distributor s recommend time allowance for the warranty repair and the geographically appropriate hourly labor rate The owner may reasonably be required to keep receipts and failed parts in order to receive compensation This Emission Control System Warranty is in addition to the standard Limited Warranty EXCLUSIONS AND LIMITAIONS This warranty does not cover the following Failures or malfunctions of the emission control systems caused by abuse alteration accident misuse the use of leaded gasoline Replacement of expendable maintenance items unless they are original equipment defective in material or workmanship under normal use and the first required replacement interval for the item has not been reached Expendable maintenance items include but not limited to spark plugs filters coolant lubricants gaskets hoses and belts Replacements of parts and other services and adjustments for required maintenance Any vehicle equipped with an odometer or hour meter where the reading is altered so that actual mileage cannot be readily determined Repairs or repla
31. ricate with lithium soap based grease e Check operation and repair or replace if 13 Steering system damaged v v v v v e Check toe in and adjust if necessary 25 INITIAL EVERY CHECK OR Whichever month 1 3 6 6 12 No ITEM MAINTENANCE JOB comes first Km 320 1300 2500 2500 5000 mi 200 800 1600 1600 3200 hours 20 80 160 160 320 14 x Engineoi ee J J J J e Check ATV for oil leakage and correct if necessary 15 x Final gear oil e Change check ATV for oil leakage and correct if J J necessary jg l Mong pans cT ibiicate J Ix J J and cables Throttle lever e Check operation and correct if necessary 17 housing and check throttle cable free play and have a sales dealer y Ni v Wi af adjust if necessary cable e lubricate throttle lever housing and cable ig x Front and rear Check operation and correct if necessary p J J J J brake switches e Check electrolyte level and specific gravity and 19 x Battery correct if necessary v v v v v e make sure that the breather hose is properly routed NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas 26 8 3 1 Toolkit You are provided a tool kit for the convenience of inspection and maintenance as well as testing tire pressure Included are some general tools such as spanner box wrench and tire pressure gauge 8
32. rvision during ride Before you guide your child you should first read this manual familiarly and practice some basic function personally then tell me the main points especially the warning parts in this manual to your child carefully 20 Following is a step by step guide to help your child have a safe and enjoyable Go kart experience Step 1 proper clothing and protective gear Clothing and protective gear are necessary for child to ride safety The requirement for clothing is not wearing any loose fitting clothes so as to avoid causing danger In addition your child should wear long pants and a long sleeved shirt these protect against abrasive injuries and loss of body heat The protective gear such as helmet eye protection and gloves is necessary for the child to wear Step2 familiarity with the vehicle Your child should become completely familiar with the name and function of all controls Let the young rider sit on the vehicle with the engine off Demonstrate operation of the controls to the child Ask him her to do such things as start the engine turn off the engine lock the parking brake etc Practice this exercise until the child can operate all of the controls hesitation and without looking at the controls Step3 Starting up the stopping You can let the child sit on the vehicle You push the vehicle from behind this will allow your child to get feel of ridding a moving vehicle and become familiar with its operation Then
33. the end of the exhaust pipe to prevent water entry A plastic bag and strong rubber band may be used b Make sure the spark plug and all filler caps are properly installed 2 Ifthe engine case is excessively Greasy apply degreaser with a paint brush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job Once most of the dirt has been hosed off wash all surfaces with worm water and mild detergent type soap An old toothbrush or bottle brush is handy for hard to reach places 5 Rinse the Go kart off immediately with clean water and dry all surfaces with a chamois clean towel or soft absorbing cloth 6 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 7 Automotive type wax may be applied to all painted and chrome plated surfaces Avoid combination cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished cleaning Start the engine and let it idle for several minutes 31 10 2Storage 10 2 1Short term Always store your GO KART in a cool dry place and if necessary protect it against dust with a porous cover 10 2 2 Long term Before storing your GO KART for several months a a h i Follow all instructions in the cleaning section of this chapter Turn the fuel petcock lever to OFF Drain the carburetor float chamber by loosening the drain bolt this
34. ty are exclusive and in lieu of all other remedies All express warranties not stated in this warranty are disclaimed Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply if it is inconsistent with the controlling state law 37 SPECIFICATIONS 125CC Type 4 Stroke Passengers Allowed Two Displacement 124CC Suspension Hydraulic Cylinders l Front Brake Disc Cooling System Forced air Rear Brake Disc Clutch Type Automatic Centrifugal Fuel Tank Capacity 7 Liters Power Stipulated 5 0 kw 8000 rpm Engine Oil Tank Capacity 0 8Liters Max Torque 8 0N m 6500 rpm Engine Lubricating Oil 4 Stroke Oil 10W40 Starting System Electric Gear Oil Type 85W90 Starter Style CDI 38 SPECIFICATIONS 150CC Type 4 Stroke Passengers Allowed Two Displacement 149 6CC Suspension Hydraulic Cylinders l Front Brake Disc Cooling System Forced air Rear Brake Disc Clutch Type Automatic Centrifugal Fuel Tank Capacity 10Liters Power Stipulated 5 9kw 7000 rpm Engine Oil Tank Capacity 0 9Liters Max Torque 8 3N m 6000 rpm Engine Lubricating Oil 4 Stroke Oil 10W40 Starting System Electric Gear Oil Type 85W90 Starter Style CDI 39 SPECIFICATIONS 175CC Type 4 Stroke Passengers Allowed Two Displacement 168 9CC Suspension Hydra
35. ulic Cylinders l Front Brake Disc Cooling System Forced air Rear Brake Disc Clutch Type Automatic Centrifugal Fuel Tank Capacity 10Liters Power Stipulated 7 6kw 7000 rpm Engine OilTank Capacity 0 9Liters Max Torque 11N m 6000 rpm Engine Lubricating Oil 4 Stroke Oil 10W40 Starting System Electric Gear Oil Type 85W90 Starter Style CDI 40 Start up System Start relay brake switch Le bel OWE mer OFF T 12v4ah a I Battery Ignition switch i M Brake Viphts rear Light Charging System Lighting system Ignition switch HE Chznging light Switch HI w Lighting switch Eg 1av4ah L W Head ights High beam Y Yy oF Battery y Be me Rectifier Py T Magneto Instrument lights Instrumen lightis Brake lights rear Light t Ignition system B R aJ Orr l ST A Ignition switch CDI Ignition coils ie A Spark Plug Battery Has Jk E K CAM T BOE ADEA IRA Fl Signal
36. will prevent fuel deposits from building up Pour the drained fuel into the fuel tank Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel from deteriorating Perform the following steps to protect the cylinder piston rings etc from corrosion remove the spark plug cap and spark plug pour a teaspoonful of engine oil into the spark plug bore install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded this will limit sparking during the next step turn the engine over several times with the starter this will coat the cylinder wall with oil Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap Lubricate all control cables and the pivoting points of all levers and pedals Check and if necessary correct the tire air pressure and then block up the GO KART so that all of its wheels are off the ground Alternatively turn the wheels a litter every month in order to prevent the tires from becoming degraded in one spot Cover the muffler outlet with a plastic bag to prevent moisture from entering it Remove the battery and fully charge it store it in a cool dry place and charge it once a month do not store the battery in an excessively cold or worm place less than OF or more than 30F Note Make any necessary repairs before storing the GO KART 32 11 Specification Engine Air cooled 4 stroke si
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