AMERICAN SPORTWORKS LIMITED WARRANTY
Contents
1. 6 0 7mm Fuel Type ONLY USE Mid Grade Unleaded 89 93 Octane Capacities Maximum Load Driver amp Passenger 300lbs Fuel Tank 0 95 Gal Engine Oil 20 Oz Climbing Angle 20 25 Battery None Fuse None Top Speed 20mph Speed Reduction Kit Available 22 24mph Miscellaneous Brakes Rear Hydrau lic Disc Front Tire 145 70 6 10psi Rear Tite ea 16 80 7 S 10psi Front Suspension Independent Dual A Arm Rear Suspension S wing Arm Double Oil Damped Shock Restraint Sys tem 3 P oint Retractor Style Belt Final Drive Chain 420 5 8 Pitch Net We ight 300 Ibs PAGE 262. MY VEHICLE IDENTIFICATION NUMBER Record the VIN number and Model number of your ASW Fun Kart below for service and insurance records The VIN number can be found on the crossbar behind the seat Model 3170B ____ AMERICAN SPORTWORKS LIMITED WARRANTY American SportWorks hereinafter referred to as ASW hereby warrants to the original purchaser that the frame components of new ASW recreational vehicles will be free from defects in material and workmanship The period of warranty is thirty 30 days from date of purchase for the component parts except as noted below and ninety 90 days from the date of purchase for the frame ASW if notified of a defect in material or workmanship during the period of warranty will repair or replace at its option defective parts at no charge other than the reasonable cost for the transportation of the component s ASW will also agree to pay reasonable charges for labor if necessary to perform a warranty repair Proof of Purchase mustbe provided to an approved ASW service center before any warranty work is performed The original purchaser must operate the vehicle and maintain the vehicle in accordance with the instructions provided in the Operator s Manual the supplements hereto and labels affixed to the vehicle Additionally within the 10 days of the discovery of an alleged defect the original purchaser must provide written notification to ASW s Customer Service Department at 4404
3. 4h WARNING This Fun Kart is not designed for use on rental tracks of any kind PAGE 4 A WARNING NEVER adjust repair or clean the Fun kart while it is in motion A WARNING The safe operation of this Fun Kart is dependent upon the operator s ability to exercise proper judgment Operator and passenger must notbe too small or too large for controlled operation Operator and passenger must be of sufficient age understanding mental capacity and physical capacity to safely operate the Fun Kart Fun Kart should only be operated after mature supervised instruction and sufficient practice in an un congested area A WARNING Operator and any passengers MUST always wear a properly fitting motorcycle helmet ap proved by agencies such as the Department of Transportation DOT Safety Helmet Council of America SHCA or Snell Memorial Foundation SNELL Mostaccident fatalities are due to head injuries Operator and any passenger should also wear face shields or goggles boots gloves and other appropriate protective clothing See KART OPERATION on Page 19 A WARNING Long hair loose clothes or jewelry can get caught in moving parts below and behind the seat or surrounding environment Remove or tie back anything loose that can reach below and behind the seat before riding A WARNING NEVER place hands feet or any body parts or clothing near the engine wheels chain
4. 2 Clean any excess dirt oil or dust from the air cleaner box with a mild detergent and water solution 3 Thoroughly dry the air box 4 Replace the air cleaner element 5 Replace the cleaner cover B Engine Lubrication URETHANE You MUST change the oil in the crankcase after the first 5 hours of operating a FOAM new engine The engine oil should then be changed every 10 hours of use thereafter This will ensure proper lubrication of the internal parts and prevent costly repairs due to excessive wear A CAUTION This unit has been shipped with special BREAK IN oil pre filled in the engine crankcase This oil MUST be changed after 5 hours of operation Replace with SAE 10W30 weight motor oil as described in the following section 4 WARNING 1 Remove the drain plug located on the bottom of the E L S f h Y right rear side of the engine Elevating the front of the YAS kart slightly will help drain all of the oil 2 The oil should be emptied into a suitable container for recycling gt 3 With the oil completely ne drained DRAIN PLUG OIL GAUGE replace the drain plug and tighten securely GASKET 4 Place the kart back onto a flat surface to level the engine and Re fill the crankcase with 200z of SAE 10W30 motor oil 5 Check the oil level using the dipstick attached to the oil fill cap Be sure to check the oil level before each use of the PAGE 21 kart Add oil when necessary to
5. aap ap H Rear Spoiler ui pa ice e KART FEATURES AND LOCATIONS eccocciccnccnoncncnnnnnnconnnonnnnnncncnnnnncnnnnonononan non rn ano ro nan anonon concurran cnn AS AMECA iio da eds fee Engine Lubica inicia E TAE Cleaning Instructions General Lubrication E Chain Lubrication and E nt gmo miog L Storage INS tU aeeoe eesis eira ene a AR DEIENE ETERRA aene 24 sevens 24 a 24 sevens 24 24 GENERAL MAINTENANCE Ser PENi A Front Wheel o O wei B Rear Wheel Replacement C Front Wheel Alignment tics D Optional Speed Reduction Installation REPLACEMENT PARTS AND SERVICE coocccccocococoonononoononconanncnonnononononan ocn nnan crono non onon stiai 2d Periodic Checks amp Services Engine Startim 9 iii ati titles Engine Stop S Witch vitrina di ita testa E aa a aE Seat AGUS HME itennu e e opina i Occupant Rest aints nai la riego A ES Carburetor AdjustMEDt sic i eers issii retiren pei naL 2 sie 22 45 22 A A ME A IO BW QQ ua 11 11 13 13 13 13 15 16 18 18 18 18 19 19 19 19 20 21 21 21 22 22 23 23 25 26 FORWARD Congratulations on the purchase of your ASW Fun Kart Before operating this vehicle the owner and each operator must understand that this vehicle was not designed or manufactured to meet specifications for use on public roads streets highways and thoroughfares The owner operator s and passenger s must
