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Carter Brothers Go Kart Interceptor GTR 250 Model 2861 – Live Axle

1. Fig 22 ENGINE MUFFLER AIR CLEANER PART NO 8213 3122 GTR 250 PARTS MANUAL QTY DESCRIPTION Engine Assy 600 4601 Screw ST M4 2x20 8200 3291 Flange Nut M6 8213 3123 Carburetor Assy 8213 3124 Air Cleaner Assy 613 6012 Radiator Fan 500 1070 Flange Bolt M08x25 8000 500 1043 Flange Lock Nut M08 8000 600 0521 Flange Bolt M12x105 900 3006 Flange Lock Nut MT2 637 6001 Engine Mount Fr 637 6002 Engine Mount Rr 600 0110 Front Suspension Bolt 8240 3203 Rear Muffier 8240 3204 EX Muffler Tube 8200 3292 Cap Nut M8 8200 3508 Muffier Tube VVasher 600 0063 Flange Bolt M06x40 640 6604 Air Cleaner Bushing 500 3018 Washer M06 900 1031 Lock Nut M06 8213 3125 Air Cleaner Cover s18 5 Alola IN gt gt 3 po pl N gt N00 LA 8213 3126 8213 3127 Air Cleaner Filter Air Cleaner Case 613 6013 Radiator Body 640 6202 Radiator Intake Tube 640 6021 Radiator Cap 640 6402 Tube Clamp 640 6022 Water Reservoir 640 6023 Secondary Combust Valve 600 0512 Flange Bolt M06x10 613 6015 Radiator Cover 8200 3406 Screw ST 4 2
2. 0 8mm Fuel Type Above 92 unleaded Engine Oil SAE 10VV 30 Idling Speed 1700 100 rpm CAPACITIES Maximum L0oad 2 riders or 180kg 400lbs Fuel Tank 15L 4Gal Engine Oil 1200cc Starting 141111 5s Climbing 20 25 Battery 12V 12Ah Head Lights 12V 35VV 35VV Tail Light 12V 21VV 5VV Gear Oll SAE140 650cc Towing gt 500 Ibs max CHASSIS Front Rear Brake Hydraulic disc Front Tir
3. 39 4 in 1000 mm Ground Clearance 5 1 in 130mm ENGINE Type 4 Stroke Engine Capacity 250cc Bore Stroke 71mm 63mm Displacement 294 4cc Corrected Compression Ratio 10 5 1 Carburetor 22mm Output Power 13 2kw 7000rpm Maximum Torque 20 6Nm 5500rpm Starting 4 Electric Ignition C D I Lubrication 4 Force amp Splash Transmission Automatic C V T system Spark Plug CR8E Plug Gap
4. V 7 9 KO 2 a 5 4 EVA 2 23 N od od 4 eo GTR 250 PARTS MANUAL Fig 21 REAR CARGO RACRISEAT BELT REF PART NO DESCRIPTION QTY 1 609 6015 Tal Light Bulb 21w 5w 12v 1 2 509 3006 Tal Light 461 500 short wire 38 1 500 1031 Lock Nut MOG 2 4 650 0621 Rear Cargo Rack Blue 4 4a 650 0622 Rear Cargo Rack Sliver 1 4b 650 0623 Rear Cargo Rack Carbon 4 5 500 1079 Flange Bolt 08x30 4 6 500 1043 Flange Lock Nut M08 4 7 682 0061 Fuel Tank Comp 1 8 512 1009 Tube Seat 25 6 9 600 0001 VVasher Cap black 6 10 537 3013 Saftey Belt 2pcs set 1 11 640 6011 Fuel Cap 1 12 500 1051 Flange Bolt M08x55 6 18 634 6002 R Seat Comp 1 14 640 6001 Side Reflector 1 15 634 6001 Seat Comp 4 16 613 6010 Fuel Cock Assy 1 17 500 1098 Tube Cip B8 98 A 18 640 6020 Gas Filter 1 19 537 3016 Fuel Tube Comp u 2 20 500 1026 Flange Bolt M08x40 4 21 600 2002 Lock Nut M05 2 22 600 0130 BoltM11x25 5 23 600 5113 WasherM11 5 24 600 5413 Lock Washer M11 5 25 500 1045 Nut M11 5 26 600 0158 Bolt M06x10 2 27 613 6011 FuelPump 1 28 640 6201 Long Intake Fuel Tube 2 29 640 6001 Side Reflector 1 30 500 1071 Lock Washer M10 4 31 634 0004 Seat Adjuster 1 FIG 22 ENGINE MUFFLER AIR CLEANER
5. Oil Pump Assembly Cylinder Head Side Cover Assembly Driven Pull y Set A 1 C V Assembly Carburetor Assembly INDEX TO FRAME GROUP Frame Group Steering Shaft Assembly Suspension Arm Assembly Rear Cargo Rack Seat Belt Engine Muffler Air Cleaner Rear Swing Arm Rear Housing Wire Harness Electrical Trail Board Tool Kit Warning Stickers Stickers GTR 250 PARTS MANUAL PART NO 8240 3107 DESCRIPTION Head Cover Gasket FIG 1 HEAD COVER QTY 8213 3001 Head Cover 8213 3002
6. 26 GTR 250 PARTS MANUAL FIG 27 TOOL KIT Fig 27 TOOL KIT REF PART NO 608 0001 DESCRIPTION Tool Bag 608 0002 Open Ended Wrench 17x19 QTY 608 0009 Open Ended Wrench 13x15 608 0004 Open Ended Wrench 12x14 608 0005 Open Ended Wrench 8x10 608 0006 Slip Joint Pliers 608 0007 Spark Plug Wrench 608 0008 Tube Wrench 1 2 3 4 5 6 7 8 9 608 0003 ROD 608 0010 Screvv Drive Stem i v h AA 28 FIG 28 GTR 250 PARTS MANUAL WARNING STICKERS A WARNING Moving parts can crush and HOT Do Not Touch cam hands clear removed AWARNING Sea WARNING THIS GO KART CAN BE HAZARDOUS TO OPERATE if driven carelessly INJURIES can result if you do not follow these instructions m READ OWNER S MANUAL AND ALL LABELS BEFORE YOU OPERATE THIS GO KART m NEVER OPERATE THIS GO KART WITHOUT PROPER INSTRUCTIONS Beginners require adult supervision Seat Belt Must Be THIS VEHICLE MANUFACTURED m NEVER OPERATE THIS GO KART ON PUBLIC ROADS FOR OFF ROAD USE ONLY It is intended for off road use only Worn At All Times DO NOT OPERATE ON PUBLIC 3031105 STREETS ROADS OR HIGHWAYS m ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and p
7. O 1 620 6012 Fr VVheel Hub Cap 2 2 500 1040 Cotter Pin 3x30 2 3 600 2511 Castle Nut M14 2 4 500 1087 Cap Lock Nut M10 8 5 618 0611 L Fr VVheel Assy K61 4 6 620 6001 Fr Hub 2 7 636 6002 R Strut amp Spindle 1 8 500 3036 Flange Bolt M08x16 A 9 500 1086 Lock Washer MO6 4 10 636 6004 R Fr Caliper 1 11 600 0159 Front Disc Brake Bolt 6 12 900 3014 Flange Lock Nut M10 12 13 500 3028 Flange Bolt M10x80 8 14 500 1091 Flange Bolt M10x40 4 15 500 1088 Castle Nut M12 4 16 600 3901 Cotter Pin 3x20 4 17 652 6007 Fr Brake Disc 2 18 936 3016 Ball Head Dust Seal 4 19 528 3000 Ball Head Spacer 4 20 653 6001 Fr Shock 2 21 636 6001 L Strut amp Spindle 1 22 653 6011 Fr Upper Svving Arm 2 23 500 1020 Fr Swing Arm Internal Bushing 16 24 500 1036 Fr Svving Arm nternal Collar 8 25 653 6020 Fr Swing Arm Dust Cover 16 26 636 6003 L Fr Caliper 1 27 618 0621 R Fr VVheel Assy R61 1 28 600 5118 VVasher 06 4 29 653 6010 Fr Lovver Svving Arm 2 20 652 6006 Fr Brake Pad Set 2 31 620 6011 Fr Wheel Hub Outer Collar 2 32 600 6010 O Ring D430 16 33 620 6010 Fr Wheel Hub Inner Collar 2 34 616 0061 Fr Tire k61 2 35 619 0061 Fr Steel Rim K61 2 26 600 5910 Strut amp Spindle VVasher 2 37 636 6005 Strut 8 Spindle Cap 2 FIG 21 REAR CARGO RACK SEAT BELT
8. REF PART NO DESCRIPTION QTY 8213 3019 Cylinder Comp 8213 3020 Cylinder Assy 8240 3105 Cylinder Gasket 8213 3021 Cam Chain Tensioner 8213 3022 Tensioner Lifter Assy 8200 3191 Adjuster Bolt cylinder 8240 3108 Tensioner Lifter Gasket 8200 3606 O Ring H6T 8257 3013 Adjuster Spring cylinder 8213 0035 Cam Chain Tensionerpivot 8213 3023 Cam Chain Guide 8200 0167 Flange Bolt SHF 6x22 8200 3301 Dowel Pin 12x20 8240 3106 Cylinder Head Gasket oO CO NN O G BI CI NN gt A N la lal LI nan dd Sd GTR 250 PARTS MANUAL FIG 4 L COVER ASSEMBLY Fig 4 L COVER ASSEMBLY PART NO 8213 3024 REF DESCRIPTION L Cover QIY 8213 3025 L Cover Plate 8240 3102 L Cover Plate Gasket 8213 3026 L Bearing Setting Plate 8213 3027 L Cover Assy 8213 3028 Bearing Stay Collar 8213 3029 Bearing Stay Collar Assy 8240 3104 L Cover Gasket 8200 3602 O Ring 26 5x2 0 DOD N1N O oO BIC NN gt 8200 3401 Pan Screw 5x12 8200 0304 Dowel Pin 8x14 8100 0160 Flange Bolt SH 6x12 8200 3111 Flange Bolt SH 6x35 8222 3001 Radial Ball Bearing 6006LLU Z N NN 1 A IN Ia a a RR mM dai FIG 5 L CRANR CASE PART NO 8213 3030 GTR 250 PARTS MANUAL Fig o L CRANK CASE DESCRIPTION L Crank Case Comp 8213 3031 Setting Plate 8240 3201 Missio
9. Tube Seat 32 QTY Headlight Bulb 35W 12V 600 2203 Flange Lock Nut M08 black 637 6401 Fr L Fender Bracket 500 1079 600 0126 Flange Bolt M08x30 Bolt M05x14 640 6003 Headlight Rubber Mount 600 0061 Cross Bolt M6x20 900 3000 Pan Screw M05x25 640 5607 940 3001 Rear View Mirror Bushing 540 3000 Rear Mirror Assy 640 6004 Left Foot Pad 640 6005 Foam Padding short 640 6030 Foam Padding top long 637 6402 640 6006 Fr R Fender Bracket Middle Foot Pad 640 6007 Right Foot Pad 609 6004 Fr L Turn Signal 609 6005 Fr R Turn Signal 609 6006 609 6007 Rr L Turn Signal Rr R Turn Signal 609 6008 Left Light Rear cover 640 6602 Light Inner Bushing 609 6009 Light Joint Line 640 6701 7200 0032 Light Inner Collar Screw ST 4 2x16 609 6010 L Light Center cover 609 6011 L Light Front cover 600 2003 Self Lock M6 612 6113 612 6153 C B C Bar R Blue C B C Bar R Sliver 612 6163 C B C Bar R Carbon 609 6012 R Light Front Cover 609 6013 R Light Center Cover 609 6014 500 1076 R Light Rear Cover Lock Nut M05 ND EI a S CE sech CS NO INNI IAA 1 sch A xc a la NIN _ sch JA Iesch O NAN IO OO O N Co 900 1043 Flange Lock Nut M08 N 640 60
