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Contents
1. Owner s Manual Parts Manual READ THIS MANUAL CAREFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION MINIMUM RECOMMENDED OPERATOR AGE 13 This operation manual is made for Go kart models MID XRX MID XRS TBM80 GK80 96 MID GK 1 MID GK 2 FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only USAonly It does not conform to Federal Motor Vehicle Safety Standards and in regards to operation on public streets roads or highwaysis illegal BV Powersports LLC EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board the U S Environmental Protection Agency and BV Powersports LLC hereinafter distributor are pleased to explain the emission control system warranty on your 2011 Off Road ATV New off road motor vehicles must be designed built and equipped to meet U S EPA Federal and California anti smog standards Distributor must warrant the emission control system on your vehicle for 5 000 km 500 hours of engine operation or at least 30 months whichever comes first provided that there has been no abuse neglect or improper maintenance of your vehicle This ATV was designed to meet the emission standards for 10 000 km 1 000 hours of engine operation or five years whichever comes first Your emission control system may include parts such as the carburetor or fuel injection system the ignition system catalyt2. WAN IN Jojouropo s 9QUPUO UTE A sumay Swedy Surmo Sunsnpy y Alessaoou Jt 3uroe do1 10 redar Jangas 8911 ueopo xoeuo surpn our uoroedsu 915 o qe ur Jedes zo SSUTULIT 1 TeAJ9 UI urea 15 pourejureur pue poxoouo oq poys o 24210 0UI 90 poog souKULIOJIOd 91 do o ELETRICITY PRINCIPLE DIAGRAM WOT 2 npow IST JT OOy 1018 19191 LOTR NSoY 73 LIH ES SEES prouo os ak R rpanoxo O J9j191q Log tt rh jo o E E KJ93119g Nvd VIG TIdIONISdd ALIOIULOSTIS isis 1 UJlOH Fi H 9 MS 181S MS UOT TUS 24 ELETRICITY PRINCIPLE DIAGRAM SUTPUNOIN 5 55 ME I UO11nq UJOH a MS 11918 WvdoVIOQ WIdIONISd ALIOIWIOTT Trail TrailMaster MID XRX Set up instruction Version 1 0 2011 9 01 This set up instruction guides our customer to set up the go kart TrailMaster MID XRX step by step to ensure a correct assembly for safe driving MID XRX Set up instruction Check the components after opening the box 1 1 Battery pic 1 type 12N9 BS 12V9Ah includes one battery one battery liquid two bolts and nuts for installation N c 2L 1 s Se Se ec I Pic 1 1 2 One set of front fenders for left and right pic 2 MID XRX Set up instruction 1 3 One set of rear fenders for left and ri
3. 13 OPERATION B Pre Drive Inspection N WARNING Perform this pre driveinspection everyday before driving the vehicle If not performed serious damage tothe vehicle or personal injury may result a Check the engine oil level is between the bottom of the dipstick and the 0 mark b Check for leaks Add oil 1f required c Check the Fuel Level Add fuel as necessary and do not overfill d Check for leaks Ensure the fuel filler cap is securely fastened e Check the Brakes Depress the left brake pedal several times and check for adequate brake pedal free play Make sure there 15 no brake fluid leakage f Check the tires Check their condition for damage or excessive wear and pressure The pressure on the front and rear tires 1s 7 9 psi respectively g Check the drive chain Check its condition and tension Lubricate 1f necessary h Check the throttle cable check its smooth operation Ensure the throttle can return back to idle and move smoothly without sticking by releasing the throttle pedal 1 Check the Engine Stop Button While the engine 15 running press and hold the engine stop button for 2 seconds Make sure the engine stops J Check all nuts bolts and fasteners k Check the wheels to see that all axle nuts and lug nuts are tightened properly Check and tighten as necessary all other nuts bolts and fasteners 1 Check the Brush Guard Ensure all C B C bars are in place before operating the kart m
4. Mc cmo mmu Fill fuel tank with unleaded gasoline and turn on the ignition switch to start the engine DIMENSIONS Overall Length E E ETE EE E Overall Width see sse see see ees seo cee sse sos sos soo soo soo soe oos ooo ooo Overall Height RRR ASR ENE aoe ae Bae Sen RES ae de Ground Clearance e ses sss sss see soo oso sso ssa sso ooo ooo soe sao ENGINE Type ooe ERE AS A34 aw WES EPA RAE Rud ood wes was Bore xX Stroke e n Corrected compression ASTRID Output Power e n n n n nn nnn nn nn nn nnn n Maximum Torque em n n n n nn nn nnn nn Lubrication IIR Transmission c mm IIR sse ooo ose oo Spark Plugs n n e e en ne en ee ne ne nee Pluggap eem ee e e e e n en ne en nn eee ne ne ene ere Fuel Type ee e eee ee n ene eem en e n n ene ene nn nn eee en een n Lubricate oil 23e CAPACITIES Maximum load s RI Engine Oilers ee e e e ee en en nn nn ene nn nn nn rn nnn Battery eee e eee hem en nn en ene ne enn nn nn nne ene nen nne enn nen eae ATi due bob axe dde 10 gas dae peeve aud dus oid Gen das cadre wed Brake Track oe coe oss ses sss oss eso ses sss tee sso see sos nee Top Speed wre ere ere ere cee cee cee cee cee cee es SPECIFICATIONS 58 5 in 1700mm 36 1n 1100mm 43 in 1300mm 41 7 1n 1230mm 321n 930mm 25 1n 850mm 3 5 in 70mm ena Forced air cooled 4 Stroke 168cc 2 67in x 2 lin 196ml 8 1 RX 6 3 HP at 3600RPM