6. Check that all other fasteners are secure Make sure all brush bars are in Replace damaged bars or fasteners and 8 Brush Bars place and securely attached tighten as necessary Make sure steering turns freel 9 Steering g y Lubricate and adjust as necessary Check for proper toe in of wheels Check for bent or otherwise 10 Frame Chassis damaged frame and or other Replace as necessary chassis components Check all guards covering moving Tighten fasteners on loose guards Replace 12 Guards parts worn or damaged guards PAGE 15 ENGINE STARTED CHECKLIST ITEM INSPECTION PROCEDURE ACTION 1 Stop Switch Perform stop switch test Repair replace as necessary 2 Throttle Check idle adjustment Adjustas necessary 3 Brakes Ensure brakes function properly Adjust replace as necessary SAFE DRIVING PRECAUTIONS Off Road Use Only Your kart and its tires are designed and manufactured for off road use only not for use on paved surfaces Driving on paved surfaces can affect the kart handling control and cause excessive wear to your tires 4A WARNING Operating this kart on paved surfaces may seriously affect handling and control of the kart and may cause the vehicle to go out of control When driving off road also remember to always obey local off road driving laws and regulations Obtain permission to drive on private property Avoid posted areas and o
7. Engle Ridge Drive Fort Wayne IN 46804 The repair or replacement of any part or parts under this Limited Warranty shall not extend the term of the warranty beyond the original term as set forth above General Exclusions This limited warranty does not cover component failure or damage caused by any of the following abnormal strain or stress neglect abuse improper assembly of components which were supplied in the factory sealed carton after the vehicle left ASW improper maintenance improper use of the vehicle including but not limited to racing jumping stunt driving or any other uses prohibited by the Operator s Manual Additionally this warranty does not cover component failure or damage to vehicles which are leased or rented or vehicles which are used at a concession track Specific Exclusions This limited warranty does not apply to components which are subject to normal wear and tear These items include but are not limited to the tires brakes throttle shift and brake cables drive belt the torque converter system chain seat lights fasteners decals or cosmetic body panels and natural discoloration of material due to ultraviolet light Downtime pick up and delivery charges are not covered by this warranty This warranty does not apply to the engine which is covered by its manufacturers warranty ASW MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU
8. PROCEDURE ACTION Engine Oil Level Add oil if required Check for leaks Tighten filler cap securely Refer to operator s manual Add fuel if necessary DO NOT overfill Refer to operator s manual 2 Fuellevel aan DO NOT refuel a hot engine Allow engine to DO NOT mix oil with gas cool before adding fuel Replace cap tightly Make sure all warning decals are 3 Warning Decals g Replace as necessary legible and securely attached Tread must have a minimum height of 1 8 at center of tire Prior to operating vehicle check Replace tires if tread height is less than 1 8 4 m and adjust tire pressure as at center of tire Add or remove air as Tires ar indicated on the sidewall of each necessary to meet requirements indicated tire A tire pressure gauge is on sidewall of each tire required to obtain accurate readings 5 Drive Train Check condition and tension Lubricate adjust tension as necessary Check for smooth operation Ensure throttle snaps back to Replace damaged cable e Hhrotie idle Clean out any mud and debris If ice is Check for frayed or loose cable present move Fun kart to a warm place and Check for mud debris and ice in allow the ice to melt and water to dry throttle mechanism Check wheels to see that all axle nuts are tightened securely o ae 7 Tighten fasteners as necessary 7 Fasteners Check for missing fasteners Replace fasteners as necessary
9. a small amount of alcohol can impair your ability to operate a kart safely Likewise drugs even if prescribed by a physician can be dangerous while operating a kart Consult your doctor to be sure itis safe to operate a vehicle after taking medication A WARNING Operating this kart after consuming alcohol or drugs can seriously affect your judgment cause you to react more slowly affect your balance and perception and could result in serious injury or death Never consume alcohol or drugs before or while operating this kart IS YOUR VEHICLE READY TO DRIVE Before each drive it is important to inspect your kart and make sure any problems you find are corrected A pre drive inspection is a must not only for safety but because having a breakdown or even a flat tire can be a major inconvenience If your kart has overturned or has been involved in a collision do notdrive it until your kart has been inspected by your dealer There may be damage or other problems that you cannot see A WARNING Improperly maintaining this kart or failing to correct a problem before driving can cause an accident resulting in serious injury or death Always perform a pre drive inspection before every drive and correct any problems Pre Ride Inspection The following checklist should be utilized to inspect your vehicle before each use to ensure that it is in proper working order PAGE 14 ENGINE STOPPED CHECKLIST ITEM INSPECTION