10. 8209 3002 C D I Unit Comp 8209 3003 Starting Relay 500 1313 Flange Bolt M06x20 8209 3004 Ignition Coil Comp 609 6032 Power Outlet cover 500 1031 Lock Nut M06 609 6023 Water Temperature Warning Unit 500 1048 Hex Nut M05 640 6018 Decal Panel Cover 600 0511 Flange Bolt M05x20 609 0007 Direction Indicator Lamp Switch 609 6024 Speaker Switch 609 6025 Blinker Relay 609 6026 Negative Wire 609 6027 Wire Harness set 609 6028 Odometer 609 6029 Ceramic Cladding Cylinder i N LL AK i Ja A I JJ TIR sech 1 sech NI 1 sch 1 sech AIN A SA ai 609 6030 Velocity Transducer 640 6017 Shorter VVire harness Lace 00 25 FIG 26 GTR 250 PARTS MANUAL Side Panels amp Hood Cover Fig 26 SIDE PANEL amp HOOD COVER REF PART NO 680 0601 DESCRIPTION Hook QTY 680 0602 Front Left Trail Board 680 0603 Front Right Trail Board 680 0604 Front Middle Left Trail Board 680 0605 Front Middle Right Trail Board 680 0606 Rear Middle Left Trail Board 680 0607 Rear Middle Right Trail Board 680 0608 Rear Left Trail Board O OO NI CO 00 BE GO 680 0609 Rear Right Trail Board A AA AA ANA 600 0135 Rubber Bolt 10PCS SET 640 6019 Self Lock M6 500 1009 Flange Bolt M06x12 600 4601 Screw ST M4 2x20
11. e The GTR must be purchased from a dealer who is an authorized Carter dealer and e Prior to delivery to the purchaser set up and pre delivery service must be performed by a dealer who is an authorized Carter dealer e All units must be registered WITHIN 10 DAYS OF PURCHASE or the warranty is void e All warranty work must be performed by an authorized Carter dealer or service center VVARRANTY OVVNER S VVARRANTY RESPONSIBILITIES As the kart ovvner you are responsible for presenting your kart to the dealer or service centre as soon as a problem exists All shipping and transportation charges for any items returned for vvarranty evaluation and or replacement are to be provided by the kart ovvner Costs from kart ovvner to dealer or service center are the kart ovvner s responsibility IMPORTANT NOTICE VVe do not charge for parts for authorized vvarranty repairs Any defective parts from repairs are required to be returned to Carter upon request All vvarranties are voided if the vehicle has been altered for use in racing or competition rented used under abnormal conditions or subject to abuse misuse neglect or improper maintenance Carter in not liable for any damage claim or liability claim personal or othervvise resulting from operation of this vehicle in any vvay Carter reserves the right to change product specifications designs and standard equipment vvithout notice and vvithout incurring obligation These vehicles ar
12. f arter A Better Built Machine Owners Manual Parts Manual READ THIS MANUAL CAREFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION INTERCEPTOR GTR 250 MODEL 2861 Live Axle This kart is designed for off road use only and does not comply with Federal Motor Vehicle Safety Standards Recommended for Ages 16 C GTR 2861 LIVE AXLE 003 03 2007 FOREVVORD Thank you for purchasing our kart VVe hope you vvill enjoy it Before you begin operating the kart please carefully read this Owner s Manual for the Interceptor GTR 250 as it contains important safety and maintenance information Failure to follovv the vvarnings contained in this manual could result in serious injury or death The Interceptor G TR 250 fits the needs of a vvide variety of kart users above 16 years old Beginners should seek instruction from your dealer or qualified instructors before and during intial use of the kart VVe also recommend that you practice in a large open area until you become familiar vvith operations of this kart Be sure to follow the recommended maintenance schedule and service your kart accordingly Preventive maintenance is extremely important to the longevity of you kart Those vvho vvill be servicing this kart should carefullly review this manual before performing any repair or services All information illustrations photographs and specifications contained in this manual are based on the latest product information avallable at the
13. i ia d 8 rT di 7 Med RE Magna Y Ee WA A 9 E Ke Y 10 Fig 11 BALANCE SHAFT REF PART NO 8213 3069 DESCRIPTION Balance Shaft Comp o 8213 3070 Balance Shaft 8200 3511 Wave Washer 28 3x36x1 8213 3071 Balance Shaft Drive Gear A 8213 3072 Balance Shaft Drive Gear B 8257 3015 Balance Shaft Drive Gear Spring 8200 3505 VVasher 28 3x47 5x1 4 8200 3504 VVasher 28 3x36x1 CO CO NI ODO G BI IN gt 8200 3802 Circlip EX 28mm a sch sa a BR sech sech a a a 8222 3016 Radial Ball Bearing 6204 11 PARTS MANUAL FIG 12 MISSION CASE GTR 250 PARTS MANUAL Fig 12 MISSION CASE REF PARTS NO DESCRIPTION QIY 8213 3073 Mission Case 8213 3074 Inner Cover Stay A 8240 3111 Mission Case Gasket 8213 3075 Drive shaftt 8213 3076 Counter Shaft Assy 8213 3077 Counter Shaft 8213 3078 Counter Gear A 8213 3079 Counter Gear B 8213 3080 Bush 20x13 8213 3081 Spacer 8213 3082 Final Shaft Comp 8213 3083 Final Shaft 8213 3084 Final Gear 8213 3085 Sliding Claw 8213 3086 Reverse Shaft Comp 8223 3001 Drive Sproket 8213 3087 Drive Sprocket Fixing Plate 8213 3088 Shift Fork Shaft 8213 3089 Shift Firk Shaft 8213 3090 Shift Drum Comp 8257 3016 Gear Indication Drill Spring 8213 3091 Gear Indication Drill 8213 3092 Gear Shift Spindle Comp 8200 3503 Washer 25mm 8200 3502 Washer
14. Head Cover Assy 8213 3003 Reed Valve Comp 8200 3190 Head Cover Bolt 8100 0161 Flange Bolt SH 6x16 FIG 2 CYLINDER HEAD COMP GTR 250 PARTS MANUAL Fig 2 CYLINDER HEAD COMP REF PARTS NO DESCRIPTION QTY 8213 3004 Cylinder Head Comp 8213 2002 Valve Stem Seal 8213 3005 Cam Shaft 8213 3006 In Valve Rocker Arm 8213 3007 In Valve Rocker Arm Assy 8213 3008 EX Valve Rocker Arm 8213 3009 EX Valve Rocker Arm Assy 8213 3010 Rocker Arm Shaft 8213 3011 Cam Shaft Setting Plate 8213 3012 In Valve 8213 3013 EX Valve 8257 3011 Valve Outer Spring 8257 3012 Valve Inner Spring 8213 3014 Valve Spring Retainer 8213 3015 Valve Spring Seat 8213 0009 Valve Cotter Set 4pcs set 8213 0010 EXH Pipe Gaske 8240 3313 Air Pipe Comp 8240 3109 Air Pipe Gasket 8213 3017 Thermostat Assy 8213 3018 Thermostat Cover Comp 8200 3405 Tappet Adjusting Screw 8200 0291 Tappet Adjusting Screw Nut 8200 3509 Sealing Washer 10 5mm 8100 0212 Flange Nut 10mm 8200 0163 Flange Bolt 6x14 8100 0161 Flange Bolt SH 6x16 8200 3115 Flange Bolt SH 6x90 8213 0012 Spark Plug CR8E 8213 0019 Thermo Unit Assy O CO 170 OI BE 10 ds s NO ete Ss A A Bla la N la o s s l V la UK Le a li iza les E a FIG 3 GTR 250 PARTS MANUAL CYLINDER ASSEMBLY Fig 3 CYLINDER ASSEMBLY
15. UDIIMS jeuBig uny J0 0Jy Yellow Red Blue White White Black nolleAPPpeld 1109 uomubi Bnig yueds MOJJ9A U98J9 yoelg UNMS JUDI one p M MuM WIMS UOH 1461 4 JOSU9SS Josuas Bulwe y aunyesoduay onig oUM SUUM PSY SHUM UMO1g xog 1402 SHUM ana YMS 1451 ng umolg U9919 an q 14617 euis uun gt Ishini U99J9 MENS i an g P MH MOH A HUMVP M d ESPE pey enu 19819 ili UJOH yy youmg uoniubi Jajayy op ds Jo UJOH is m UMOJg ua an q n e jeu is uan 40 TROUBLE SHOOTING CHARTS A Engine hard to start or can not be started Check and Adjustment Fault Condition Probable Causes V Loosen carburetor drain bolt to check if there is gasoline inside e No fuel in fuel tank e Check if the pipes fuel tank to carburetor and intake vacuum are clogged e Float valve clogged Fuel supplied to No fuel is supplied to l H 99 i Ss e Lines in fuel tank evaporation system carburetor sufficient carburetor clogged e Malfunction of fuel pump e Loose or damaged fuel pump vacuum hose e Fuel filter clogged the carburetor Remove spark plug install it into spark plug cap and perform a spark test against engi
16. and other protective gear Drive Off Road Only Your kart is designed and manufactured for off road use only Its tires are not made for pavement and the kart does not have features required for use on public roads If you need to cross a paved or public road shut the kart s power off get off and walk your kart across Take Time to Learn amp Practice Even if you have driven other karts take time to become familiar with how this kart works and handles Practice in a safe area until you build your skills and get accustomed to this 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 Be Alert for Off Road Hazards The terrain can present a variety of challenges when you drive off road Continually read the terrain for unexpected turns drop offs rocks ruts and other hazards Always keep your speed low enough to allow time to see and react to hazards IMPORTANT SAFETY INFORMATION Drive vvithin Your Limits Pushing limits is another major cause of kart accidents Never drive beyond your personal abilities or faster than conditions vvarrant Remember that alcohol drugs fatigue and inattention can significantly reduce your ability to make good judgments and drive safely Alcohol Drugs and Driving Alcohol drugs and driving don t mix Eve
