Olympia/Luggage America 65 User's Manual
Contents
1. J u Lii og Uefa at Y rui eet Totes 913 LSOd 32N34J V HO P ANUN v 3dnionats v 3o TU NIS H3hNHO2 JHL TVOLLH3A Y diat T3A31 51 1 ONY LH9IS 3d0 1S TRANSPORTING It is best to transport the Go kart in the normal position Drain screw Before transporting the Go kart drain the fuel from the carburetor as follows 1 Drain fuel from carburetor into an empty container by loosening the carburetor drain screw located on bottom of carburetor 2 When the fuel has been drained retighten the drain screw Draining fuel from the carburetor could be hazardous Fuel could catch fire if you do not handle it properly When draining fuel from the carburetor be sure to shut the engine off Do not smoke and never drain or refuel in an area where there are open flames or sparks Do not spill the fuel or you may create a fire hazard Dispose of the drained fuel properly Failing to secure the Go kart properly could be hazardous Failing to secure the vehicle properly may result in an accident or damage to the vehicle When transporting the Go kart lock the parking brake lever and tie down the vehicle securely with straps rope or some other suitable means Use extra tie downs when you transport the vehicle in the standing position 34 CLEANING PROCEDURE Athorough cleaning of your Go kart2. TEMP 22 22 2 2 2 22 22 F 22 4 14 32 50 68 86 104 Use the chart to select a viscosity rating based on the temperature range in your area WARNING LABELS Read and follow all of the warnings labels on your Go kart Make sure you understand all the labels Keep the labels on the Go kart Do not remove them for any reason If a label comes off or becomes difficult to read you should get a replacement by contacting Baja Motorsports THE GO KART HAZARDOUS TO OPERATE H drian 55 result F you gdo not follow these inomi READ OWNERS MANUAL ALL LABELS BEFORE TOU OPERATE THIS GO KART HEVER OPERATE THIS GOHRAAT WITHOUT PROPER INSTRUCTIONS Beginners require mature supervision NEVER OPERATE THIS GO KART ON PUBLIC ROADS it is intened off road use only HEVER OPERATE THIS GO KART AT EXCESSIVE SPEEDS ATTEMPT WIHEELIES JUMPS OTHER STUNTS LOSS OF CONTROL COLLISION OR GETTING CAUGHT IN MOVING PARTS CAN RESULT IN SERIOUS INJURIES Adult supervision for under 16 years olds wear D O T approved motorcycle helmet Secure long hair and loose clothing Wear protective eye wear and clothing Keep arms legs and feet inside kart Do not use alcohol drugs 11 WARNING LABELS HOT SURFACES Allow to cool before refueling ALL HAIR MUST BE TIED UP AND SECURED AT OR ABOVE SHOULDER LENGTH ALL LOOSE CLOTHING MUST BE SECURED
3. At the end of each interval be sure to perform the maintenance listed 20 MAINTENANCE SCHEDULE WARNING Improper maintenance or failing to perform recommended maintenance could be hazardous If you perform improper maintenance or do not maintain your Go kart you may have an accident Keep your Go kart in good condition Ask your authorized service center or a qualified mechanic to do the maintenance items marked with an asterisk You may perform the unmarked maintenance items by referring to the instructions in this section if you have mechanical experience If you are not sure how to do the maintenance ask your authorized service or call Baja Motorsports If you use your Go kart under severe conditions it will need maintenance more often than shown in the chart Operating your Go kart under severe conditions causes more wear on your Go kart Severe conditions include operating under frequent full throttle or in dusty wet sandy or muddy areas These conditions could cause the Go kart to wear more quickly Perform maintenance more often than shown in the chart If you have any questions regarding maintenance intervals consult your authorized service center or call Baja Motorsports Using poor quality replacement parts could damage your Go kart Poorly made replacement parts could cause your Go kart to wear more quickly and shorten its useful life When replacing parts on your veh
4. be operated after mature supervised instruction and sufficient practice in decongested areas Safe operation includes responsibility for the safety or a passenger if any 10 A DOUBLE SEAT VEHICLE IS DESIGNED FOR ONE OPERATOR AND ONE PASSENGER No one should ever attempt to ride on this vehicle without being seated with the seat belt properly secured For double seat vehicles ridden without passenger the passenger seat belt must be secure to prevent it from getting caught in operating components Any passenger must be of sufficient age understanding mental capacity and physical capability to act to protect himself herself ALWAYS FOLLOW THE RECOMMENDED AGE RESTRICTION OF 16 YEARS FOR OPERATORS AND PASSENGERS 11 Theengine should be stopped when the vehicle is not in use 12 The operator and passenger if any of this vehicle should always wear a helmet approved by agencies such as Department of Transportation DOT Safety Helmet Council of America SHCA or Snell Memorial Foundation SNELL Most off road vehicle accident fatalities are due to head injuries The operator should also wear face shields or goggles boots or closed toe shoes gloves and other appropriate protective clothing NOTICE TO USERS 13 LOOSE CLOTHING LONG HAIR OR ARTICLES WORN BY ANY OPERATOR OR PASSENGER MUST BE FULLY CONTAINED OR COVERED TO PREVENT THEM FROM POSSIBLY BEING CAUGHT IN ROTATING PARTS OF THE VEHICLE OR THE SURROUNDING ENVIRONMENT WHILE R