10. keep the oil level between the bottom of the dipstick and the O mark NOTE Oil level should be checked by dipping the oil level stick into the crankcase WITHOUT screwing the cap in C Spark Plug DIRT CARBON 1 Remove and inspect the spark plug each time you change the oil TE o6 0 7mm The electrodes should be kept clean and free of carbon The presence of carbon dark matter or excess oil wet will greatly reduce engine performance If possible check the spark plug gap area between the electrodes using a wire feeler gage or spark plug gap tool 2 Correct gap is 0 6 07mm 3 Before installing the spark plug coat the threads lightly with graphite lubricant to ensure easier removal of the plug in the future Spark plug should be replaced once a year for optimum engine 8 performance D Carburetor Adjustment All the necessary carburetor adjustments have been made at the factory and the recommended settings are correct for most applications To adjust the engine idle setting on the carburetor 1 Allow the engine to warm up for 5 10 minutes oe 2 Using a Phillips screwdriver adjust the idle screw shown until Idle Screw the engine settles at approximately 1400RPM NOTE For further carburetor adjustments refer to the Engine Service Manual available online from Robin Subaru at www robinamerica com INS i 2 E Cleaning Instructions Keep your kart clean by using a clean rag and a mild detergent and water
11. may result in Death or Injury This information is contained in the Warning Labels Owner s Manual amp Supplements Safety Video and Engine Manual supplied with this product Make sure that you understand and follow all Warnings and Instructions in this material Read owner operator manuals carefully Adult supervision required and protective clothi Do NOT ope properly and belt must be fastened and brake r ride aft her intoxicants If you did not receive any of the material listed above please call 1 800 643 7332 and request to have them sent to you at no charge 11 suming a NO RIDING All occupants must be inside the vehicle and wearing the proper restraints and safety gear Absolutely no riding on the outside of the vehicle or on the cargo rack EXHAUST GAS HARMFUL Engine exhaust from this product contains chemicals known in certain quantities to cause cancer birth defects or other reproductive harm 1133 LIGHT CARGO ONLY This rack is intended for light cargo only not exceeding 25 Ibs All cargo must be secured with proper tie downs WEAR A HELMET Always wear a D O T approved motorcycle helmet when operating this vehicle 11 CAUTION USE ONLY MID GRADE UNLEADED GASOLINE 89 93 OCTANE This engine is not designed for fuels other than automotive gasoline Attempting to use anything other than this will cause damage to the engine 11330 4 QUALIFICATIONS FOR FUN KART USERS This Fun Kart is r
12. ment parts are not available from a dealer they may be ordered directly from American SportWorks at 1 800 643 7332 or online at www amsportworks com Orders may be subject to a minimum fee A listing of authorized service center locations in your area is also available from our Customer Service department Record the vehicle VIN number in the spaces provided at the front of this manual The VIN number can be found on the crossbar behind the seat Periodic Checks amp Services The maintenance intervals in the following table are based upon average driving conditions Driving in unusually dusty areas may require more frequent servicing Item Initial Service Monthly Quarterly Yearly First Week Tire Pressure Wear I Inspect Daily Brake System I I Fastener Tightness I I Air Cleaner R Carburetor I C Spark Plug C A R Brake Fluid I I Engine Oil R 5hr R every 10hr Chassis C I L Fuel Filter I R Drive Chain Tension I A 2 hours LA A Adjust C Clean I Inspect L Lubricate R Replace PAGE 25 SPECIFICATIONS Dimensions Overall Leng th 71 0 in 1803mm Overall Width 47 0 in 1194mm Overall Height 49 0 in 1244mm Wheelbase 5 1 0 in 1295mm
13. read and understand all the instructions for proper assembly and safe operation as well as the instructions conce ming the engine and all other portions of the vehicle as described and illustrated in this manual and on the included safety DVD Children must be of the specified age or older and supervised by an adult at all times when using the Fun Kart Be sure to follow the recommended maintenance schedule and service your kart accordingly Preventative maintenance is extremely important to the longevity of your kar NOTE A new kart requires an engine break in period of 5 hours whereby the engine oil MUST be changed See Engine Lubrication section page 21 Beginners are urged to seek instruction from a dealer or qualified instructor before and during the initial use of this kart It is also recommended to practice in a large open area to become familiar with the operation of the kart We hope you will have a fun safe experience with our products and thank you again for choosing an ASW Fun Machine CAUTIONS AND WARNINGS A This is the safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury A Read and follow all instructions in this Owner s manual and any accompanying supplements before attempting to operate this Fun Kart Make sure to view the Operations and Safety video amp WARNING Indicates a potential hazard that could result in severe personal injury or de
14. solution Wipe off all dirt and oil from around the controls Wipe off any spilled fuel and oil Keep the engine clean and clear of foreign objects especially those around the air intake fan and air inlet ductwork F General Lubrication Lubricate the vehicle at least every 90 days and more often if the kart is used daily or in unusually dusty conditions G Chain Lubrication and Adjustment For optimum chain life lubrication with a spray on chain lubricant should be performed on a regular basis DO NOT USE OTHER OILS PAGE 22 A new chain will stretch within the first few hours of use and therefore will require adjustment The first chain adjustment should be made after the first 2 hours of use If the chain has more than Y of slack or flex then it will require adjustment To adjust 1 Loosen Nut 1 2 Adjust nut 2 until the proper chain tension is achieved 3 Re tighten Nut 1 H Belt Replacement Ensure the kart is on a smooth flat surface and the engine is OFF Apply parking brake Remove the three mounting bolts for the belt cover Remove mounting screw located behind the belt cover at the bottom Using a 1 2 socket or box wrench remove the drive front pulley mounting bolt and pull the pulley off the crank shaft If the existing belt is still in tact remove existing belt If not look for anything that may have caused the belt to fail prematurely Inspect and clean pulley with dry cloth or comp