17. 20mm 8200 3510 Thrust Washer 20 5x38x2 8200 0511 Washer 8mm 8222 3011 Needle Bearing HK2016 8222 3014 Needle Bearing K25x29x10 8200 3705 Oil Seal TC 30x46x7 8200 3702 Oil Seal TC 14x26x6 8200 3703 Oil Seal TC 25x40x7 8200 3002 Hex Bolt 6x10 8200 0193 Drain Plug Bolt 12mm 8200 0591 Drain Plug Washer 12mm 8100 0302 Dowel Pin 10x14 8200 3801 Circlip EX 25 8200 3805 Circlip IN 52 8100 0131 Flange Bolt 8x12 8100 0137 Flange Bolt 8x40 8222 3016 Radial Ball Bearing 6204 8222 3019 Radial Ball Bearing 6304 8222 3020 Radial Ball Bearing 6305 8222 3018 Radial Ball Bearing 6205LLU 613 6021 Engine Shift Arm 0 JO 01 bh W IN a 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 2 1 1 2 2 1 1 9 3 1 1 1 1 12 FIG 13 GTR 250 PARTS MANUAL OIL PUMP ASSEMBLY Fig 13 OIL PUMP ASSEMBLY REF PART NO DESCRIPTION 8213 3093 Oil Pump Assy 8223 3002 Oil Pump Driven Sprocket 8231 3011 Oil Pump Chain 48L 8200 3605 Roller 2 5x11 8 8200 3402 Pan Screw 6X25 8200 0801 Circlip EX 10 QTY 13 GTR 250 PARTS MANUAL FIG 14 CYLINDER HEAD SIDE COVER ASSEMBLY Fig 14 CYLINDER HEAD SIDE COVER ASSEMBLY REF PARTS NO DESCRIPTION OTY 8213 3094 Cyl Head Side Cover Assy 8213 3095 Breather Tube 8223 0001 Cam Sprocket
18. 6061 Rr Drive Axle 1 10 640 6015 Rear Drive Axle Fix Base 4 11 622 6101 Rear Drive Axle Bearing 2 12 619 0062 Rr Steel Rim K61 2 13 627 6062 Rr CV Axle 2 14 637 6005 Rear VVheel Knuckle 2 15 600 5117 VVasher M27 A 16 620 6002 Rr Hub 2 17 600 2513 Castle Nut M22 2 18 500 1040 Cotter Pin 3x30 2 19 618 0622 R Rr VVheel Assy K61 1 20 620 6014 Rr Drive Axle Housing 1 21 616 0062 Rr Tire k61 2 22 618 0612 L Rr VVheel Assy K61 1 23 600 8007 Circlip 20 round 2 24 620 6013 Rr VVheel Hub Cap 2 25 600 0114 Rear Drive Axle Bolt 4 26 500 1073 Nut M08 A 27 600 2602 Lug Nut Cap M10 8 28 652 6011 Rear Dlsc Brake Pump 4 29 600 0517 Flange Bolt M08x16 2 30 600 5810 Spring VVasher M08 2 31 652 6009 R Brake Pad Set 1 32 640 6023 Speedomanet FIG 25 WIRE HARNESS ELECTRICAL GTR 250 PARTS MANUAL Fig 25 WIRE HARNESS ELEC TRICAL REF PART NO DESCRIPTION QTY 609 6019 Front VVire Harness 609 6020 Rear VVire Harness 609 6021 Switch Panel Cover 500 1066 Pan Screw M05X12 609 6031 Power Outlet 609 0015 Wire Harness zip Tie 609 6022 Ignition Start Switch 609 0006 Engine Stop Button 509 1005 Light Switch 600 0515 Flange Bolt M06x70 640 6016 Electric Cover Lid 8209 3001 Regulate Rectifier Comp
19. 612 6561 C B C Side Bar L R Carbon 650 061 1 Frame Comp Blue 650 0615 Frame Comp Sliver 650 0616 Frame Comp Carbon a e IN NIN RRI a ia ai dai na i 600 0001 Washer Cap black 600 0524 Flange Bolt M08x55 Chrome Blackk 640 6001 Side Reflector 640 6001 Side Reflector 680 0061 Rear Cargo Bottom Panel Blue 680 0065 Rear Cargo Bottom Panel Sliver 680 0066 Rear Cargo Bottom Panel Carbon 500 5302 Flange Bolt M06x16 500 1031 Lock Nut M06 63 6003 Drive Chain Guard 640 6401 Front Fender Bracket Clamp 500 1108 Flange Bolt M08x20 609 6001 Headlight Unit FR L 609 6002 Headlight Unit FR R 637 6201 Fr Fender L R 637 6201 Fr Fender L R 600 0520 Flange Bolt M10x24 652 6001 Brake Hose Assy L 652 6002 Brake Hose Assy R 652 6003 Brake Hose Assy RR 7 639 6003 Reverse Cable Comp 658 0560 Throttle Cable Comp 652 6004 Parking Brake Cable Comp 630 6001 Manual Choke Cable 18 a i SA _ ai i OG gt sech sai SR IN FIG 18 FRAME GROUP OD DN N 25 EN A GTR 250 PARTS MANUAL DESCRIPTION REF PARTS NO 534 1002 609 6003 Fia 18 FRAME GROUP 2
20. Gear Shift Lever YORE ADJUSTMENT a Each end of the cable has a threaded yoke on it b You must remove the pin or bolt in either end of the cable to vvhich the yoke is attatched c To adjust an end loosen the jam nut and turn the yoke the appropriate vvay CABLE MOUNT ADJUSTMENT a The cable has a threaded stud and jam nuts on each end that is used to attatch itself to the frame b To adjust loosen one jam nut on one or both ends and adjust the appropriate direction c Tighten jam nuts SHIFT LEVER ADJUSTMENT a On the rear end of the cable a shift lever is attatched to both it and the engine b The lever is on a splined shaft protruding from the engine c Remove the bolt vvhich holds this lever to the engine Slide the lever off the shaft and turn the appropriate vvay o one spline at a time e Once in the appropriate position tighten all bolts back 23 OPERATION G Starting And Operating Instructions a Before starting the engine be sure that the driver is seated properly in the kart vvith the seat belt fastened b Test the kart in an open space at the beginning to learn hovv to start turn and stop c Operate the kart slowly until you are familiar with it d The tuming radius of this kart is small and agile so the centrifugal force is very high vvhen turning at high speed Slovv dovvn to a more controllable speed vvhen turning to prevent the kart from rolling over e Alvvays turn the vehicl
21. Oil Filter Screw Spring 8213 3042 Oil Level Gauge Assy 8213 0050 Water Pump Impeller 8213 3043 Mechaniacl Seal 8240 3110 Water Pump Gasket 8213 0045 Water Pump Cover Comp 8213 3044 Water Pump Shaft 8213 3045 Water Hose 8213 3046 Water Hose Clamp A 8213 0047 Acg Cap Assy 14mm 8200 3501 Washer 7 2x13x1 2 8222 0001 Radial Ball Brg 6901 8213 0048 Oil Seal 12x20x5 8213 0049 O Ring 30 8 8200 3601 O Ring 18x3 8200 0304 Dowel Pin 8x14 8200 0302 Circlip IN 26 8100 0164 Flange Bolt SH 6x22 8100 0166 Flange Bolt SH 6x32 8100 0168 Flange Bolt SH 6x45 8200 3113 Flange Bolt SH 6x70 8222 0002 Radial Ball Bearing 6000 CO 100 NO 2 BA 62 N IN SIN la _ ai S Ko N A Ad dai dai p ai FIG 8 GTR 250 PARTS MANUAL MOVABLE DRIVE FACE Fig 8 MOVABLE DRIVE FACE PART NO DESCRIPTION 8213 3047 Slide Piece Set 8213 3048 Ramp Plate 8213 3049 Weight Roller Set 6pes set 8213 3050 Movable Drive Face Comp 8213 3051 Drive Face Boss 8213 3052 Movable Drive Face Assy 8213 3053 Drive Face 8200 0551 Thrust VVasher 14x28x2 8200 0214 Flange Nut 14mm CO CO NO G GO DN GTR 250 PARTS MANUAL FIG 9 CRANK SHAFT Fig 9 CRANK SHAFT REF PART NO 8213 3054 DESCRIPTION Crank Shaft Comp QTY 8213 3055 Piston Ri
22. alvvays make sure the petcock is in the OFF position N Chassis Grease chassis bushings and bearings vvith grease every six months to assure smooth operation and extended life of the bushings and the components f used in extreme vvet muddy or dusty conditions greasing is recommended more often 33 SERVICE INFORMATION O Steering Shaft a Remove the nuts from steering block Grease inside of steer block periodically Needle Bearing x i x SH c Remove steering shaft 34 SERVICE INFORMATION P Steering Gear Box and Ball HEAD AND STEERING GEAR BOX b Remove and chect ball head dust cover and a Remove four bolts on LH and RH clamp nut steering gear box for vvear and steering gear box Ball Head Dust Cover x il AA Steering Gear Box Bolts and Nuts Ball Head d Fill steering gear box with grease after cleaning the dust Replace the ball joint if it is loose or not smooth Steering Knuckle Support Ball Joint 35 SERVICE INFORMATION Q Steering Knuckle Support a Remove rubber dust cover of the knuckle support Ball Head Dust Cover Steering Knuckle Support Ball Joint 36 SERVICE INFORMATION R Throttle and Brake Pedal a Remove throttle throttle pedal and axle nut check for signs of vvear Replace if vvear is present b Fill vvith grease in order to make the throttle and brake pedal svving more flex
23. into bottom front suspension mounts vvith the grease fittings pointing dovvnvvards The bottom a arms have shock mount brackets The mounting brackets are located underneath the floorboard b Tighten bolts with 13mm and 14mm wrench FRONT SHOCK a Place the bottom eye hole of the shock into the shock mounts on the bottom a arms z insert bolt b Place the top eye hole of the shock into the shock mount located on the frame and insert bolt c Tighten bolts with 13mm and 14mm wrench FRONT STRUT a On each end of the struts is a threaded stud On the bottom of each stud you can see a square b Align each square of the threaded stud with that of the tabs on each a arm The squares of the stud and a arms MUST be aligned c Be sure the steering arm on each strut is pointing towards the front of the unit d Tighten each castle nut with an 18mm wrench and lock into place with a cotter pin and needle nose pliers The cotter pins are in a zip lock bag in the hardware box e Cap the top end of each stud with a provided rubber cap 46 10 STEERING LINRAGE a SET UP INSTRUCTIONS INTERCEPTOR GTR 250 Attach each tie rod end to the struts by inserting the ball joint studs into the steering arm of each strut b On each stud place flat vvasher locX vvasher tighten with 17mm vvrench and Zock with cotter pin and needle nose pliers FRONT BRARE CALIPER a Slide each brake caliper over the brake discs and align th