5. fouled Engine overheated Replenish fuel Air filter clogged Check oil level Exhaust clogged Clean engine exterior Contact service center Fuel line kinked or plugged Water in fuel 38 SERIAL NUMBER LOCATION You need to know the frame and engine serial numbers to get title documents for your Go kart You also need these numbers to help your authorized service center or Baja Motorsports order parts The Frame number is stamped on the frame on the passenger side front end The engine number is located on the front of the engine housing facing the seat Frame number Engine serial number Write down the serial numbers here for your future reference Frame No Lo Engine No 2 39 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall it trit etur ra m eaten 2184mm 86 in Overall aai eraai 1346mm 53 in Overall eo ierit 1473mm 58 in Ground 2 229 9 Diy Weight nti erc unies 181Kg 400 Ibs ENGINE MY mne TN Four stroke Displacement 196cc PIOPSCDOWO c 6 5 HP rg enr REDE Recoil Foam Approximate speed MPH eene 25 30 TRANSMISSION X Torque Converter FUEL Main fuel tank capacity e
6. is a necessary part of maintenance It will help keep your Go kart looking and performing best Proper cleaning can also extend the life of your Go kart It is important to clean and inspect your Go kart after every ride especially if it is used in mud brush grass water salt water or very dusty conditions The build up of mud brush grass etc especially on the engine and exhaust system can reduce engine cooling ability conceal damage or increase wear of certain parts It is important to remove all debris during cleaning PREPARATION FOR CLEANING Wash the Go kart before any mud dries on the Go kart Block or seal the end of the exhaust pipe muffler and air filter using a piece of plastic wrap cloth rag or another method to prevent water from entering engine High pressure washers could damage your Go kart High pressure washers such as those found at coin operated car washes have enough pressure to damage the parts of your Go kart It may cause rust corrosion and increase wear Do not use high pressure washers to clean your Go kart 35 WASHING YOUR GO KART With some care your Go kart can be washed in a similar manner to washing an automobile Note Avoid spraying or allowing water to flow over the following places Ignition switch Spark plug Fuel tank cap Carburetor Air filter Use a garden hose at low pressure to remove the majority of dirt or other debris Hand wash your Go kart with mild soap or det
7. ALL NECKLACES AND SCARVES MUST BE SECURED SMOKING OR FIRES WARNING STRICTLY FORBIDDEN 11 Ibs NEVER sit here THROTTLE AND BRAKE PEDAL KILL SWITCH Brake pedal Brake fluid resevoir Kill switch Throttle pedal Brake pedal Depressing the brake pedal draws the brake calipers against the brake rotor and slows or stops the go kart Throttle pedal Depressing the throttle pedal will engage the torque converter and move the go kart forward Kill Switch The engine will shut off by pressing the kill switch button Brake fluid resevoir Check brake fluid by making sure the fluid is above the low mark Use only DOT3 or DOT4 brake fluid DO NOT MIX BRAKE FLUID TYPES ENGINE STARTING CAUTION Verify oil level prior to starting see page 10 Starting the engine with low or no oil will damage the engine A WARNING Never start the engine in a closed place as the exhausted gas from the vehicle contains toxic carbon monoxide To start turn ON OFF switch located on engine to ON position To turn engine off turn switch to OFF position To start a cold engine Place choke lever in the CLOSED position Engine on off switch 1 2 Place fuel lever in the ON position 3 Start the engine using the pull start Choke lever recoil 4 Once engine has warmed up move choke lever to OPEN position Procedures for stopping the engine 1 Release throttle peda
8. IDING FAILURE TO OBEY COULD ENDANGER THE PERSONAL SAFETY OF THE OPERATOR OR PASSENGER 14 DO NOT PLACE HANDS FEET OR ANY OTHER PART OF THE BODY OR ANY CLOTHING NEAR THE ENGINE MUFFLER WHEELS CHAIN AND OTHER ROTATING PARTS OF THE VEHICLE WHILE RIDING OR RUNNING THE ENGINE Caution must be used in performing required maintenance on or near an operating engine Special caution should be taken after the engine has been running since the engine and other drive components may be extremely hot 15 Wet slippery rough or steep terrain is potentially dangerous and may result in injury if proper caution in not observed Slow speeds are required to safely operate this vehicle under those conditions The operator must use mature judgment skill and experience to choose a speed suitable for the terrain and riding conditions 16 The governor settings for this vehicle s engine must not be tampered with altered or changed The governor is set by the engine manufacturer and limits the maximum speed of the engine and vehicle and protects the engine from damage Excessive speeds are potentially dangerous to the operator passenger and the engine 17 Eachtime before using this vehicle the fuel supply should checked The fuel tank should never be filled while the engine is running or while the engine is hot Do not fill tank in a closed area such as a garage while smoking or in the vacinity of an open flame Do not overfill the tank There should n