15. the Fun Kart is in safe operating condition WARNING Prevailing torque type locknuts must be replaced with new after the old locknuts have been removed Replace with the same type of locknut to make sure they function properly Refer to the maintenance section for more information on locknuts WARNING Keep the engine free of dirt and debris especially in the throttle linkage area A WARNING NEVER start the engine without the operator properly seated and the restraint system properly adjusted and secured PAGE 6 4 WARNING NEVER start the engine without checking to see that the throttle control is in idle position A WARNING NEVER tamper with alter or change the Fun Kart s engine governor settings The governor as set by the engine manufacturer limits maximum engine speed and protects the engine from damage Excessive engine speed is potentially dangerous to operator passengers bystanders and A WARNING Check fuel supply before each use NEVER fill fuel tank while the engine is running or hot DO NOT overfill tank ALWAYS allow at least 2 of expansion space at the top of tank There shoud not be any fuel in the filler neck Replace cap tightly to prevent a fuel spillage fire hazard NOTE Always use an original gas cap or OEM replacement NEVER fill fuel tank while the Fun Kart is inside a building After filling the tank move the Fun Kart at least ten feet before atte
16. the Fun Kart with long hair loose clothes or jewelry that can get caught in moving parts below the seat or surrounding environment Remove or tie back anything loose that can reach belowor behind the seat before riding PAGE 11 11 10 12 13 14 Fun Kart operators and passengers shall adhere to all manufacturer s recommendations and instructions as well as comply with all laws and ordinances and the following a Operators shall stay seated with both hands on the steering wheel and both feet in the Fun Kart at all times whether moving or stationary unless the Fun Kart is stopped completely and the engine has been shut off b Passengers shall remain seated with arms and legs inside the Fun Kart at all times during Fun Kart operation c Shall observe minimum age restrictions d Shall not ride the Fun Kart if long hair loose clothes or jewelry reach below or behind the seat A WARNING Long hair loose clothes or jewelry can get caughtin moving parts below and behind the seat or surrounding environment Remove or tie back anything loose that can reach below or behind the seat before riding e Shall not allow smoking in the Fun Kart f Persons under the influence of drugs alcohol or intoxicants shall not supervise operate or ride in a Fun Kart g Fun Karts shall operate only on a surface or terrain recommended by the Fun Kart s manufacturer h Fun Karts shall not be operated on roads street
17. Front Track C L of Tire 41 5 in 1054mm Rear Track C L of Tire 35 0 in 889mm Ground Clearance 6 0 in 152mm Engine Type S ingle Cylinder Oil amp Air cooled 4 S troke Engine Capacity 169cc Bore Stroke 67 0mm x 48 0mm Dis placement 169 0 cm Corrected Compression Ratio 8 5 1 Carburetor Z6Y4 Maximum Horsepo wer 5 7 hp 4000rpm Maximum To 1q ue 8 3 ft lbs E 2500rpm Starting Pull Recoil Ignition Induction Lubrication Splash S AE 10W 30 Trans mis sion C VT automatic Spark Plug BR 6HS NGK Plug Gap
18. LAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITATIONS SPECIFIED IN THE WARRANTY ABOVE ARE HEREBY DISCLAIMED BY ASW AND EXCLUDED FROM THIS WARRANTY ADDITIONALLY THIS WARRANTY EXCLUDES ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE SOME STATES DO NOT ALLOW A MANUFACTURER TO EXCLUDE OR LIMIT INCIDENTAL OR CONSEQUENTIAL DAMAGES AND THEREFORE THE ABOVE EXCLUSION MAY NOT APPLY TO YOU SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY WILL LAST IT IS POSSIBLE THAT THE ABOVE LIMITATION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE PAGE 1 TABLE OF CONTENTS AMERICAN SPORTWORKS LIMITED WARRANTY FORWARD a CAUTIONS AND WARNINGS IMPORTANT SAFETY INFORMATION 0 ceeseseceesceetessneeecoesececseseeesescnssuescaececsnsceesanecesanaeneees SAFETY LABELS has QUALIFICATIONS F FOR FUN KART USERS Consumer Responsibility for Safe Use and Maintenance of a Fun Kart eee eee eeeeeneeees Protective ADD rei re Helmeta d Bye Pro te COM idilio A adi Additional Driving Gear A AA R ER ES a14 vee 14 14 Driver Training No Alcohol or Dane ns IS YOUR VEHICLE READY TO DRIVE Pre Ride Inspection 16 SAFE DRIVING PRECAUTIONS As Operation controls cetro da seasons A 2 3 to oh safc cae eee e 88 dec eater ania at te a 18 Brake occas
19. and other rotating parts of the Fun Kart while riding or running the engine Use caution in performing required maintenance on or near operating engine Use caution after the engine has been running since the engine and other drive components may be extremely hot 4h WARNING STOP the engine if the Fun Kart makes unusual noises or vibrations Check the Fun Kart for damage Excessive noise or vibration is a sign of loose or wom parts PAGE 5 amp WARNING Keep guards in place at all times Prevent accidental contact by the operator or service personnel while the Fun Kart is running The guards over the brake clutch or torque converter axle and drive sprockets also help prevent mud and debris from coming in contact with those items 4h WARNING Be sure the passenger restraint system i e Seat Belt is properly adjusted and fastened at all times during operation If the passenger restraint system is not properly used by the operator and or passengers loss of control and possible personal injury and or Fun Kart damage can occur A WARNING When there is no passenger in the Fun Kart the passenger seatbelt must be securely fastened within the Fun kart Ifthe passenger restraint system is not properly used by the operator and or passenger loss of control and possible personal injury and or Fun Kart damage can occur amp WARNING All screws nuts and bolts must be properly tightened to make sure