5. Check the Lights Check the headlights brake light and tail light are all working n Check the steering system Check that the steering wheel moves freely in both directions but without any unusual looseness o Check all Cable Housings Check these for wear and the fitting for any looseness p Check the underbody and exhaust system Remove all dirt vegetation and mud and check any damage due to impact with rocks or uneven terrain q Check the air cleaner housing drain tube Check the deposits in the drain tube If necessary check the tube and air cleaner housing r Check leaks and loose parts Walk around your kart and look for anything that appears unusual such as a leak or loose cable s Check the parking brake Make sure the kart does not move forward or backward when the parking brake 1s applied OPERATION STEERING WHEEL FUEL TANK CAP TANK COMP FUEL B 4 T n ES iS J Figure 2 Component locations OPERATION C Passengers The vehicle is designed for two people only The combined maximum weight of the driver and the passenger should not exceed 180kg or 400lbs Remark Different versions of TrailMaster Go kart MID could have different seats design D Seat Adjustment The seat should be securely fastened in the position which gives the operator best control of the foot pedals steering wheel and the engine stop button a Pull the seat adjustment handle upward to disengage t
6. a Figure 6 Spark plug year to ensure easy starting and good engine performance 18 SERVICE INSTRUCTIONS C Adjusting the throttle and idle speed a Warm up the engine 5 10min b Tighten the air screw gently Back out 2 3 8 turns counter Prem clockwise c Connect the tachometer adjust the throttle to limit the idle speed The standard value is 1400RPM d Turn the air screw counter clockwise slowly and observe the RPM of the engine stop adjusting as the RPM reaches the top speed e Adjust the screw and adjust the idle speed to an ideal Figure 7 adjusting the throttle value f Recheck and readjust the idle speed if necessary D Cleaning Instructions Keep your kart clean With a clean rag wipe off all dirt and oil from around the controls Wipe off any spilled fuel and oil Keep the engine clean of foreign objects and be sure to check that the air intake fan is free of debris for proper cooling E Go kart Lubrication Lubricate this TrailMaster Go kart MID every 90 days of use Lubrication should be done more often 11 the kart 15 used everyday F Chain Lubrication To increase chain life it should be lubricated with a spray on type chain lubricant See Fig 8 Figure 8 Drive chain lubrication 19 SERVICE INSTRUCTIONS G Adjustment of front and rear shock There are five adjustable positions on each shock The default position is 1 the middle set by manufacturer See Fig 9 Use a round nut w
7. a variety of forms including Safety Labels On the 7railMaster Go kart MID Safety Messages Preceeded by a safety alert symbol N and one of two signal words WARNING or CAUTION These signal words mean NWARNING Physical harm may result from failure to adhere to the instructions that are described within the WARNING labels Safety Headings such as Important safety reminders or important safety precautions Safety Section such as kart safety Instructions how to use this TrailMaster Go kart MID correctly and safely This entire manual is filled with important safety information please read it carefully IMPORTANT SAFETY INFORMATION You TrailMaster Go kart MID will provide you with many years of service and pleasure The Safety Information will provide you to take responsibility for your own safety and understand the challenges youcan meet while driving There is much that you can do to protect yourself while operating your TrailMaster Go kart MID You ll find many helpful recommendations throughout this manual The ollowing are afew points we consider most important for safety protection Follow the Age Recommendation Adult supervision should be present for all people under the age of 13 Always Wear a Helmet Always wear an approved motorcycle helmet We also recommend that you wear eye protection sturdy boots gloves and other protective gear Drive Off Road Only Your TrailMaster Go kart MID is designed
8. inability to use the distributor vehicle for any purpose Some states do not allow the exclusion or limitation of any incidental or consequential damages so the above limitations may not apply to you BV Powersports LLC EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS B No express emission control system warranty is given by Distributor except as specifically set forth herein Any emission control system warranty implied by law including any warranty of merchantability or fitness for a particular purpose is limited to the express emission control system warranty terms stated in this warranty The foregoing statements of warranty are exclusive and in lieu of all other remedies Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you IV LEGAL RIGHTS This warranty gives you specific legal rights and you may also have other rights which vary from state to state V ADDITIONAL INFORMATION Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs However distributor is not liable for these parts The owner is responsible for the performance of all required maintenance Such maintenance may be performed at a service establishment or by any individual This warranty is in addition to the Distributor limited vehicle warranty No dealer is authorized to modify this Limited