24. mixture tighten the screvv Air sucked through carburetor gasket Poor heat insulation gasket e Carburetor lock loose Air sucked e Poor intake gasket e Poor carburetor O ring e Vacuum hose crack No air sucked Remove spark plug install spark plug into spark plug cap and perform spark test against engine ground A A Spark plug fouled e Malfunction of CDI e Malfunction of AC generator Poor spark e Malfunction of ignition coil e Open or short circuit in spark plug leads to malfunction of main switch Good spark D Engine Runs Sluggish High speed Check and Adjustment Fault Condition Probable Causes Abnormal e Malfunction of CDI e Malfunction of AC alternator Check for fuel supplying system in automatic fuel cup e Insufficient fuel in fuel tank 57 Fuel filter clogged e Restricted fuel tank vent Check for carburetor clog IN TROUBLE SHOOTING CHARTS E Clutch Driving and Driving Pulley Fault Conditions Engine can be started but kart can not be moved Engine running and misfire vvhen kart begins moving forvvard or umps suddenly rear wheel rotates vvhile engine is idling Poor initial driving poor climbing performance F Poor Handling A Fault Conditions Steering is heavy One vvheel is vvobbling Vehicle pulls to one side Probable Causes Drive belt vvorn out or deformed Ramp plate of movable drive face damaged Dri
25. with non flammable or high flash point solvent and then squeeze it dry N WARNING Never use gasoline or acid organized solvent to clean the element Soap the element in clean engine oil and then squeeze it out Install the element on the element seat and then install the air cleaner cover 26 SERVICE INSTRUCTIONS B Engine Lubrication You must change the oil in the crankcase after the first 5 hours of operating your new engine and after 10 hours of use thereafter This will insure proper lubrication Of internal parts and prevent costly repairs due to excessive vvear N WARNING Used oil must be disposed of at a proper collection center a Remove drain plug located on the right rear side of engine Tip kart backwards slightly by blocking the front tires and drain oil into suitable container b Remove and clean oil screen c Replace drain plug and tighten securely Place kart in a level position d Refill crankcase approximately 1200 cc or 1 1 4 quarts to top of filler neck with SAE 10VV30 oll e Check oil level before each use of kart or after each 10 hours of operation Add oil to bring up to proper level Do not mix ENGINE OIL PLUG COVER various grades of oil C Gear Oil Check and Change JOIN BOLT a Remove oil join bolt Remove drain bolt and drain oil out b Install the drain bolt after drained Torque value 1 1 1 5kgf m c Make sure that the drain bolt washer can be re used d Add oil
26. your kart the terrain visibility and other operating conditions and your experience Use Care on Unfamiliar or Rough Terrain Before driving in a nevv area alvvays check the terrain thoroughly Don t drive fast on unfamiliar terrain or when visibility is limited it s sometimes difficult to see obstructions like hidden rocks bumps or holes in time to react 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 N WARNING Failure to use extra care when operating on excessively rough slippery or loose terrain could cause loss of traction or vehicle control vvhich could result 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 terrain Alvvays be especially cautious on these kinds of terrain Do Not Perform Stunts You should alvvays operate your kart in a safe and reasonable manner VVhen driving alvvays keep all four vvheels on the ground N VVARNING Attempti
27. 0061 Botton Front Sticker 603 0062 Front Pannel SticRer 603 0063 Sterring VVheel SticRer 603 0064 Center Left Side Sticker 603 0065 Center Right Side Sticker 603 0066 Rear Decoration Sticker 603 0067 Rear Cargo SticRer arter Carter Brothers Manufacturing Co Inc arter 1871 U S Highway 231 South A Better Built Machine Brundidge Alabama 36010 Phone 800 523 5278
28. 08 250 ID Plate 640 6009 Trailered Plates FIG 18 FRAME GROUP OD DN N 25 EN A GTR 250 PARTS MANUAL Fig 18 FRAME GROUP 3 REF PART NO DESCRIPTION QTY 65 640 6010 Trailered Hitch 4 66 500 3025 Washer M10 12 67 600 0133 Bolt M16x35 1 68 600 5811 Spring VVasher 14 2 69 500 1041 VVasher M14 2 70 600 5812 Spring VVasher M16 1 71 600 5115 Washer M16 4 72 600 0132 Bolt M14x45 2 73 640 6702 C B C Cross Bar Collar 4 74 609 6017 Speaker 2 75 637 6004 RR Fender Pole Cover 2 76 610 6001 Vinly Top ACCESSORY 4 77 337 2250 Brush Guard Assy ACCESSORY FIG 19 STEERING SHAFT ASSEMBLY 2 20 21 22 S NZ 16 19 0 16 24 Y 7 18 43 o e E SSL 07533 Pai 40 PART NO GTR 250 PARTS MANUAL Fig 19 STEERING SHAFT ASSEMBLY DESCRIPTION 636 6010 Steering Wheel Cover logo 600 4602 Bolt M06x12 K61 steering wheel o ol 4 lt 600 5118 Washer M06 636 6007 Steering Wheel 636 6008 Steering Shaft O 0 Oli OI BIC INIT gt 1 1 1 500 1078 Pan Scre
29. 8200 0590 Cam Sprocket Washer 8213 0029 Centrifugal Disk 8231 3012 Cam Chain 100L 8200 0196 Lock Bolt 6mm 8100 0162 Flange Bolt SH 6x18 NO OG S WIN IN la a 1 sech ai 14 FIG 15 DRIVEN PULLEY SET GTR 250 PARTS MANUAL Fig 15 DRIVEN PULLEY SET REF PARTS NO DESCRIPTION QTY 8913 3096 Outer Clutch Comp 8213 3097 Drive Plate Assy 8213 3098 Drive Plate Comp 8213 3099 Clutch Side Plate 8257 3017 Clutch Spring 8213 3100 Clutch Weight 3pes set 8213 3101 Clutch Damper Rubber 8213 3102 Driven Pulley Assy 8238 3000 Drive Belt 8213 3103 Drive Face Assy Co 10 Ol85 8213 3104 Drive Face Comp 8213 3105 Movable Driven Face Comp 8213 3106 Roller Guide Pin 8213 3107 Guide Roller 8257 3018 Driven Face Spring 8213 3108 Seal Collar E 15 8213 3109 Spring Collar 8200 0214 Flange Nut 14mm 8200 3293 Special Nut 36mm 8200 0551 Thrust VVasher 14x28x2 8200 3803 Circlip n 8222 3013 Needle Breaing HKS 25x32x14 8222 3021 Radial Ball Bearing 6903LU 8200 3706 Oil Seal TC 41x48x4 8200 3604 O Ring 47x2 0 8200 3901 E Ring 8 O NIN la la la a i sa ai ci JR JS Aa SA pa ili eS Co _ ai 15 FIG 16 GTR 250 PARTS MANUAL A 1 C V ASSEMBLEY Fig 16 A 1 C V ASSEMBLEY REF PART NO DE
30. Chain AIR BOX BOLTS Lubricate chain with a spray on type chain lubricant to increase the life of the chain 29 SERVICE INSTRUCTIONS H Adjustment of Front and Rear Shocks There are five adiustable positions on each shock The default position is in the middle a Use a round nut vvrench to adjust the shock b The tension of the shock spring vvill increase as you scevv to the right c Adjust accordingly to the weight of the riders LEFT ROTATE I Front or Rear Shock Removal a You must first lift either the front or the rear of the kart off the ground depending on which shocks SPRING ADJUSTMENT CAM you want to remove b Once the kart is off the ground remove the bolt from both top and bottom of each shock BOLT BOLT BOLTS BOLTS REAR SHOCKS FRONT SHOCKS 30 SERVICE INFORMATION J Front VVheel Replacement Do not disassemble the castle nuts vvhen you replace the front vvheels It is only necessary to remove the four 4 lug nuts to remove the wheel Tighten the nuts after replacing the wheels K Rear Wheel Replacement Do not disassemble the castle nuts when you replace the rear wheel and hub assembly Remove the cotter pin and the 24mm nut Then slide off wheel and hub assembly It is only necessary to remove the four 4 lug nuts to remove the wheel by itself 31 SERVICE INFORMATION L Front VVheel Alignment a The front vvheels should be toe in from 1 8 to 1 4 To checR for ali
31. Do not drive in rough terrain until you get accustomed to the kart s controls and feel comfortable with its size and weight N WARNING Operating this kart without your seat belt could cause you to be thrown from the kart causing serious injury or death Age Recommendation Itis strongly recommended that no one under the age of 16 be permitted to operate this go kart N WARNING A child driving a kart that is not recommended because he she could lose control of the kart resulting in severe injury or death No Alcohol or Drugs Alcohol drugs and karts don t mix Even 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 WARNING Operating this kart after consuming alcohol or drugs can seriously affect your judgment cause you to react more slovviy 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 DR VE 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 breakdovvn or even a flat tire can be a major inconvenience If your kart has overturned or has been involve