20. ath amp CAUTION Indicates a potential hazard which may result in personal injury or damage to the Fun Kart NOTE Use of the word NOTE will alert you to key information or instructions PAGE 3 IMPORTANT SAFETY INFORMATION amp WARNING Exhaust fumes are toxic California Proposition 65 WARNING Gasoline engine exhaust from this Fun Kart contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The engine exhaust contains carbon monoxide which is a tasteless odorless poisonous gas NEVER operate this Fun Kart indoors or in an enclosed area without adequate ventilation 4 WARNING This Fun Kart may have been supplied to you completely assembled To prevent injury or death read and follow the assembly instructions to make sure the Fun Kart was assembled properly WARNING Check tire pressure before each use Prior to operating the vehicle check and adjust tire pressure to the proper operating pressure as indicated on the sidewall of each tire A tire pressure gauge is required to obtain accurate readings A WARNING Fun Kart modification or removal of original equipment or safety decals can render the Fun Kart unsafe for operation amp WARNING Safety decals must be replaced if they become unreadable or detached from the Fun Kart If decals are unreadable or missing waming of potential hazards or safety requirements may be lacking
21. ating the Fun Kart in conditions where water mud snow dirt sand or other debris can get into the throttle cable conduit and or on the throttle mechanism can cause binding of the cable and or the throttle mechanism This may result in the throttle sticking which can cause the engine to continue to run and result in loss of control 4h WARNING Assembly maintenance and or repair of this Fun Kart should only be performed by designated dealers or authorized small engine centers for engine repairs so that no unsafe conditions or modifications are made A WARNING Read and keep all supplied printed material Supplements to this Operator s Manual contain updated information relative to your specific Fun Kart model It is important to keep all of these documents for reference A WARNING When making repairs or adjustments to the Fun Kart the spark plug wire MUST be disconnected and kept away from the spark plug to prevent accidental starting When working on around or restarting the engine use extreme caution to avoid contact with the muffler cylinder head or any potentially hot area on or around the engine Ensure that all guards are in place prior to starting the engine PAGE 8 A CAUTION During Fun Kart storage keep it in a place where gasoline fumes will not reach and open flame spark or other source of ignition For long term storage fuel tank should be drained in an open cool area Engine must be a
22. bey NO TRESPASSING signs You should never drive your kart on public streets roads or highways even if they are not paved Drivers of street vehicles may have difficulty seeing and avoiding you which could lead to a collision 4 WARNING Operating this kart on public streets roads or highways could result in a collision with another vehicle Never operate this kart on any public streets roads or highways whether they are dirt gravel or paved surfaces Keep Hands and Feet on Controls When driving your kart always keep both hands on the steering wheel and both feet on the foot controls It is important to remain alert and remain focused when driving the kart Removing hands or feet from the controls can reduce your ability to react and maintain control of the kart WARNING Removing your hands from the steering wheel or feet from the foot controls during operation can reduce your ability to control the kart and could result in a collision Always keep both hands on the steering wheel and both feet on the foot controls of your kart during operation Control Speed Driving at excessive speeds increases the likelihood of an accident In choosing an appropriate speed you must cons der the capability of your kart the terrain visibility and other operating conditions in addition to the skill and experience of the driver PAGE 16 4h WARNING Operating this kart at excessive speeds increases your chances of losin
23. d securely h That the braking system is functioning properly i That all safety labels are in place legible and understood j That any and all axle guards chain guards torque converter covers or other covers or guards supplied by the manufacturer are in place and in serviceable condition k That tires are in good condition inflated properly and have sufficient tread remaining and That all fasteners are in place and tightened securely Fun Kart engines shall not be started unless the operator is seated in proper position for vehicle operations and the brake fully engaged and locked with park brake mechanism Long hair loose clothes or jewelry can get caught in moving parts below the seat or surrounding environment Remove or tie back anything loose that can reach below or behind the seat before riding Fun Karts shall only be fueled by a supervisor knowledgeable with regard to proper fueling techniques A supervisor shall verify personally that everyone operating or riding is knowledgeable capable and has the cognitive capacity to operate the Fun kart safely including those items specified in 1 through 6 a The supervisor shall only allow the use and operation of the Fun Kart after demonstration that each operator can understand and operate all components of the Fun Kart prior to use b The supervisor shall provide continuous supervision during Fun Kart use c The supervisor shall not allow anyone to ride in or operate