9. regarding your warranty rights and responsibilities you should contact distributor at 2848 Reward Dallas TX 75220 the U S Environmental Protection Agency 2000 Traverwood Avenue Ann Arbor MI 48105 or for California registered off road vehicles only the California Air Resources Board at 9528 Telstar Avenue El Monte CA 91731 BV Powersports LLC EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS BV Powersports LLC hereinafter Distributor warrants that each new 2011 and later Distributor off road vehicle A is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board and B is free from defects in material and workmanship which cause such vehicle to fail to conform to applicable regulations of the United States Environmental Protection Agency or the California Air Resources Board for the periods specified above The warranty period begins on the date the vehicle is delivered to the initial retail purchaser or on the date the vehicle is first placed in service as a demonstrator rental lease prior to retail sale I Coverage Warranty defects shall be remedied during customary business hours at any authorized Distributor dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the Unit
10. set up the rear wheel onto the rear axle screw the washer and nut screw tightly with 98 103NM then open the cotter pin 3X40 for fixing cover the hub COVCTI MID XRX Set up instruction 2 3 Assemble the front wheel pic 16 Take off the nut MI2x1 5 and 12 washer from the rear axle Raise up the front part and set up the rear wheel onto the rear axle screw the washer and nut screw tightly with 55 62NM cover the hub cover Pic 16 2 4 Assemble the front fender pic 17 Take down the bolts MOXI2 on the strut assemble the fender fix the bolt with torque 11 16NM P1c 17 2 5 Assemble the rear fender pic 18 take down the M6x12 bolts from the fender bracket assemble the rear fender and screw on the bolts with torque 11 16NM MID XRX Set up instruction Pic 18 2 6 Assemble the head rest pic 19 Insert the assembly bars of head rest into the mount holes of seat Pic 19 2 7 Assemble the long bar cages pic 20 put two sides of long bar cages onto the connection rods on frame and rear cargo rack fixing with bolt M x50 R washer and M8 nut Tighten the bolts MID XRX Set up instruction 2 8 Assemble the side bar pic 21 Put one side of side bar attaching the long bar cage connect the side bar and the long bar cage together with bolt M8x50 R washer screw the bolts 3 turns Connect another side of side bar onto the connection rod of frame with R washer bolt M8x50 and bolt Screw on all
11. the bolts tightly ae E WO EN a Pic 21 2 9 Assemble the cross bar pic 22 Connect the cross bar with two long bar cages with bolt M8X50 and R washer do not tightening the bolts at this step 10 MID XRX Set up instruction 2 10 Assemble the roof rack bars pic 23 fix the rear cross bar with long bar cage together using bolt M8x50 and R washer Pic 23 2 11 Screw on the bolts from step 2 6 to 2 10 with torque 22 29NM 2 12 Assemble the Bikini top pic 24 Put the foam padding around the top of long bar cage cover the awning on the right position and fasten the string Pic 24 2 13 Assemble the yellow flag and flagpole use the plastic bolt and nut to fix the flagpole on the rear cargo rack 1 MID XRX Set up instruction 2 14 Install the battery battery cover put the battery liquid into the battery body close the battery cover Put the cushion plate into the battery mount box Connect the battery wires to the battery poles to to cover them Put the wired battery into the battery mount box covered with the plastic protection cover put the wires out through the protection cover slot fasten the battery with battery strap Note because the battery liquid and wiring of battery poles are dangerous only experienced adult can carry out this carefully with protection measures protective glove Prevent electric screwdriver 2 15 Assemble the ste