32. SCRIPTION QTY 8213 3110 A I C V Unit 8213 3111 A I C V Assy 8213 3112 A 1 C V Inlet Pipe Joint Tube Assy 8213 0117 Setting Band GTR 250 PARTS MANUAL FIG 17 CARBURETOR ASSEMBLY Fig 17 CARBURETOR ASSEMBLY REF PART NO DESCRIPTION QTY 8213 3113 Carb Assy 8213 3114 Inlet Pipe Assy 8200 3603 O Ring 34x2 0 8100 0206 Flange Nut 6mm 8100 0164 Flange Bolt SH 6x22 8213 3115 Carb Needle Fixing Set 8213 3116 Carb Screw Fixing Set 8213 3117 Carb Float Fixing Set 8213 3118 Carb F C B Fixing Set 8240 3001 Carb Gasket Fixing Set CO CON O Oo CO bh n ea A NN NN lA _ a FIG 18 FRAME GROUP OD DN N 25 EN A GTR 250 PARTS MANUAL Fig 18 FRAME GROUP 1 REF PART NO 612 6210 DESCRIPTION C B C Cross Bar FR Blue QTY 612 6250 C B C Cross Bar FR Sliver 612 6260 C B C Cross Bar FR Carbon 612 6012 C B C Bar L Blue 612 6052 C B C Bar L Sliver 612 6062 C B C Bar L Carbon 612 6310 C B C Cross Bar RR Blue 612 6350 612 6360 C B C Cross Bar RR Sliver C B C Cross Bar RR Carbon 612 6511 C B C Side Bar L R Blue 612 6551 C B C Side Bar L R Sliver
33. ain bars are at the hood and behind the seat b From the hardware box remove the remaining black anodized bolts vvashers and lock nuts c On each end of the main bar cage place 1 bolt 2 washers and 1 lock nut Finger tighten only Do not tighten any bolts for the brush bars until all bolts are in place d Place cach shoulder bar over the shoulder bar mount posts on the frame These posts are on cach arm rest e Al gn the top of the shoulder bars vvith the holes in the main bars and insert bolt and vvasher and finger tighten At the bottom of each shoulder bar insert 1 bolt 2 vvashers and 1 lock out and finger tighten f Place the top cross bar betvveen the ma n bars vvith hoop pointing towards the front of the kart Align holes Of the top cross bar vvith holes in the main bars g Inserta bolt and washer in each hole and finger tighten h Place the bottom cross bar between the main bars toward the rear of the kart just above the back of the seats Align holes of the bottom cross bar with the holes in the main bars 1 Insert a bolt and washer in each hole and finger tighten 1 With all members of the brush bar in place tighten with a 10mm and 12mm wrench 23 REAR VIEW MIRROR a From the hardware box remove the rear view mirror The rear view mirror will be ina small white box b With a Phillips head screw driver remove the screw in the mounting hole of the mirror c Remove black metal clip and d
34. b Remove the seat hardware from the hardware box This will be the silver bolts nuts and washers The seat belts are shipped bolted together It 1s easier to install the seat belts with them separated Start on the driver side by bolting the outer end of the seat belt to the seat belt mount located behind the driver seat and in front of the rear fender d With the driver seat turned upside down slide the seat adjusters all the way back Put the seat in place by aligning the front brackets and rear holes Insert a bolt in each hole from top to bottom leaving the head of the bolt in the seat adjuster track You will have to hold the top of the bolt with a flat head screw driver Wedge the flat head screw driver between the bolt head and the seat adjuster track and tighten with a 12mm wrench Feed the seat belt through the holes in the top of the seat Bolt the top seat belt bracket to the seat belt mount located directly behind the drivers head Follow the same steps with the passenger seat The bolts for the passenger seat will be inserted from bottom to top because the passenger seat does not have an adjuster Tighten the passenger seat bolts with a 10mm wrench Tighten the seat belt bolts with a 14mm and 19mm wrench 50 SET UP INSTRUCTIONS INTERCEPTOR GTR 250 22 BRUSH BARS a Place the main bars in proper location by inserting the open ends over the bar mount posts on the frame The bar mounting posts for the m
35. d in a collision do not drive it until your kart has been inspected by your dealer There may be damages or other problems you cannot see N WARNING Improperly maintaining this kart or failing to correct a problem before driving may 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 Pre drive Inspection Check the following items beford you get on the kart m Engine Oil Check the level and add oll if needed Check for leaks m Fuel Check the level and add fuel if needed Also make sure the fuel fill cap is securely fastened Check for leaks Tires Use a gauge to check the air pressure Adjust if needed Also look for signs of damage or excessive wear Nuts amp Bolts Check the wheels to see that the axle nuts are tight Use a wrench to make sure all accessible nuts bolts and fasteners are tight m Underbody amp Exhaust System Check for and remove any dirt vegetation or other debris that could be a fire hazard or interfere vvith the proper operation of the kart Air Cleaner Housing Drain Tube Check for deposits in the drain tube f necessary clean the tube and check the air cleaner housing 11 IS YOUR VEHICLE READY TO DR VE Leaks Loose Parts VValk around your kart and look for anything that appears unusual such as a leak or loose cable Lights Make sure the headlights brake light and tail light ar
36. d replaced under this vvarranty are covered only for the remainder of the kart s vvarranty VVARRATNY PERIODS FOR ALL KARTS ARE AS FOLLOVVS FRAME FOR 1YEAR Void if frame is broken or bent due to abuse 1 Underside scraped abusively 2 VVheels are bent or broken due to impact 3 Spindles are bent due to impact 4 Paint is vvorn off of rear bumper indicating an extra rider 5 Axles are bent out of ordinary position either horizontally or vertically 6 Non factory altering of engine or frame and its components If the frame is found to be defective due to material and or vvorkmanship when inspected at an authorized Carter Service Center Carter vvill at its option repair or replace defective parts to the original purchaser at no charge INTERCEPTOR GTR 250 2R PARTS COVERAGE VVarranty starts from the date of purchase by the first retail purchaser gt Engine 2 year Limited factory warranty gt A Arm Spindles Axles Rack amp Pinion 90 days gt Electronics Carburetor amp Muffler 90 days gt Battery 30 days gt Radiator 90 days gt CVT 60 days VVARRANTY The second year of the engine vvarranty is for the FUNCTION of certain engine parts Function is described as vvarranty coverage for parts that are not normally exposed to misuse abuse or extreme vvear These engine parts are vvarranted to be free of manufacturing flavvs such as stress cracks inferior material metal castin
37. e 23x 10 14psi Rear Tire 25x7 12 14ps Front Suspension Dual A Arm Rear Suspension Dual A Arm Restraint System Dual 4 point Harness Final Drive Chain 520 x 66 WEIGHT Net Weight 372kgs 819lbs The specifications are subject to change without notice LOCATION OF PARTS MIRROR SEAT BELI HEADLIGHTS STEERING WHEEL R R WHEEL FR WHEEL REAR CARGO RACK TOW BALL DRIVE CHAIN LOCATION OF PARTS 12V OUTLET HORN KEY SWITCH HEADLIGHT SVVITCH BLINRER ENGINE STOP BUTTON REAR CARGO RACR RADIATOR ENGINE FUEL TANK OPERATION A Operation Controls VVARNING Do not attempt to start or operate the engine until you are completely familiar vvith the location and use of each control necessary to operate this vehicle The operator must knovv hovv to stop this machine before starting and driving it a Throttle The right foot pedal is t