9. Motorsports BLASTER 65 Go kart Read this manual carefully It contains important safety information No one under the age of 16 should operate this Go Kart OWNER S MANUAL gt gt Minimum Age Requirement 16 REV Always wear a helmet It could save your Life Please obtain review and follow provincial municipal government acts and regulations pertaining to owning and operating an off road vehicle Motorsports Congratulations on your purchase of the Baja Motorsports Blaster 65 Go Kart It is warranted to be free of manufacturing defects in the material of workmanship for a period of 90 days form the date of purchase During the warranty period BAJA MOTORSPORTS LLC will at its option repair provide replacement parts or replace your Baja Motorsports Blaster Go Kart at no charge This warranty does not cover normal wear items or damage caused by neglect or misuse of the product Engine Warranty 90 days Frame Warranty 90 days Warranty is void if Frame is bent or broken due to abuse If wheels are bent or broken Fender bent or broken due to abuse Any sign of impact accident jumping spin outs or roll over BAJA MOTORSPORTS LLC is not liable for any damage claim or liability claim person or otherwise resulting from the operation of this product in any way Should you experience a problem or need to return your Baja Motorsports Blaster 65 Go kart for repair please call the BAJA M
10. OTORSPORTS customer service department TOLL FREE at 1 888 863 BAJA 2252 between the house of 7am and 5pm Monday thru Friday PST and Saturday 8am to 4pm PST During DST hours change to MT You will be instructed how to proceed A COPY OF THE SALES RECEIPT IS REQUIRED A WARNING This manual should be considered as a permanent part of the vehicle and should remain with the vehicle when resold or otherwise transferred to a new user or operator The manual contains important safety information and instructions which should be read carefully before operating the vehicle TABLE OF CONTENTS NOTICE TO UERS BLASTER 65 treten ins FUEL AND OIL WARNING LABELS THROTTLE AND BRAKE LEVER KILL SWITCH ENGINE STARTING RIDING YOUR GO KART inttr teens INSPECTION BEFORE RIDING SAFETY GEAR SEAT BELTS BREAK IN GHAIN ADJUSTMENT 5 tetti rt cialis IGNITION SYSTEM CHECK SLOPE GUIDE TRANSPORTING CLEANING PROCEDURE WASHING YOUR GO KART rere STORAGE PROCEDURE TROUBLESHOOTING SERIAL NUMBER LOCATION SPECIFICATIONS NOTICE TO USERS Please read this manual and follow all instructions carefully To emphasize the special information the symbolA and the words WARNING or CAUTION have some special meanings Pay great attention to the messages Indicates a potential hazard that could result in A WARNING death or injury Indicates a potential hazard that
11. attery if applicable contains sulfuric acid and must not come in contact with skin eyes or clothing since this will cause severe burns possibly causing disfigurement Also battery may generate explosvie gases and must not be exposed to sparks flame cigarettes or anything flammable or an explosion may result causing severe injury Protective gloves and face protection must be worn when servicing the battery 30 ANY OPERATOR OR PASSENGER UNDER 18 YEARS OF AGE MUST ALWAYS BE APPROPRIATELY SUPERVISED BY AN ADULT AT ALL TIMES WHILE OPERATING THE VEHICLE 31 Operating this vehicle requires skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting to operate the vehicle 32 Operate only on safe and familar terrain Avoid loose gravel and rocks Be careful on wet surfaces and allow for extra braking distance Headrest Front tire Torque converter Fuel tank Off button Steering wheel Rear tire Recoil pull start Right FUEL AND OIL FUEL The proper fuel is very important for the engine Ensure that there is no dust dirt or water which has mixed in the fuel Please use regular unleaded gasoline ENGINE OIL Your 6 5 HP Go kart has a four stroke engine Please use oil as described in the chart below By using the prescribe oil you will realize the best lubrication for the engine 20W 50 15W 40 ENGINE
12. could result in CAUTION vehicle damage NOTE Indicating special information which is to make maintenance easier or instructions clearer WARNING and CAUTION are arranged like this WARNING The first part will identify a POTENTIAL HAZARD The second part will describe WHAT COULD HAPPEN if you ignore the WARNING or CAUTION A CAUTION The third part will describe HOW TO AVOID THE HAZARD This user s manual contains important safety and maintenance information Read it carefully before riding Failing to follow the warnings contained in this manual could result in INJURY or DEATH It is important that this manual remain with the vehicle when you transfer it to another user or owner All information illustrations photographs and specifications contained in this manual are based on the latest product information available at the time of publication Due to improvements or other changes there will be some discrepancies in this manual We reserve the right to make product changes at any time without notice and without incurring any obligation to make the same or similar changes to the vehicle previously built or sold 2 NOTICE TO USERS This off road product IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE This product handles differently from other vehicles including ATV s and motorcycles A collision or rollover can occur quickly even during routine maneuvers such as turning and riding on hills or over obstacles To h