12. 9 6 Ib ftat 2500RPM Electric Pull start backup C D I Force amp Splash Automatic C V T system F7RTC 0 7 0 8mm Rq 90 SAE 10W 30 Double Seats 400105 30z 5s I2V9Ah 10A 25 mph or limited as customers require 1 SPECIFICATIONS CHASSIS Front tire oco ooo ooo 0o00 CHS 0o00 OSS ooo SEN ooo ooo ER ooo ooo ooo ooo ooo ooo ooo ooo ooo ooo Front Suspension E E EE Rear Suspension Restraint System TIRE PRESSURE Front Rear eco 0600 000 0600 0600 000 e800 0600 000 000 000 000 000 000 000 000 000 000 000 000 000 000 0009 0600 0009 960606 600 eee WEIGHT Net Weight 150Kg PACKING DIMENSIONS Dimensions 9 rm mh tee see oon oe wee oes Loading quantity Disc brake l6x 6 8 16x 7 8 Dual A Arm Swing A Arm Double Oil Damped Shock Dual 4 point Harness 1 9 psi 7 9psi 66 91n x 43 31n x 25 91n 330105 385lbs S pes 1 1 x 40ft HQ OPERATION A Operation controls WARNING Do not attempt to start or 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 a Throttle The right foot pedal is the throttle that controls the kart speed As the engine speed increases above idle the clutch 15 engaged automatically and moves t
13. D We hope you will enjoy it Before you start to operate the 7railMaster Go kart MID please read through this Owner s Manualcarefully asit containsimportant safety and maintenance information Failure to follow the warnings containedin this manual canresult inserious injuries or death Be sure to follow the recommended maintenance schedule and service your JrailMaster Go kart MID accordingly Preventive maintenanceis extremely important to thelongevity ofyour TrailMaster Go kart MID Beginners should seek instructions from your dealer or qualified instructors before and during initial use of the TrailMaster Go kart MID It 1s also recommended to practice ina large open area and familiar with operations of this Trail Master Go kart MID We hope you will have a pleasant experience with our products and thanks again for choosing our Zrail Master Go kart MID A FEW WORDS ABOLLT SAFETY In order to keep everyone safe you must take responsibility for the safe operation of your TrailMaster Go kart MID To help you make informed decisions about safety we have provided operating procedures and other information on labels and in this manual This information alerts you to potential hazards that could hurt you or others It 1s not practical or possible to warn you about all hazards associated with operating or maintaining a 7railMaster Go kart MID You must use your own good judgment You will find important safety information in
14. Emission Control System Warranty issued by Distributor CONLENTS OWNER S MANUAL Page SAMPORTANTSAEETY INFORMATION esse eruat RR acto Rd pb rennin Q0 Uo oh aan tnd CD QUE sine con ane Neste one eub dal awh lice adole aX ex reddis aus Ged EEA ons wel Gelade gue dere BIS SOUR VERICLE READY TODRIVE 9 due sab oo ose ce steve pe bie a Hep Er dto dices na atadus 7 SAFE DRIVING PRECAUTIONS EE ura oes STE UE ton senda noes Wai wae aha Bic wade Ran akt 15 ELETRICITY PRINCIPLE DIAG RAM k es cee cee I cee cee I I IIIA IIR IRR RII cae cae cae RR RIA wee wee cae coo ece ooe ococce IRI m PARTS MANUAL INTAKE EXHAUSTMECHANISM ASSY ettet tre ees ete ttt tete ttt tt eee sans sua see see oett ti te cess te eee anaes te D MIHI MMEMMREIU Ua v MP NM Ut EDS CARBURETOR BUSSENSION ARIA essere ects EIU ME MEC UM E UNUM DUM teen HEARNOUSING rive ee ee ee en ee N eee dt WIRE HARNESS ELECTRICAL SEAT ENGINE eee teet t ett tt t tt esas see eee susan eee se ua aoe tt t at as cee ea e cee cee tans eee tdi WARNING STICKERS ASGSY e I cee I cae nee aoe II II one wee Rh Rh RI hh HO Ee Oe Oe wee wee Hee Hae oce aoe one cn nnn eel FOREWORD Thank you for purchasing our TrailMaster Go kart MI
15. and manufactured for off road use only The tires are not made for pavement and the 7railMaster Go kart MID does not have turn signals and other features required for use on public roads If you need to cross a paved or public road please get off and walk with your Go kart across Take Time to Learn amp Practice Even if you have driven other Go karts take time to become familiar with how this TrailMaster Go kart MID works and handles Practice in a safe area until you build your skills and get accustomed to this Go kart s size and weight Because many accidents involve inexperienced or untrained drivers we urge all drivers to take a training course approved by the Go kart Safety Institute Check with your dealer for more information on training courses IMPORTANT SAFETY INFORMATION Be Alert for Off road Hazards The terrain can presenta variety of challenges when you drive off road Continually judge the terrain for unexpected turns drop offs rocks ruts and other hazards Always keep your speed low enough to allow time to see and reactto hazards Drive within your limits Pushing limits 15 another major cause of TrailMaster Go kart MID accidents Never drive beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs fatigue and inattention can significantly reduce your ability to make good judgments and drive safely Don t drink and drive Do not drive your TrailMaster Go kart MID aft