24. d slows or stops the kart The locking lever can be applied to actas a park brake and should remain applied during starting and engine warming choke cycle D Engine Starting Apply foot brake and ensure the Engine Stop Switch is in the RUN ON position Have a supervisor start the engine by opening the choke located on the engine then pulling the recoil starter NOTE Your Fun Kart is equipped with 2 engine stop switches one located on the dash and one located on the engine electrical cover BOTH switches must be in the RUN ON position for the engine to start Engine Stop Switch Brake Pedal The engine will warm up within 5 minutes allowing the engine to operate at the normal RPM The choke may be closed at this time On a warm day this period of time may be reduced to less than 1 minute CAUTION This unit has been shipped with special BREAK IN oil pre filled in the engine crankcase This oil MUST be changed after 5 hours of operation Replace with a 10W30 weight motor oil as described in the SERVICE section of this manual PAGE 18 E Engine Stop Switch Before driving this vehicle test the Engine Stop Switch to ensure that it is operating properly With the engine running switch the Engine Stop Switch to the STOP OFF position to shut down the engine F Seat Adjustment The unit is equipped with an adjustable seat To adjust lift the lever justin front of the seat bottom between the driver
25. els should be set with a toe in from 1 4 to 1 2 At the centerline of the tires measure the Distance A and the Distance B For proper toe adjustment Dimension A should be 1 4 1 2 greater than Dimension B While adjusting ensure rubber boots are in good condition To make adjustments 1 Loosen the lock nuts on both sides of Front Tie Rods 2 Ensure the steering wheel is centered and adjust Dimension B by equally rotating the tie rods in orout with a 12mm wrench 3 After adjusting to the desired length tighten the lock nuts against the Tie Rods 4 Recheck the dimensions for proper alignment Lock Nuts E rj A A Left Rotate L y K Right Rotate CIS A Y Right Rotate gt __ Left Rotate Y B d Tie Rod Toe Adjustment Diagram D Optional Speed Reduction Installation This kart has been equipped with provision for a speed reduction kit to reduce the overall speed of the unit to 20mph max This kit is available from your dealer or directly from American SportWorks by calling customer service at 1 800 643 7332 Or visit our website at www amsportworks com PAGE 24 REPLACEMENT PARTS AND SERVICE Most replace ment parts are typically available from your dealer Because of immediate availability and convenience it is recommended that replacement parts be ordered from an authorized dealer Take this manual and all supplements to the dealer when ordering parts in person If replace
26. estricted to use by operator and passenger with a minimum age of thirteen years Fun Karts are intended for use by operators who meet the physical and cognitive capabilities set out by the manufacturer in the material provided with the Fun Kart A 20mph speed reduction kit is available for this fun kart Consumer Responsibility for Safe Use and Maintenance of a Fun Kart Fun Karts shall not be modified from the manufacturer s original design and configuration Fun Karts shall not be used to perform racing stunt riding jumps spinouts donuts or other maneuvers as they may cause loss of control As such these activities are likely to result in possible injury to the operator passenger bystanders or all Prior to each use the operator shall perform the preoperational checks specified by the manufacturer and further verify a Smooth throttle operation and positive retum of the throttle linkage to a closed throttle position when released b That the throttle cable and linkages operate properly and the throttle cable or other linkages are adjusted properly That the steering linkage is adjusted and operates smoothly That the engine stop switch is properly functioning c d e Thatallguards originally supplied by the manufacturer are in proper place in serviceable condition f That engine idle speed is below the point of clutch or torque converter engagement g That the gas tank is in good condition and the proper gas cap is fastene
27. g control of the kart resulting in an accident Always drive ata speed thatis appropriate for your skill your kart the terrain visibility and other operating conditions Use of this Karton Unfamiliar or Rough Terrain Before driving in an unfamiliar area always check the terrain thoroughly Don t drive fast on unfamiliar terrain or when visibility is limited it is often difficult to react to hidden obstructions like rocks bumps or holes WARNING Failure to use extra care when operating this kart on unfamiliar terrain could result in the kart overturning or going out of control Go slowly and use extreme caution when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the kart Never drive past the limit of visibility Maintain a safe distance between your kart and other off road vehicles Always exercise caution and use extreme care on rough slippery and loose terrain 4 WARNING Failure to use extra care when operating on excessively rough slippery or loose terrain could cause loss of traction or vehicle control resulting in an accident or overturn Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the kart on such terrain Always be especially cautious on these types of terrain Do Not Perform Stunts You should always operate your kart in a safe and reasonable manner When driving a