13. d be hazardous If the air filter element did not filter dirt severe engine damage would occur if the dirt entered the running engine Never run the engine without the air filter element in place CAUTION Failing to inspect the air filter element frequently if the vehicle is used in dusty wet or muddy conditions could damage your Go kart The air filter element could become clogged under these conditions and engine damage may result Always check the air filter element after riding in severe conditions Clean or replace the elements as necessary If water gets in the air filter case immediately clean the element and the inside of the case A torn air filter could damage your Go kart Dirt and dust may get inside of the engine if the element is torn Examine carefully the element for tears before and after cleaning it Replace the element with a new one if it is torn Failing to position the air cleaner element properly could damage your Go kart Air will bypass the air cleaner element if the element is not positioned properly This will cause the engine parts to wear more rapidly Be sure to position the air cleaner element properly 25 TORQUE CONVERTER Inspection and Cleaning WARNING Removing Torque Converter cover while engine is running could be hazardous Running engine while Torque Converter cover is removed increases the chance of hair clothing or body parts being entangled in moving component
14. e a heart condition or wear a pacemaker Do not perform this test is any near any open fuel containers for near fuel which has spilled on the ground on the engine or any part of the Go kart COMPLAINT Engine stalls 1 Make sure there is enough fuel in the fuel tank 2 Check to see that the spark plug is not fouled Remove the spark plug and clean it Replace it if necessary 3 Make sure the fuel valve is not clogged and the fuel tank is not clogged either 4 Check the idle speed If necessary adjust it using a tachometer The correct idle speed is 1400 1600 r min 32 TT TT A O 7 1 7398 OL ui pp suonngene pube neu vo Buggrado en piia soseau yey iy ades esabap y gua asp adog Bug SSOP codo up 1 U 168 g z Apgeiunenuddeg dn ua uj K15 88 WAS 160 e 51 ados BL uj euo SusAnsiviW uei Wa GAY pug a EMED SWA ed aS ESI Rer Ut 9905 epi ou op pur epi sng s n suns y fumar Me j078JES OU JI pue dn epu o3 eyes y adgs sabap edaps ejPus au cq oad saaiBap L ados
15. ed DOT motorcycle helmet eye protection and protective clothing could be hazardous Operating without an approved DOT motorcycle helmet or eye protection increases your chances of a severe head injury or death in an accident Operating without protective clothing also increases your chances of severe injury in an accident You should wear eye protection when you ride If a rock or a branch hits your eyes you could be severely injured Wear goggles or a face shield Wear proper clothing when you ride The proper clothes can protect you from injury Wear a good pair of gloves strong boots that are over the ankle long pants and a long sleeve shirt SEAT BELT Operating this go kart without wearing seat belts could hazardous Riding in this go kart driver or passenger without wearing seatbelts could contribute to severe injury or death in the event of an accident Always wear seat belts provided Wear seat belt by placing shoulder strap 1 over shoulder Place lap portion 2 over lap Buckle seat belt 3 After seat belt is buckled pull on belt to make sure buckle is fully engaged BREAK IN The first month is the most important in the life of your vehicle Proper operation during this break in period will be helpful for assuring maximum life and performance of your new vehicle The following guidelines explain proper break in procedures Maximum Throttle Opening Recommendation During the first 10 hours of op
16. elp you make informed decisions about safety you will find provided in this manual operating procedures and other safety procedures which must be followed In addition to the safety information in this manual you will find safety labels on the product FOLLOW ALL WARNING BOTH IN THIS MANUAL AND ON THE PRODUCT Information which is particularly important is distinguished in this manual by the following notations FAILURE TO FOLLOW WARNING INSTRUCTIONS COULD RESULT IN SEVERE INJURY OR DEATH A WARNING TO THE OPERATOR OR PASSENGER A BYSTANDER OR A PERSON INSPECTING OR REPAIRING THE PRODUCT CAUTION INSTRUCTIONS ARE PROCEDURES TO PREVENT DAMAGE TO THE VEHICLE OR INJURY TO THE OPERATOR OR PASSENGER A BYSTANDER A CAUTION OR A PERSON INSPECTING OR REPAIRING THE PRODUCT NOTE A NOTE provides key information to make procedures easier or clearer IMPORTANT RULES FOR SAFE OPERATION 1 This vehicle is not licensable IT IS NOT TO BE OPERATED ON ANY PUBLIC ROAD STREET HIGHWAY PARKING LOT SIDEWALK OR ALLEY To do so would be in violation of local law This vehicle may be operated only on pirvate property and upon areas approved by local law Avoid operating this vehicle in any area with stationary objects that the vehicle could travel under Do not ride in areas where other recreational vehicles are being operated Be respectful of landowners and the environment 2 This vehicle should NEVER be operated indoors The exhaust from the