16. care when operating on excessively rough slippery or loose terrain could cause loss of traction or vehicle control which could res in an accident including an 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 errain Always be especially cautious on these kinds of terrain Do Not Perform Stunts You should always operate your TrailMaster Go kart MID in a safe and reasonable manner When driving always keep all four wheels on the ground WARNING Attempting wheelies jumps and other stunts increases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off P D I A Install rear shocks and tighten the nuts B Install rod end tie rod tighten the castle nut and insert the cotter pin C Install ball head dust seals align the ball head bolt knuckle support to the square hole on the lower A Arm Install flange nut and tighten it 788 9 foot Ibs Install front tires and tighten the nuts Install rear tires tighten the nuts insert cotter pin and put on the rubber cover Raise the C B C custom bar cage as in picture Install C B C rear custom bar cage put on R Washer Install Head Rest Check all nuts and bolts wiring cables fuel line switches and tire pressure Fill battery with acid and charge check and fill the engine with the recommended oil
17. ecessary to remove the 4 nuts to remove the wheel See Fig 11 Figure 11 Replace the rear wheel 21 REPAIR C Front Wheel Alignment a The front wheels should be toe in from 1 8 to 1 4 inch Measure the distance A and B between the centerline CL of the wheels to check for alignment The proper toe in dimension A should be 1 8 1 4 inch greater than dimension B b To adjust the alignment loosen the lock nuts on both sides of front tie rod To make Dimension B smaller turn the rod to left Adjust the rod to right direction to make Dimension B larger After adjusting to the desired length tighten the lock nut against the rod end Recheck the dimensions for proper alignment LOCK NUT FR WHEEL TIEROD Nf x REZ N i h LA SS LEFT ROATE LEFT ROATE CL CL FR WHEEL B TIEROD RIGHT ROATE RIGHT ROATE rv Figure 12 Front wheel alignment 22 MAINTENANCE TABLE puonbo y ueopo 0 popueurumo21 st 11 998 4 snp uo SUL x 3 qe aq uo 195 poured au oj Supose uuopred oseo d o qe I uo JSOUSTY aq 1940 SI IFEI IY USu A s Lo EI pop pL uL p LLL ers Lo LL 11 11 1 1 1i emi loa d E LE B LLL LL lal lo eee oa da dada d daa aL m S S S ee ee ee ee 50 o 19 j j9 y i y wo 1 1 V P 1 1v 1 1 m Aressaoou UAM JL BUCY uny900p 900c 19 9 WeI pue ury090 EIU onjd reds Kressooou uou 11 90100 Wy 0006 0087 A199 1
18. ed States Environmental Protection Agency and the California Air Resources Board Any part or parts replaced under this warranty shall become the property of Distributor II Limitations This Emission Control System Warranty shall not cover any of the following A Repair or replacement as a result of 1 accident 2 misuse 3 repairs improperly performed or replacements improperly installed 4 use of replacement parts or accessories not conforming to specifications set forth by Distributor which adversely affect performance and or 5 use in competitive racing or related events B Inspections replacement of parts and other services and adjustments required for required maintenance C Any vehicle equipped with an odometer or hour meter on which the odometer mileage or hour meter reading has been changed so that actual mileage cannot be readily determined III Limited Liability A The liability of Distributor under this Emission Control System Warranty is limited solely to the remedying of defects in material or workmanship by an authorized Distributor 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 or from the Distributor or authorized dealer Distributor shall not be liable for any other expenses loss or damage whether direct incidental consequential or exemplary arising in connection with the sale or use of or
19. er drinking Even one drink can reduce your ability to respond to changing conditions and your reaction gets worse with every additional drink So don t drink and drive and don t let your friends drink and drive either Do not operate this TrailMaster Go kart MID at night Dark vision can greatly reduce a driver s visibility and judgment So driving at night 1s dangerous and can increase the possibility for an accident Never run your ZrailMaster Go kart MID indoors The exhaust from the engine contains a tasteless odorless and poisonous gas called carbon monoxide Keep away from moving parts of the TrailMaster Go kart MID The operator of the TrailMaster Go kart MID should never place their hands orother parts of their body nearany moving part ofthe TrailMaster Go kart MID Failure to adhere to this warning will cause physical harm to your body Skidding or Sliding The terrain surface can be a major factor affecting turns Skidding ina turn is more likely to occur on slippery surfaces such as snow ice mud and loose gravel If youskid onice you may lose all directional control To avoid skidding on slippery terrain keep your speed low and driving carefully SAFETY LABELS This section presents some of most important information and recommendations to help you driving your 7railMaster Go kart MID more safely Please take some time to read this section The safety labels should be considered as permanent parts of the 7railMa