38. e at a slovv controllable speed to prevent the vehicle from turning over Keep your left foot ready to press the brake f at any time the vehicle feels unstable reduce your speed 24 PERIODICAL CHECR AND SERVICES Have your kart checked adjusted and record maintenance performed Have these services performed periodically by your Carter Authorized Dealer to maintain the kart at the optimum condition Every 300km 1 Month 3 Months 6 Months 1 Year Item 180 mi Air Cleaner RR FuelFilter________ _ J PR Engine Oil Change Replacement for every 1000 km 600 miles Tire Pressure 1 J LL LL Battery Inspection 1 J J o Brake Check 1 J 1I J J o Steering Check CITT TightnessofScrevs 1 J ______ Frame Lubrication 06021 Gear Oil Check 0 1 J 1 Gear Oil Change R Replacement for every 5000 km 3000 miles Spark Plug al LL LS LI ExhaustPpe I J Ignition Timing CITT o Emission J J Throttle DEE J I ____ Engine Bolt Tightening 1 1 CVT Driving Device belt 5100 1001 1 R CVT Driving Device c DriveChan mw w __ C Lights Electrical Equipment 1 CITT Fuel Lines LL J J Aa _____ CamChain ____ Valve Clearance 1 J J 1 Lines Cooling Connections 1 50 q1 J J o Coolant Reservoir Coolant 17 CIS I Inspection Cleaning and Adjustment R Replacement C Cleaning replace if nec
39. e event that your kart is not to be operated for a period exceeding 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 motor dies c Do not save or store gasoline over winter Using old gasoline which deteriorates from storage will cause hard starting and affect engine performance 38 SERVICE INFORMATION X Front Hubs a Check seals for rips or tears and replace if any exist b nspect bearings for ease of movement f bearings are dirty or muddy vvash them in cleaning solvent and spin vvith your finger c Apply an ample amount of grease to the bearing and reinstall with bearing tool making sure it goes in straight Damage to the hub can occur d Install seals into hub t is recommended to that your apply a small amount of grease to the lip of the seal If the retention spring is in bad shape replace it 39 VVIRING DIAGRAM euBis unt CH niq n due eL abuelo eld MOI 2A UB4IS U89 9 BUIpUIM MOJISA u lb 34617 ib o YMS lemneN Jejsoog EI Pay auuym yoelg Jpeujuesi9 pay abuelo Reis PoH SUM perg onia SYUM leubis uni Jun Jeusel4
40. e mounting holes vvith those of each strut b Tighten bolts vvith a 10mm FRONT V HEEL AND CAP wrench a In the hardware box you will find 4 chrome wheel caps The smaller set will be used on the front Also get out 8 acorn shaped lug nuts b Slide the wheel cap into the center hole of the wheel from the back c Place the wheel assembly into position by aligning the holes in the wheel with the lugs on the front hubs d Tighten the lug nuts with a 15mm socket With the wheels off the ground you may not be able to tighten the lugs completely Lower the kart and tighten the lug nuts completely HEAD LIGHT a Place the front head lights in their mounts Each mount is on either side of the front hood b Tighten with 10mm and 12mm wrench REAR BOTTOM A ARMS a b Place the floor jack under the rear of the unit and lift off the ground The rear bottom a arm is the large a arm without shock mounts Insert bottom a arms into bottom rear suspension mounts with the grease fittings pointing downwards Finger tighten only It is easier to assemble the rear suspension without the bolts tight 47 11 12 13 14 15 SET UP INSTRUCTIONS INTERCEPTOR GTR 250 CV SHAFT a Slide the female end of each CV shaft over the male end of each s de of the center axle b Lock into place with lock ring The lock ring should already be in place on each end of the center axle REAR TOP A ARMS a Insert top a ar
41. e not designed or manufactured for racing or use on rental tracks public streets public roads highvvays paved surfaces or right of vvays Alvvays vvear an approved helmet and eye protection vvhen riding Alvvays secure loose clothing and long hair Alvvays vvear seatbelts Read the operations manual arter CUSTOMER SAFETY INFORMATION AND WARRANTY REGISTRATION FORM A Better Built Machine INTERCEPTOR GTR 250 Warranty registration must be filed with Carter Brothers Manufacturing within 10 days of purchase or warranty will be void In order to validate the warranty purchaser agrees and promises to hold Carter Brothers Manufacturing and the Dealer harmless and indemnify them from all claims and demands or causes of action which may arise or be asserted against them arising or allegedly arising from any claim related to the delivery of the Vehicle or its use by the Purchaser or any third parties including all attorney fees and legal costs whether or not any claim or assertion is deemed or found to be valid or not All parties agree and stipulate that any legal proceedings which relate to or arise out of this transaction shall be brought only in afederal or state court located in the County of Pike State of Alabama This form and Owner s Manual contains vital safety information Carter Brothers Manufacturing asks that you review the warnings and verify that you have read and understood each warning by placing your initials on the line beside it
42. e the Kart without wearing a proper helmet eye protection and protective clothing 15 Never operate the Kart at night The attached lights are for ornamental purposes only They will not provide sufficient lighting for night time operation In signing this document the Purchaser acknowledges and agrees that he has read the Owner s Manual and that failure to do so voids all warranties both implied and expressed certify that understand all of the above warnings warnings in the Owners Manual and that failure to obey these warnings could result in death or severe injury Date of Purchase mm dd yy Model Number VIN Number First Name Last Name e mail Street Address City Zip Code Dealer Name Website Address City 4 Zip Code Home Telephone Purchaser Signature Please fill out this form and fax or mail it back to Carter Brothers Manufacturing Carter Brothers Manufacturing 1871U S Hwy 231 Brundidge AL 36010 Ph 8005235278Fax 3347353500 Web www carterbro com C A WR 03 2007 ABOUT SAFETY In order to keep everyone safe you must take responsibility for the safe operation of your kart To help you make informed decisions about safety vve 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 is not practical or possible to warn you about all the hazards associated with operating or ma
43. e vvorking properly Throttle Check the freeplay and adjust if needed Press the throttle to make sure it moves smoothly without sticking and snaps back automatically when it is released Brakes Press the brake pedal several times check for proper brake pedal freeplay Make sure there is no brake fluid leakage Engine Stop Button While engine is running press and hold the engine stop button for two seconds Make sure engine stops Steering Wheel Check that the wheels turn properly as you turn the steering wheel Cable Check all cable housings for wear Check the fittings for looseness Replace or tighten as needed 12 SAFE DRIVING PRECAUTIONS Off Road Use Only Your kart and its tires are designed and manufactured for off road use only not for pavement Driving on pavement can affect handling and control You should not drive your kart on pavement N WARNING Operating this kart on paved surfaces may seriousiy affect handling and control of the kart and may cause the vehicle to go out of control Never operate the kart on any paved surfaces including sidevvalks drivevvays parking lots and streets VVhen driving off road also remember to alvvays obey local off road driving lavvs and regulations Obtain permission to drive on private property Avoid posted areas and obey no trespassing signs You should never drive your kart on public streets roads or highvvays even if they are not paved Drivers of str
44. ed wheel bearing Wheel bearing needs lubrication Punctured tire Faulty tire valve Fuel air mixture ratio too rich or lean Clogged in air cleaner Clogged in muffler Restricted fuel flow Clogged fuel tank cap breather hole Faulty pulse generator Faulty CDI unit Leaking head gasket Worn cylinder and piston rings Clean Clean the spark plug Spark plug is incorrect heat range Excessive carbon deposited in combustion chamber Wrong type of fuel Fuel air mixture ratio is lean Use of poor quality fuel Worn piston and cylinder Fuel air mixture ratio is lean Wrong type of fuel Ignition timing too advanced Excessive carbon deposited in combustion chamber SET UP INSTRUCTIONS INTERCEPTOR GTR 250 TOOLS NEEDED Floor jack Flat head screvv driver Needle nose pliers Phillips head screw driver Protective gloves Adjustable vvrench Metric wrench and socket set LIFT THE KART In order to assemble the front suspension and steering the unit must be lifted high enough to put the front tires on it Place a floor yack under the front of the unit in the center and lift the kart FRONT TOP A ARM a Insert top a arms into top front suspension mounts with the grease fittings pointing upwards The top a arms are the shortest a arms The mounting brackets are located both in front and behind of each front blinker b Tighten bolts with 13mm and 14mm wrench FRONT BOTTOM A ARM a Insert bottom a arms