17. engine contains carbon monoxide which is a tasteless odorless and poisonous gas 3 Unless otherwise specified in this manual all screws nuts and bolts must be kept tight to ensure that the vehicle is in safe operating condition The engine must be kept free of all dirt and other accumulations paying particular attention to throttle linkage area 4 Prevailing Torque type locknuts lose their locking capability with repeated use and require replacement Ensure locknuts are functioning properly 5 The tire pressure should be checked prior to each use The recommended inflation NOTICE TO USERS T THE VEHICLE SHOULD NEVER BE STARTED WITHOUT FIRST CHECKING TO SEE THAT THE THROTTLE IS IN IDLE POSITION Do not start engine without verifying proper function of the throttle Never attempt to start this vehicle without having the operator seated in the proper position When starting with the operator in the seat the operator should have their left foot on the brake 8 This vehicle is not designed or intended for racing any form of competion or use on metal tracks 9 The operator s ability to operate this off road vehicle safely is largely dependent upon the operator s ability to excercise proper judgment An operator also must not be too small or too large for controlled operation The operator must be of sufficient age understanding mental capacity and physical capability to safely operate this vehicle This vehicle should only
18. entire vehicle FUEL Drain the fuel from the fuel tank by a hand pump Drain the fuel from the carburetor by releasing the carburetor drain screw Draining the fuel could be hazardous Fuel could catch fire if you do not handle it properly When draining the fuel from the fuel tank be sure to shut the engine off Do not smoke and never drain fuel in an area where there are open flames or sparks Keep pets and children away from the fuel and dispose of the drained fuel properly TIRES Inflate tires to the normal pressure EXTERNAL 1 Spray all vinyl and rubber parts with rubber protection 2 Spray unpainted surfaces with rust preventative 3 Coat painted surfaces with car wax PROCEDURE FOR RETURNING TO SERVICE 1 Clean the entire vehicle 2 Make sure that the vehicle is properly lubricated 3 Perform the INSPECTION BEFORE RIDING as listed in this manual 4 Start the vehicle as outlined in this manual 37 TROUBLESHOOTING The following information is provided to help you identify probable questions you may have concerning the operation of you Go kart See your authorized service center with any additional questions you may have Engine turns over but fails to start On Off flip switch is in off position Replenish fuel Spark plug No spark to spark plug Water in fuel No compression Contact service center Clogged fuel filter Engine stops or loses power Spark plug
19. eration you should always use less than 7 throttle opening Vary the Engine Rotating Speed Vary the engine rotating speed during the break in period This allows the parts to load and then unload allowing the parts to cool Although it is essential to place some stress on the engine components during break in you must be careful not to load the engine too much Avoid Constant Low Rotating Speed Operating the engine at constant low rotating speed light load can cause parts to glaze and not seal properly Allow the engine to accelerate freely without exceeding the maximum throttle limit Allow the Engine Oil to Circulate Before Riding Allow enough idling time after warm or cold engine starting This allows the lubricating oil to reach all critical engine components Observe Your Initial and Most Critical Service The initial service break in maintenance is the most important service that your vehicle will receive Observing a proper break in operation will help engine components seal properly Maintenance required as part of the initial service includes proper adjustments tightening of all bolts amp nuts and replacement of dirty oil Timely performance of this service will help you get the best service life and performance of the engine MAINTENANCE SCHEDULE It is very important to inspect and maintain your Go kart regularly Follow the guidelines in the chart The intervals between periodic services in months are shown
20. ere 95 gal 3 6L OIL e GABAGIEY 93 qt BRAKES Front brake Hydraulic Disc 5255442 Left pedal SUSPENSION ji eet Dual A arm Trailing Arm Independent TraveHronUreal oio ci aod aset 152mm 6 in TIRES Size Front frr 19x7 8 Size detenti a A 19x7 8 40 4 PM oss Baja Motorsports LLC 2801 So Fair Ln Ste 101 Tempe AZ 85282 Tel 480 222 8280 Toll Free 888 863 2252
21. ergent and water Try to thoroughly remove all dirt and debris without excessive water pressure even at remote areas such as between engine cooling fins linkages or mounting brackets Cloth rags washing mitts or cleaning brushes can be used Be careful with brushes as they may scratch plastic or painted surfaces Rinse the Gokart thoroughly with clean water Dry all areas using a chamois or soft absorbent cloth INSPECTION AFTER CLEANING Remove the rags or wrapping from the exhaust pipe For extended life of your Go kart lubricate according to GENERAL LUBRICATION section Follow the procedures in the INSPECTION BEFORE RIDING section to check your Go kart for any problems that may have occurred during your last ride WARNING Operating the Go kart with wet brakes could be hazardous Wet brakes may not provide as much stopping power as dry brakes This could lead to an accident Test your brakes after washing the Go kart riding at a slow speed If necessary apply brake several times to let the friction dry out the linings 36 STORAGE PROCEDURE If you do not use your Go kart for a long time it will need special service requiring appropriate materials equipment and skill For this reason we recommend that you trust this maintenance work to your authorized service center If you wish to service the machine for storage yourself follow the general guidelines below VEHICLE Place the vehicle on level ground and wash the