20. ering wheel Check the front wheel is at the straight position Take down the bolts on steering shaft put the steering wheel correctly onto the steering shaft as shown in pic 25 Screw the bolts with 11 16NM torque Cover the steering bolt cover 12 MID XRX Set up instruction Before driving please read the user manual of TrailMaster Go kart MID XRX carefully you will be given with important safety information and advices Thanks a lot for choosing TrailMaster Go kart MID XRX For more other products of TrailMaster please visit www bvpowersports com BV Powersports LLC 13
21. ety Before you drive this TrailMaster Go kart MID for this first time we urge you to Read this owner s manual and the labels on your 7railMaster Go kart MID carefully Make sure you understand all the safety messages Know how to operate all the controls Before each drive be sure Q You wear your seat belt at all times while driving your TrailMaster Go kart MID You feel well and are in good physical and mental condition Q You are wearing an approved motorcycle helmet with chin strap tightened securely eye protection and other protective clothing Q You don t consume any alcohol or drug Protective Apparel For your safety we strongly recommend that you always wear a D O T approved motorcycle helmet eye protection boots gloves long pants and long sleeved shirt or jacket whenever you drive Although complete protection 1s not possible wearing proper gear can reduce the chance of injury by an accident The following suggestions will help you choose the proper protective gear Helmets and Eyes 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 An open face helmet offers some protection but a full face helmet offers more Regardless of the style look for a D O T Department of Transportation sticker on any helmet you buy Always wear a face shield or goggles to protect y
22. ght pic 3 Pic 3 1 4 One set of Bikini Top and two foam paddings pic 4 Pic 4 MID XRX Set up instruction 1 5 One sport steering wheel pic 5 Ld Pic 5 1 6 1 one standard parts package one manual one flag one battery cover one battery strap one battery lower cushion four hub coves plastic fixing bolt and nut for flag 5 cable bundles and one steering bolt cover pic 6 MID XRX set up instruction 1 6 2 In the standard parts package 14 bolts M8x50 2 cotter pins 3X40 2 cotter pins 2 5 X25 20 R washers 6 self locking nuts M8 pic 7 Pic 7 1 7 Two head rests pic 8 Pic 8 MID XRX Set up instruction 1 8 Two bar cages pic 9 Pic 9 1 9 One top cross bar preassembled with tube seats pic 10 Pic 10 1 10 Two side bars for left and right side with tube seats pic 11 Pic 11 MID XRX Set up instruction 1 11 One top cross bar with tube seats pic 12 Pic 12 1 12 front wheels left and right rear wheels left and right pic 13 Pic 13 MID XRX Set up instruction 2 Assembly 2 Assemble the rear shocks pic 14 take down the bolts from the shocks lift the rear swing arm to let the top of shock into the fixing seats of frame use 37 44NM torque to fix the shocks attached the frame Note INM 0 74 lb ft Pic 14 2 2 Assemble the rear wheels pic 15 Take off the nut M16x1 5 and 16 washer from the rear axle Raise up the tail part and
23. he seat slide b Move the seat to the desired position c Be sure that the seat adjustment handle snaps back into place and that seat 1s locked into position N WARNING Figure 3 seats Before attempting to adjust the seat ensure that engine 1s stopped N WARNING Never operate this kart when the seatis not securely in place to do so could result in personal injury or loss of life 16 OPERATION E Starting and Operating Instructions a Before starting the engine the driver must seat properly in the kart with the seat belt on b Practice in the kart in an open space at the beginning to learn how to start turn and stop the kart c Drive slowly until you are familiar with the operation of the TrailMaster Go kart MID d The turning radius of this kart is small and agile so the centrifugal force is very high when turning at high speed Slow down to a more controllable speed when turning to prevent the kart from rolling over The driver should keep their heels on the ramp of the main board when turning Keeping their legs on the foot pedal See Fig 4 the driver can feel that the kart 1s stable and won t roll over Figure 4 Heels and legs position by driving the kart SERVICE INSTRUCTIONS A Engine Lubrication You must change the oil in the crankcase after the first 5 hours of operating of your new engine See Fig 6 and after every 10 hours of use thereafter This will insure proper lubrication of the i
24. he vehicle forward To disengage the clutch at any time allow the throttle to return to the idle position See Fig 1 NOTICE Each 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 if pedal or engine throttle linkage fail to return to idle If unable to correct the problem through lubrication adjustment or replacement of worn parts contact your dealer for assistance b Brake The brake 15 the left foot pedal See Fig 1 Applying pressure to the pedal draws the brake caliper around the brake disc at the rear wheel and slows stop the kart c Start Engine HORN V ual IGNITION START SWITCH Insert the key into key switch turn the key clockwise release the key when the engine starts The engine will warm within 5 minutes and the engine choke will close automatically and run at normal RPM Warning Do not crank starter more than 5 seconds at one time Remark the TrailMaster Go kart MID basic version XRS has also variant model without electric start function Only pull start THROTTLE PEDAL BRAK PEDAL Figure 1 front panel d Engine stop button Before driving this vehicle test the Engine Stop Button to ensure that it is operating properly With the engine running push and hold the Engine Stop Button for two seconds until the engine has been shut down