45. eet vehicles may have difficulty seeing and avoiding you vvhich could lead to a collision In many states it is illegal to operate karts on public streets roads and highvvays N VVARNING Operating this kart on public streets roads or highvvays could cause a collision vvith another vehicle Never operate this go kart on any public streets roads or highvvays vvhether dirt gravel or pavement Keep Hands and Feet on Controls VVhen driving your kart alvvays keep both hands on the steering vvheel and both feet on the foot controls Removing hands or feet avvay from the controls can result in loss of balance and reduce your ability to react and control the kart N WARNING Removing hands from steering vvheel or feet from foot controls during operation can reduce your ability to control the kart or could cause you to lose your balance and fall off the kart Alvvays keep both hands on the steering vvheel and both feet on the foot controls of your kart during operation SAFE DRIVING PRECAUTIONS Control Speed Driving at excessive speeds increases the chance of an accident In choosing a proper speed you need to consider the capability of your kart the terrain visibility and other operating conditions plus your own skills 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 Alvvays drive at a speed that is proper for
46. eplacements The vehicle must be stationary and the engine at idle before selecting gears TH SVEH CLEMANUFACTURED Seat Belt Must Be VVorn ROAD UEN At All Times DO NOT OPERATE ON PUBLIC STREETS ROADSORHIGHVVAYS 3031112 Moving parts Id ace Keep hands j MI AX L OA D clear P operate 200LBS ONLY with guard removed THIS GO KART CAN BE HAZARDOUS TO OPERATE if driven carelessly INJURIES can result if you do not follow these instructions m READ OWNER S MANUAL AND ALL LABELS BEFORE YOU OPERATE THIS GO KART m NEVER OPERATE THIS GO KART WITHOUT PROPER INSTRUCTIONS Beginners require adult supervision NEVER OPERATE THIS GO KART ON PUBLIC ROADS It is intended for off road use only ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing ALL HAIR MUST BE TIED UP AND m NEVER OPERATE THIS GO KART AT EXCESSIVE SECURED AT OR ABOVE SHOULDER SPEEDS You increase your risk of losing control if LENGTH you operate it at speeds too fast for the terrain ALL LOOSE CLOTHING MUST BE visibility conditions or your experience SECURED ALL NECKLACES AND NEVER ATTEMPT WHEELIES JUMPS OR SCARVES MUST BE OTHER STUNTS SECURED 303115 Loss of control collision or getting caught in moving parts can result in serious injuries Adult supervison for under 16 years old Wear a D O T approved motorcycle helmet Secure long hair and loose clothing Wear protective eye wea
47. er Svving Arm 2 11 609 6018 Battery FPM12 12 R61 509 3011 1 12 653 6012 Rr Lower Swing Arm 2 13 639 6002 Reverse Lever Bracket 1 14 600 0514 Flange Bolt M06x1 25x20 3 15 900 1064 Flange Lock Nut M06 3 16 639 6001 Reverse Lever 1 17 600 0522 Flange Bolt M12x95 8 18 653 6021 Rear Svving Arm Dust Cover 24 19 653 6022 Rear Svving Arm nner Collar 24 20 653 6023 Rear Svving Arm Short Collar 8 21 652 6012 Parking Brake Assy 1 2 652 6013 Brake Lever Assy 1 23 609 6016 Battery Strap 1 24 699 0003 Reverse Parking Shifter Knob 2 25 500 3044 Flange Bolt M08x50 2 26 528 3003 Lever Spacer 4 27 557 1005 Lever Spring 2 28 900 1004 Flange Lock Nut M08 2 29 600 0113 Rear Carrier Bolt 4 30 657 0060 Cable Spring 1 31 500 1108 Flange Bolt M08x20 2 22 500 1073 Nut M08 1 33 652 6010 Parking Lever Bracket 1 34 652 5008 Brake Lever 1 35 637 6202 Rr Fender L R 1 36 63 6202 Rr Fender L R 1 37 653 6002 Rr Shock 2 38 500 1031 Lock Nut M06 8 39 653 6024 Rear Swing Arm Long Collar 4 FIG 24 REAR HOUSING GTR 250 PARTS MANUAL Fig 24 REAR HOUSING REF PART NO DESCRIPTION QTY 1 600 2101 Nut MO6 Rear Disc Brake S 2 652 6008 Rr Brake Disc 1 3 620 6003 Rr Drive Hub 4 4 623 6001 Rr Sprocket 4 5 500 1071 Lock Washer M10 5 6 500 1317 Bolt M10x20 5 7 631 6001 O ring Drive Chain 1 8 640 6014 VVoodruff key 4 9 627
48. essary L Lubrication The above maintenace schedule is established by taking the monthly 1000km 600 miles as a reference which ever comes first Clean or replace the air cleaner element more often when the kart is operated in a dusty or polluted environment Maintenance should be performed more often if the kart is frequently operated at high speeds and after the kart has accumulated higher mileage 25 SE RVICE INSTRUCTIONS Torque Values The torque values listed in this table are for more important tightened torque values Please see standard values for torques not listed in the table Torque Tightening Chart Bolt Conventional Marked Bolt 8 8 Marked Bolt Diameter N m Kg m Ib ft N m Kg m Ib ft ie 0 1 0 2 0 7 1 5 1555 0 15 0 3 1020 1 4 0 2 0 4 19 30 20 00 00 2 0 4 5 4 7 0 4 0 7 3 0 55 0 8 12 0 8 1 2 6 0 8 5 10 16 TOSTO 70211 5 18 28 192 2 8 13 0 20 0 22559 2 2 3 5 16 0 25 5 40 60 4 0 6 0 29 0 43 5 50 55 55 25 5 40 70 100 TOTOO 3000570 50 80 5 0 8 0 36 5 58 110 160 11 0 16 0 2 01100 005150 60150 58 94 lz 17 025 123 0 181 0 130 190 13 0 19 0 94 137 5 200 280 20 28 0 144 5 202 5 A Service Air Cleaner ELEMENT Service air cleaner every 20 hours NOTE Service more often under dusty conditions a Loosen 4 hooks from the air cleaner cover and then remove the cover b Loosen the clamp strip and 1 screw of air cleaner element and then remove the air cleaner element c Clean the element
49. follovv rules for safe operation and vvear a helmet 21 OPERATION C Passengers The vehicle allovvs for tvvo riders only Combined maximum vveight of driver and the passenger should not exceed 180kg or 400lbs D Seat Adjustment The seat must always be securely fastened in the position which best affords the operator control of the foot pedals steering wheel and the remote stop button a Pull seat adjustment handle upward to disengage seat slide i sua SEAT ADJUSTMENT HANDLE b Move seat to desired position c Be sure seat adjustment handle snaps back into place and that seat is locked into position N WARNING Before attempting to adjust the seat ensure that kart engine is stopped N VVARNING Never operate this kart vvhen the provided seat is not securely fastened to do so could result in a strong possibility of severe personal iniury or loss of life Before attempting to adiust the seat ensure the kart engine is stopped F Parking Brake Adjustment a Push forvvard the brake lever so that the unit can roll freely Pull back the lever to engage the parking brake ADJUSTING NUT 2 b When brake lever is in forward position there REVERSE CABLE needs to be 1 2 of freeplay If the adjustment is not correct loosen lock nut 2 then adjust lock nut 1 to the proper amount of freeplay ADJUSTING NUT 1 REVERSE CABLE Always stop the kart before changing gears 22 OPERATION F
50. g flavvs and machining flavvs Upon part failure only Carter Brothers Manufacturing nc may determine if it is covered Any failure or damage to a part that does not influence its function vvill not be covered Normal vvear of these parts is not covered Parts covered under the second year period would include but not necessarily be limited to e Head cover e Right Crankcase Cylinder and Cylinder Head Mission Case e Left Case Cover e Cylinder Head Side Cover e Left Crankcase e Certain Internal Engine Parts e Right Case Cover e Certain Bearings and Gears PARTS NOT COVERED This warranty does not cover consumable wear and tear items such as but not limited to e Throttle cable e Brake pads e Brake cable e Tires e Chains e Oil changes e Seats e Problem occurring due lack of proper maintenance e Fasteners e Problem occurring due to abuse e Air Filters Modifications to your GTR 250 that are not Carter approved will void the warranty Defective parts are subject to recall by Carter upon failure and are required to be held by the dealer or service center until the warranty claim is settled WARRANTY COVERAGE Carter Brothers Manufacturing Inc will repair or replace at its option any part that is found defective in material or factory workmanship under normal use Parts used in the repair or replace process under this warranty are covered only for the remainder of the GTR warranty TO QUALIFY FOR THIS WARRANTY