22. erial is unclear contact the manufacturer 22 NEVER OPERATE THIS VEHICLE WHILE UNDER THE INFLUENCE OF ALCOHOL DRUGS OR MEDICATION OF ANY KIND SUCH OPERATION COULD BE DANGEROUS TO YOURSELF AND OR OTHERS 23 Always slow down when turning High speed turning may cause loss of control possible turnover of the vehicle and or possible injury to the operator or passenger 24 When turning knobby tires amy increase the risk of loss of control ALWAYS SLOW DOWN A collision or rollover can occur quickly even during routine maneuvers such as turning and riding on a hill or over obstacles if you fail to take proper precautions 25 DO NOT RACE JUMP PERFORM STUNT RIDING OR SPINOUTS WHEN OPERATING THIS VEHICLE THIS VEHICLE IS NOT DESIGNED OR INTENDED FOR SUCH OPERATION NOTICE TO USERS 26 This manual along with the other supplements provided with your vehicle provide guidlines for the assembly maintenance and operation of this vehicle and is not intended as a service manual 27 Assembly maintenance and or repair of this vehicle should only be performed by persons of sufficient mechanical skill experience and judgment such as outdoor equipment dealers motorcycle dealer shops or small engine dealers so that no unsafe condition or modification is made 28 Always use extreme caution when starting the engine Avoid touching the engine muffler or drive components These areas could cause burns on contact 29 The b
23. g t opbefm pre NG INSPECTION BEFORE RIDING _ WARNING Overloading could be hazardous Overloading could cause changes in vehicle handling and could lead to an accident Never exceed the stated load capacity for this Go kart A WARNING Operating this Go kart with improper modifications could be hazardous Improper installation of accessories or modifications to this vehicle may cause changes in handling In some situations this could lead to an accident Never modify this Go kart through improper installation or use of accessories Check the condition of the Go kart to make sure that the Go kart does not have mechanical problems or you could get stranded when you ride Before riding the Go kart be sure to check the above items Be sure your Go kart is in good condition to ensure the safety of the rider Checking maintenance items when the engine is running could be hazardous You could be severely injured if your hands or clothing get caught in moving Go kart parts Shut the engine off when performing maintenance checks except checking the engine stop switch and throttle SAFETY GEAR A DOT approved motorcycle helmet is the most important part of you safety gear A DOT approved motorcycle helmet can help prevent a serious head injury Choose a helmet that fits snugly Motorcycle dealers can help in selecting a good quality helmet which fits properly Operating this Go kart without wearing an approv
24. icle use only genuine replacement parts or their equivalent 21 ENGINE OIL To check oil level 1 Park vehicle on level ground 2 Remove dip stick and wipe off with a clean rag Insert the dipstick in the filler hole 3 Remove dipstick and inspect oil level 4 Oil level should be between the minimum and maximum marks on dipstick 5 Add oil if oil is below minimum mark on dipstick Do Not fill above maximum mark Refer to page 10 for correct engine oil type Engine and gearbox oil replacement The engine oil should be changed every 20 to 40 hours of operation It should be changed more often in dirty and dusty areas 1 Park vehicle on level ground Remove oil dipstick 3 Remove oil drain bolt drain oil into proper container Dispose oil at a proper oil reclaim facility 4 Fill with clean oil Refer to page 10 for correct engine oil type Cil drain bolt ENGINE OIL New and used oil could be hazardous Children and pets may be harmed by swallowing new or used oil Continuous contact with used oil can cause skin cancer in laboratory animals Brief contact with the used oil may irritate the skin Keep new and used oil away from children and pets To minimize your exposure to used oil wear a long sleeve shirt and moisture proof gloves such as dish washing gloves when changing oil If oil contacts your skin wash thoroughly with soap and water Launder any clothing or rags if wet with oil Recycle