28. l Foundation SNELL sticker on any helmetyou buy Always wear a face shield or goggles to protect your eyes and help your vision WARNING Operating this kart without wearing an approved motorcycle helmet eye protection and protective clothing could increase your chances of head and or eye injury and the possibility of death in the event of a severe accident Always wear an approved motorcycle helmet that fits properly eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Additional Driving Gear In addition to a helmet and eye protection we also recommend Sturdy off road motorcycle boots to help protect feet ankles and lower legs Off Road motorcycle gloves to help protect your hands Driving pants with knee and hip pads a driving jersey with padded elbows and chest protection Driver Training Developing your driving skills is an ongoing process Even if you are and experienced driver take time to become familiar with the kart controls and how the kart handles Practice driving in a safe open area to develop your skills Do not drive on rough terrain until you get accustomed to the kart controls and feel comfortable with its size and weight PAGE 13 4 amp WARNING Operating this kart without your seat belt could cause you to be thrown from the kart causing serious injury or death No Alcohol or Drugs Alcohol drugs and karts don t mix Even
29. llowed to cool before storage in any enclosure NEVER store the Fun kart in close proximity to appliances such as hot water heaters or furnaces A WARNING NEVER operate the Fun Kart while under the influence of alcohol drugs or medication of any kind Such operation is dangerous to yourself and or others CAUTION Brush Bars assembled to this Fun Kart are for decorative purposes and limited brush protection Brush Bars were not designed for roll over or to restrict all brush or tree branches from protruding into operator passenger compartment A CAUTION If the Fun Kart should start making an unusual noise or vibrating abnormally the engine should be stopped and the spark plug wire disconnected The vehicle should then be checked for damage Excessive noise or vibration is generally a warning of loose or worn parts SOME WORDS ABOUT SAFETY The following pages present important information and recommendations to help you drive your Kart safely Please read through these pages thoroughly and view the Kart Safety DVD that was included with your unit PAGE 9 SAFETY LABELS The following labels have been applied to your Fun Kart and should be considered as permanent parts of the vehicle If a label should come off become hard to read or become damaged contact your dealer or American SportWorks Customer Service department for warning label replacements HOT SURFACES Surfaces around the engine a
30. lways keep all four wheels on the ground WARNING Attempting wheelies jumps and other stunts increase the chances of an accident including an overturn Never attempt stunt riding of any type and ride responsibly Don t try to show off PAGE 17 KART OPERATION A Operation controls 4 WARNING Do not attempt to startor operate the engine until completely familiar with the location and use of each control necessary to operate this vehicle The operator must know how to stop this machine before starting and driving it B Throttle The right foot pedal is the throttle controlling the speed of the kart As the engine speed increases above idle the clutch automatically engages and moves the vehicle forward To disengage the clutch at any time allow the throttle to return to the idle position See Fig Below 4A WARNING Every time prior to starting the engine check the throttle assembly to ensure that when the pedal is pushed all the way forward the assembly is working smoothly and returns to idle when released Do not operate this unit if pedal or engine throttle linkage fail to return to the idle position If unable to correct the problem through lubrication adjustment or replacement of worn parts contact your dealer for assistance C Brake The brake is controlled by the left foot pedal See Figure below Applying pressure to the pedal draws the brake pads against the brake disc at the wheels an
31. mpting to start the engine 4A WARNING ALWAYS use extreme caution when starting the engine Hotengine muffler or drive components can bum on contact WARNING Wet slippery rough or sloped terrain is potentially dangerous and may result in injury if engine proper caution is not observed ALWAYS SLOW DOWN Operator must use mature judgment skill and experience to choose a speed suitable for terrain and riding conditions in protecting operator passenger and or any bystanders Operator must use mature judgment skill and experience in choosing suitable terrain for individual operational capabilities A WARNING When turning on pavement loose gravel or similar surfaces there is an increased risk in loss of control ALWAYS SLOW DOWN PAGE 7 4 WARNING ALWAYS SLOW DOWN when turning High speed turning can cause loss of control and or possible operator injury Tuming on a slope increases the risk of rollover Practice operation is required to coordinate tuming skill Failure to operate this Fun kart at a safe speed while tuming can result in a strong possibility of severe personal injury A WARNING Washing or operating the Fun Kart in freezing temperatures can result in water freezing in the throttle cable conduit and or on the throttle mechanism This may result in the throttle sticking which can cause the engine to continue to run and result in loss of control WARNING Oper
32. nd exhaust can be extremely hot Allow surfaces to cool before servicing 11330 ENTANGLEMENT HAZARD Shoulder length and longer hair or loose clothing can get caught in moving parts behind or below the seat Restrain hair at or above shoulder level Restrained hair must not interfere with the proper fit of the helmet Securely restrain anything loose that reaches behind or below the seat 11330 B CHECK TIRE PRESSURES Improper inflation of tires can cause loss of control resulting in serious injury or death Refer to Owner s Manual for proper operating pressure sso 11330 ALWAYS WEAR SEATBELT Seatbelt must be properly fastened and adjusted for each occupant prior to operating the vehicle See Owner s Manual This vehicle is not to be operated by anyone under 13 years of age A speed reduction kit is available for this vehicle 1139 GUARD MUST BE IN PLACE This guard must be in place during engine operation Keep hands feet and loose garments away from engine chain and drive components CAUTION DO NOT PUT FOOT ON DRIVE COVER 11330 C PINCH HAZARD Exercise caution when working on drive components Drive chain turns when vehicle is in motion Chock wheels before removing drive cover Never remove drive cover or attempt to service with engine running s 5 2 PAGE 10 OBSERVE THE FOLLOWING INSTRUCTIONS Failure to understand and follow Warnings and Instructions for the safe use and maintenance of this product