25. ic converter and engine computer if it is equipped Also included may be hoses belts connectors and other emission related assemblies This vehicle is warranted for its emission control devices for the full useful life of the vehicle Where a warrantable condition exists 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 distributor This is your emission control system DEFECTS WARRANTY OWNER S WARRANTY RESPONSIBILITIES As the vehicle owner you are responsible for the performance of the required maintenance listed in your owner s manual Distributor recommends that you retain all receipts covering maintenance on your vehicle but Distributor cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance You are responsible for presenting your vehicle to the Distributor dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days As the vehicle owner you should be aware that Distributor may deny your warranty coverage if your vehicle or a part has failed due to abuse neglect improper maintenance or unapproved modifications If you use your vehicle in any type of competitive event this warranty is immediately and completely void If you have any questions
26. nternal parts and prevent costly repairs due to excessive wear N WARNING Used Oil Must Be disposed of at a proper collection Center a Remove the drain plug located on the right rear side of engine Tip the kart backwards slightly by blocking up the front end and drain the oil into suitable container b Remove and clean the oil filter c Replace drain plug and tighten securely Place the kart 1n PLUG COVER a level position d Refill the crankcase approximately 11 4 pint to the top of the filler neck with SAE 10W40 oil e Check the oil level before each use of the kart or after each 10 hours of operation Add oil when necessary to keep Figure 5 Engine oil plug cover the level between the bottom of the dipstick and the 10 mark Do not mix various grades of oil B Spark Plug SEAM DIRT CARBON VERIFY a Remove the spark plug and inspect it each time you 0 7 0 8mm change the oil use a spark plug wrench The electrodes should be kept clean and free of carbon The presence of carbon or excess oil will greatly reduce engine performance oe cum If possible check the spark plug gap area between electrodes using a wire feeler gauge This specification 1s 0 7 0 8 mm SEAM VERIFY b Before installing the spark plug coat the threads lightly with graphite grease 1f possible to ensure easy removal next time the spark plug needs Inspection c It is advisable to replace the spark plug at least once
27. ontrol N WARNING Operating this karton paved surfaces may seriously affecthandling and control of the kart and may cause the vehicle to goout of control Never operate the kart on any paved surfaces including sidwalks driveways parks lots and streets 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 obey ino 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 N WARNING Operating this kart on public streets roads or highways could cause 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 pedals It 1s important to maintain your balance and to control the kart Removing hands or feet away from the controls can reduce your ability to react and control the kart N WARNING Removing your hands from the steering wheel or feetfrom the footcontrols during operation can reduce your ability tocontrol the kartor could cause you to loseyour balance and fall off the kart Always keep both hand
28. our ability to operate a kart safely Likewise drugs even if it s prescribed by a physician can be dangerous while operating a kart Consult your doctor to be sure it is safe to operate a vehicle after taking medication N 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 Pre drive inspection is a must not only for safety due to a break down or even a flat tire can be a major inconvenience If your kart has overturned or has been involved in a collision do not drive it until your kart has been inspected by your dealer There may be damage or other problems that you can not see N WARNING Improperly malntaining this kart or failing to correct a problem before driving can cause a crash in which you can be seriously hurt or killed Always perform a pre drive inspection before every drive and correct any problems 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 TrailMaster Go kart MID handling and c