25. l to slow down go kart 2 Press down brake pedal to slowly stop go kart Fuetiever 3 Push kill switch to turn engine off 4 Set fuel lever to OFF position RIDING YOUR GO KART WHAT YOU SHOULD KNOW BEFORE RIDING Before riding you should read all the following information carefully If you are properly prepared you will have a more enjoyable ride Before riding you should find a good place to practice the skills Find a flat open area with enough space to practice the new skills Make sure that it is legal to ride in the area you selected Review the local laws and make sure you are not trespassing Call the police if you don t know where you can ride Protect your riding areas When you are riding remember to keep the terrain in good condition Don t destroy plants trees or other vegetation Don t litter and don t bother wildlife With your help your riding area can remain open for use in the future After you have found a good place to practice review the control system on your Go kart before riding Learn to find these controls without looking for them because you will not have time to look for them when you are riding Canadian residents must obtain review and follow all provincial and municipal government acts and regulations pertaining to owning and operating an off road vehicle INSPECTION BEFORE RIDING WARNING Failing to inspect the Go kart before operating could be hazardouss80ilin
26. or properly dispose of used oil Failure to use the correct oil could harm your Go kart Be sure to use the oil specified in the FUEL AND OIL RECOMMENDATION section Running the engine without an adequate amount of engine oil could cause severe engine damage Running the engine without any engine oil could cause engine overheating Always check the amount of engine oil before starting the engine 23 AIR FILTER 1 2 3 4 The air filter element must be kept clean to provide good engine power If you use your vehicle under normal low tension conditions you should service the air filter at the intervals specified in the maintenace schedule page of this manual If you ride in dusty wet or muddy conditions you will need to inspect the air filter element much more frequently Use the following procedures to remove the element and inspect it AIR FILTER REMOVAL Foam air filter Air filter cover Locate Air Filter on left side of Go kart Unscrew wing nut and remove air filter Wash foam air filter as instructed below Reinstall air filter and tighten wing nut Wash with water Wash the air filter element as follows 1 Remove air filter element 2 Wash air filter element gently in water or a mild non flammable solvent 3 Squeeze water and let dry 4 Reinstall air filter element Squeeze out excess water 24 AIR FILTER WARNING Operating the engine without the air filter element in place coul
27. ot be any fuel in the filler neck Replace cap tightly to prevent spillage of fuel and potential fire hazard After filling tank move the vehicle at least 15 feet away from the spot of filling before starting 18 Ifthe vehicle should start making unusual noise or vibrating abnormally the engine should be stopped and the spark plug wire disconnected The vehicle should then be checked for damaged Excessive noise or vibration is generally a warning of loose or worn parts NOTICE TO USERS 19 When making repairs or adjustments to the vehicle which do not involve adjustments to the engine the spark plug wire must be disconnected and kept away from the spark plug to prevent accidental starting When working on or around or when restarting engine use extreme caution to avoid contact with the muffler cylinder head or any other potentially hot area on or around the engine 20 Always perform a pre ride inspection before starting the engine See Pre Ride Inspection section in this manual 21 When storing the vehicle it must be kept in a place where gasoline fumes will not reach an open flame or spark For long period storage such as for winter the fuel tank should be drained in an open cool area The engine must be allowed to cool before storage in any enclosure Read and keep all printed material supplied with this vehicle Timely and specific instructions and an Operator s Manual revisions are included in supplements If any printed mat
28. ould be hazardous if you do not inspect brake wear often Operating in mud water sand or other extreme conditions can cause accelerated brake wear This could lead to an accident If you operate your vehicle under these conditions the brake must be inspected more often than recommended in the MAINTENANCE SCHEDULE CHAIN ADJUSTMENT Check the chain adjustment after the first two hours of use Readjust if it has more than 1 25 flex Adjusting the Chain To Tighten Chain 1 Loosen all four bolts under engine mount plate 2 Slide engine back until chain is adjusted to the desired tension 0 8 to 1 2 of slack To Loosen Chain 1 Loosen all four bolts under engine mount plate 2 Push engine forward toward the seat 20 30 mm 0 8 1 2 in 31 IGNITION SYSTEM CHECK 1 Remove the spark plug and reattach it to the spark plug lead E 2 Apply the brake pedal to make sure the rear wheels are locked If the ignition system is operating properly a blue spark should jump across the spark plug gap If there is no spark take your machine to your service center A WARNING Performing the spark test improperly could be hazardous You could get a high voltage electrical shock if you are not familiar with this procedure Do not perform this check if you are not familiar with the procedure Do not point the spark plug near the spark plug hole during this test Do not do this test if you hav