33. ressed air Install new belt with the tapered edge away from the engine Place belt around the driven rear pulley and stretch over the crank shaft and onto the spanner Replace the drive pulley and mounting bolt Tighten bolt to 30 ftlb Storage Instruction If you plan to store and not operate your kart for a period in excess of 30 days or at the end of each driving season the unit should be set up for storage as follows 1 Drain fuel tank and carburetor by allowing the engine to run until the fuel system is dry 2 Lubricate the engine cylinder by removing the air cleaner and by spraying an engine fogging oil through the carburetor 3 Do NOT save or store gasoline over the winter Using old gasoline which will deteriorate from storage will make the engine difficult to start and affect the performance of the engine 4 To protect the paint plastics and upholstery it is a good idea to keep the unit covered when not in use PAGE 23 GENERAL MAINTENANCE A Front Wheel Replacement Remove cotter pin and castle nut Wheel should be easily removed After replacing the wheels tighten castle nut and replace cotter pin with a new one Replace rubber cover B Rear Wheel Replacement Remove cotter pin castle nut and washer Wheel should be easily removed After replacing the wheels replace the washer tighten castle nut and replace cotter pin with anewone Replace rubber cover C Front Wheel Alignment The front whe
34. s highways or any other location where road vehicles are intended to travel i Fun Karts shall be operated only with adequate lighting and under conditions of suitable visibility Persons with the following conditions shall not ride in or operate a Fun Kart a Those with heart conditions b Pregnant women c Persons with head back or neck ailments or prior surgeries to those areas of the body d Persons with any mental or physical conditions which may make them susceptible to injury or impair their physical dexterity or mental capabilities to recognize understand and perform all of the safety instructions and be able to assume the hazards inherent in Fun Kart use Fun Kart shall not be used to a Transport a passenger except in the seating area provided b Transport materials or equipment c Transport animals Fun kart operators always shall use appropriate protective clothing including but not limited to a motorcycle helmet and eye protection with appropriate certification and any other equipment recommended by the Fun Kart manufacturer including gloves footwear long sleeve shirts and long pants No operator or other person shall contact any portion of the engine wheels or drive train for any purpose including maintenance until the engine has been tumed off and allowed to cool and the Fun Kart is in a stable and stationary position Passenger restraints must be used in accordance with and limited to the manufac
35. s legs and move the seat either forward or backward Release the lever at the desired seat location ensuring that the lever snaps back into place to lock the seat 4 WARNING Never operate this kart when the seat is not securely locked into position Serious injury or death could occur due to loss of control Always make seat adjustments with the kart fully stopped and the engine shut off G Occupant Restraints This kart is equipped with 3 point retracting seat belts Insert the metal tongue into the buckle until it is securely attached Final adjustments should be made with the plastic tension stop such that the belt is against the shoulder and chest with no excess slack H Rear Spoiler The spoiler is NOT to be used as a cargo rack Do not place items on or tie items to the spoiler 4 WARNING Attempting to use the spoiler as a cargo rack may cause serious injury or death Do not place items on or tie items to the spoiler PAGE 19 KART FEATURES AND LOCATIONS Steering A Engine Stop Switch Spoiler Fuel Tank amp Air Cleaner Engine Stop Switch _ Brake Pedal Y PAGE 20 SERVICE INSTRUCTIONS A Air Cleaner CLEANER This unit is equipped with a foam style air filter element and should be COVER replaced after every 20 hours of operation NOTE Operation in unusually dusty conditions may require more frequent replacement 1 Remove the air cleaner cover by releasing the tab
36. turer s guidelines Fun Kart components shall be maintained and repaired in accordance with the manufacturer s specifications and utilizing only the manufacturer s authorized replacement parts with installation performed by designated dealers or other skilled persons PAGE 12 ARE YOU READY TO DRIVE Before each drive you need to make sure that you and your kart are both ready to drive To help get you prepared this section discusses how to evaluate your driving readiness what items you should check on your kart and adjustments to make for your comfort convenience or safety Before you drive your kart for the first time we urge you to Read this owner s manual and the labels on your kart carefully Make sure you understand all the safety messages Know how to operate all the controls View and understand the included safety DVD Protective Apparel Although complete protection is not possible wearing proper gear can reduce the chance of injury should you have an accident The following suggestions will help you choose the proper protective gear Helmet and Eye Protection Your helmet is your most important piece of protective gear because it offers the best protection against head injuries A helmet should fit your head comfortably and securely Open face helmets offer some protection but a full face helmet offers more Regardless of the style look for a D O T Department of Transportation or Snell Memoria
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