29. our eyes and help your vision N 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 andthe possibility of death inthe eventof a severe accident Always wearan approved motorcycle helmetthat fits properly and wear eye protection goggles orface shield gloves boots long sleeved shirt or jacket and long pants ARE YOU READY TO DRIVE Additional Driving Gear In addition to a helmet and eye protection we also recommend Q Sturdy off road motorcycle boots to help protecting your feet ankles and lower legs Off road motorcycle gloves to help protecting your hands Driving pants with knee and hip pads a driving jersey with padded elbows and a chest shoulder protector Driver Training Developing your driving skill 15 an on going process Even if you have driven other karts before please take time to become familiar with how this kart works and handles Practice driving this TrailMaster Go kart MID in a safe area to develop your skills Do not drive on rough terrain until you get accustomed to the kart s controls and feel comfortable with its size and weight 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 a small amount of alcohol can impair y
30. rench as you adjust the shock the tension of shock spring will increase as you screw to left decrease as you screw to right Adjustment is according to the weight of the riders LIII tf RIGHT ROTATE Figure 9 Shock adjustment LEFT ROTATE H Storage instruction In the event your TrailMaster Go kart MID 15 not to be operated for period in excess of 30 days or at the end of each driving season prepare for storage as follows a Drain fuel tank and carburetor by allowing engine to run out of fuel and use a fuel stabilizer b Lubricate engine cylinder by removing the air cleaner then spray engine fogging oil through the carburetor until the motor dies c Do not save or store gasoline over winter Using old gasoline which has deteriorated from storage will make the engine difficult to start and affect engine performance N WARNING Do not drain fuel while engine is hot Be sure to move the kart outside before draining fuel 20 REPAIR A Front Wheel Replacement Do not disassemble the castle nuts when you replace the front wheels It s only necessary to remove the 4 nuts to disassemble the wheel See Fig 10 Tighten the nuts after replacing the wheels Figure 10 Replace the front wheel B Rear wheel replacement Do not disassemble the castle nuts when you replace the rear wheels and hub assembly Remove the cotter pin and then 24 mm nut After that slide off the wheel and hub assembly It is only n
31. s onthe steering wheeland both feeton the footcontrols of your kartduring operation READY TO DORIVE Control Speed Driving at excessive speed increases the chances of an accident In choosing an appropriate speed you need to consider the capability of your kart the terrain visibility and other operating conditions plus your own skill and experience N WARNING Operating this kart at excessive speeds increases your chances of losing control of the kart which can result in an accident Always drive at a speed that is appropriate for your kart the terrain visibility and other operating conditions and your experience Use Kart on Unfamiliar or Rough Terrain Before driving in a new area always check the terrain thoroughtly Don t drive fast on unfamiliar terrain or when visibility is limited it s sometimes difficult to react in time if the obstructions like hidden rocks bumps or holes are seen too late N 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 be extra careful 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 extra care on rough slippery and loose terrain WARNING Failure to use extra
32. ster Go kart MID becomes If a safety label becomes hard to read please contact your dealer for replacement Moving parts THIS VEHICLE MANUFACTURED can crush and FOR OFF ROAD USE ONLY at oe Seat Belt Must Be Wom AT All Times BON clear 3031105 STREETS ROADS OR HIGHWAYS P Do notoperate with guard removed N WARNING 303115 THIS GO KAPT GAN BE HAZARDOUS TO OPERATE ifdriven carelessly HAIR INJURLES can resulf If you do not follow these ALL HAIR MUSTBE TIED UP AND Instructions SECURED AT OR ABOVE SHOULDER LENGTH READ OWNER SMANUALA NDA LLL ABELSB EFORE YOU OPER ATE THIS GO KART ALL LOOSE CLOTHING MUST BE SECURED NEVER OPERATE THIS GO KART WITHOUT PROPER ALL NECKLACES AND SCARNES MUST BE INSTRUCTIONS Beglnners require mature supervision NEVER OPERATE THIS GO KART ON PUBLIC ROADS SECURED Itis intended off road use only NEVER OPERATE THIS GO KART AT EXCESSLVE SPEEDS NEVER ATTEMPT WHEELIES JUMPS OR OTHER STUNTS A WARNING Eust This vehicle is not to be operated by anyone 12 under13 years of age A speed reduction kit is Age available for this vehicle ARE YOU READY TO DRIVE Before each drive you need to make sure that you and your Go kart are ready to drive To help you be prepared this section discusses how to evaluate your driving readiness what items you should check on your T7railMaster Go kart MID and which adjustments would be done for your comfort convenience and saf
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