29. ponents according to diagram above With brake cleaning fluid spray each component 1 2 3 liberally and wipe clean Lubricate Driver component 2 3 with a dry spray lubricant Make sure no lubricant is placed on surfaces where drive belt will contact Note Dry spray lubricant can be purchased at most auto motorcycle and hardware stores Do not use Grease oil graphite or silicone lubricants Lubricate Driven Torque Converter Driven Cleaning and Lubrication Remove Driven from jackshaft Do not take apart if the Driven needs to be taken apart please contact your local service center With brake cleaning fluid spray Driven liberally and wipe clean Lubricate Driven with a dry spray lubricant Make sure no lubricant is sprayed on surfaces which will come in contact with the drive belt Re install Torque Converter Drive Drivebelt and Driven 1 Install Driven unit 2 Install inside belt disk 3 Install Drive belt 4 Install drive cover and weight assembly Make sure bolt on driven and nut on driver snug TIRES The Go kart is equipped with low pressure tubeless tires of the size and type listed Trent D Et 19x7 8 19x7 8 Operating this Go kart with improper tires or even improper tire air pressure could be hazardous If you use improper tires or improper tire air pressure you may lose control of the Go kart Always use the size and type tires specified Always main
30. s which could result in severe injury or death Never run engine while Torque Converter cover is removed Note If you do not feel comfortable performing maintenance on the torque converter please take your go kart to an authorized service center The Torque Converter must be kept clean and lubricated to extend the life of the components and to provide proper operation If you use your vehicle under normal conditions you should service the torque converter at intervals specified in the maintenace schedule page of this manual If you ride in dusty wet or muddy conditions you will need to inspect clean and re lubricate the torque converter more frequently If you experience Jerky conditions while throttle is applied it is more than likely the torque converter needs cleaning Use the following procedures to remove torque converter inspect clean and lubricate diver and driven components Removing Torque Converter components Remove Torque Converter cover 1 by removing screws located around outside of cover Remove Driver 2 of torque converter by removing Shaft bolt 3 Remove Drive belt 4 Remove Driven 5 of torque converter by removing Jackshaft nut 6 Pull Driven off shaft Torque Converter Driver Cleaning and Lubrication Lubricate D river inside races Lubricate The Driver consists of 3 main parts Cover 1 Weight assembly 2 inside belt disk 3 Remove Driver from engine and seperate com
31. t to damage the inner wheel rim surface or the tire bead WARNING Tubeless Tire Repair If a leak or flat tire occurs due to a puncture the tire may be repaired using a plug type patch If the damage is from a cut or if the puncture cannot be repaired using a plug the tire should be replaced When operating your Go kart in areas where transportation or service facilities are not readily available it is strongly recommended that you bring a plug type repair kit and a tire air pump with you 29 BRAKES 1 Inspect the rear disk brake caliper for leakage If brake fluid leaks the safety of riding could be affected 2 Inspect the brake hose for cracks and the joints for leakage 3 Check the brake fluid level in the brake fluid reservoir if level is at or below the LOWER mark inspect brake pads for wear and hydraulic system for leaks 4 To add brake fluid remove cap on top of brake fluid container Add DOT3 or DOT4 brake fluid Do not mix brake fluid types Brake fluid cap Brake fluid resevoir Brake caliper WARNING Failing to inspect and maintain your Go kart s brake system properly could be hazardous Improper maintenance of the brake increases your chance of having an accident Be sure to inspect the brake before riding according to the INSPECTION BEFORE RIDING section Always maintain your brakes according to the MAINTENANCE SCHEDULE WARNING Operating the Go kart in harsh conditions c
32. tain proper tire air pressure as described in this section Tire Tread Condition Using worn tires could be hazardous The traction of the vehicle will be decreased This increases your risk of having an accident Replace the front and rear tires when the depth on the tread is 4 0 mm 0 16 in or less Tire Air Pressure Check the air pressure in all tires before riding Improper air pressure would effect handling steering response traction tire life and rider comfort Be sure that the tires are inflated to the pressures shown below Tire pressure should only be measured or adjusted when the tires are cold 28 Overfilling the air to the tires could be hazardous If you put too much air into the tire may burst and causing severe injury Check the air pressure from time to time while inflating the tire gradually until the specified air pressure is obtained Tire Replacement Your Go kart has low pressure tubeless tires Air is sealed by the contact surfaces of the inner wheel rim and the tire bead If the inner wheel rim or tire bead is damaged air may leak Be extremely careful not to damage these sections when replacing tires It is very important to use the proper tools when repairing or replacing tires in order to protect the tire bead or wheel rims Have this work done by your authorized service center or a qualified tire repair station When breaking the tire bead loose from the wheel be extremely careful no
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