51. gnment measure distance A and B betvveen the centerline CL of the vvheels The proper toe in dimension A should be 1 8 1 4 greater than dimension B b To adjust the alignments loosen the lock nuts on both sides of Front Tie Rods To make Dimension B smaller turn the rod to the left Adiust the rod to the right direction to make Dimension B larger After adiusting to the desired length tighten the lock nut against the rod end Recheck the dimensions for proper alignment LOOK NUT FR VVHEEL TIE ROD LEFT ROTATE 6 RIGHT ROTATE RIGHT ROTATE LEFT ROTATE FRONT WHEEL TIE ROD B 32 SERVICE INFORMATION M Fuel Svvitch Petcock This vehicle has a manually operated fuel petcock vvith three positions Please follovv maintenance procedures accordingly a Periodically clean the petcock externally with grease remover and water b Check for any leaks or seeping fuel ON Position The normal operating position for the fuel valve lever is the ON position In this position fuel will flow to the carburetor RES Position Reserve If the fuel level in the fuel tank becomes too lovv for the engine to operate vvith the fuel valve lever in the ON position turn the lever to the RES position to use the reserve fuel supply and refuel as soon as possible OFF Position The closing position for the fuel valve is the OFF position VVhen the vehicle is not in use
52. he throttle that controls the kart speed As the engine speed increases above idle the clutch automatically engages and moves the vehicle forvvard To disengage the clutch at any time allovv the throttle to return to the idle position N WARNING Each time prior to start 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 is located on the left side of the kart Applying pressure to the pedal draws the brake caliper around the brake pump at the rear wheel and slows or stops the kart KEY SWITCH ENGINE STOP BUTTON c Start engine Insert the key into key switch turn the key clockwise release the key when the engine starts Kart must be in neutral The engine will warm up within 5 minutes if the engine is cold you will need to pull the choke lever under the seat Warning Don t crank starter more than 5 seconds at one time e Engine stop button IMPORTANT STOP BUTTON TEST Before driving this vehicle test the engine BRAKE THROTTLE stop button to assure that it is operating properly VVith the engine running push and hold the engine stop button for tvvo seconds for the engine to shut dov
53. ibly before installation S A Arms a Grease the flex points of the upper and lovver A arm front vvheel periodically b Remove bolt of upper and lower A arm front wheel c Check the nylon bushing of upper and lovver A arm front vvheel for vvear Replace immediately if vvear is present T Tie Rod a Tie rods should be checked for ease of movement in their full rotation b Remove protective boot and apply grease c Check tie rod ends periodically for tightness at the adiusting nuts d Alvvays use a nevv cotterpin after removal U Seat a Remove all the nuts and bolts underneath the seat rall b Remove seat 37 Frontal upper A arm Rear upper A arm PP Rear lower A arm Frontal lower A arm SERVICE INFORMATION V Radiator N WARNING While engine is running never attempt to open the radiator filler cap The pressurixed hot coolant may shoot out and cause serious scalding injury No maintenance work is allowed to be performed unless the engine is completely cooled down a Refill the radiator with distilled water or specified additives b Add coolant to the reservoir c The cooling system can be serviced on the kart d Never spill the coolant on the painted surface e Test the cooling system for any leakage after the repair W Storage Instructions N WARNING Do not drain fuel while engine is hot Be sure to move kart outside before draining fuel In th
54. ines in fuel tank evaporation system increased increased clogged e Exhaust pipe clogged Check ignition timing using e Fuel nozzle clogged in carburetor ignition lamp Ignition timing correct Incorrect ignition timing e Malfunction of CDI e Malfunction of AC alternator Check cylinder compression using cylinder compression guage e Cylinder amp piston ring worn out e Cylinder gasket leaked Compression pressure No compression pressure e Sand hole in compression parts correct e Valve deterioration Check if carburetor jet is clogged e Seized piston ring Clogged e Remove foreign material Remove spark plug No discoloration Fouled and discoloration e Remove dirt e Incorrect spark plug heat range 7777757 e Piston and cylinder vvorn out e Lean mixture Poor fuel quality combustion chamber e Ignition timing too advanced Poor circuit on the cooling system Continually drive in acceleration e Too much carbon deposited in combustion chamber e Poor fuel quality A e Ignition timing too advanced 42 TROUBLE SHOOTING CHARTS C Engine Runs Sluggish especially in lovv speed and idling Fault Condition Probable Causes Check and Adjustment Check ignition timing using ignition lamp Normal Abnormal Incorrect ignition timing malfunction of CDI or AC alternator Adjust the air screw of carburetor Good Poor S Rich mixture loosen the screvv e Lean
55. intaining a kart You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels On the kart Safety Messages Preceded by a safety alert symbol A and one of tvvo signal vvords VVARNING or CAUTION These signal vvord mean Physical harm may result from failure to adhere to the instructions that are described vvithin the VVARNING labels Safety Headings such as important safety reminders or important safety precautions Safety Section such as kart safety Instructions how to use this kart correctly and safely This entire manual is filled vvith important safety information please read it carefully IMPORTANT SAFETY INFORMATION Your kart vvill provide you vvith many years of service and pleasure providing you take responsibility for your ovvn safety and understand the challenges you may meet vvhile driving There is much that you can do to protect yourself while operating your kart You ll find many helpful recommendations throughout this manual The following are a fevv that vve consider most important Follovv the Age Recommendation Experienced adult supervision should be present for all inexperienced operators Alvvays VVear a Helmet It s a proven fact wearing helmets significantly reduces the number and severity of head injuries Always wear an approved motorcycle helmet We also recommend that you wear eye protection sturdy boots gloves
56. iscard Phillips head screw Black metal clip d From the white box remove the chrome spacer and Phillips head screw 51 24 25 SET UP INSTRUCTIONS INTERCEPTOR GTR 250 BATTERY a Put on protective gloves b Remove red strip covering acid ports from battery c Place funnel into acid ports on battery Press acid container firmly into funnel allowing acid to flow into battery d Let acid settle in battery for about 10 minutes e Place black cap into acid ports and press firmly to secure f Let battery charge on 2A for about 30 minutes g Remove electric box cover from behind driver seat h Place battery into electric box 1 Place rectangular nuts under each pole of the battery j Bolt the green cable to the pole and the red cable to the pole k Secure battery with rubber strap and reinstall electric box cover ENGINE OIL a Remove the dipstick from engine and wipe clean b Place the dipstick back into engine but do not tighten c Remove dipstick and check oil level d If oil does not cover the marked portion of the dipstick add oil e The engine holds approximately 1 2 liters 52 SET UP INSTRUCTIONS INTERCEPTOR GTR 250 26 PILIING THE COOLING SYSTEM VVTTH COOLANT It is very important that you do not just fill the radiator and reservoir with coolant and begin to ride the unit The cooling system MUST have all the air bled from it or the system will not cool the engine a Remove the
57. ms into top rear suspension mounts with the grease fittings pointing upwards The top a arms have shock mounts on them b Finger tighten only REAR KNUCKLE a Connect the rear knuckle to the rear suspension by inserting the outer ends of each a arm into the top and bottom of the knuckle b Insert top and bottom bolt of the knuckle c With all suspension bolts in place tighten with 14mm and 17mm wrench REAR SHOCRS a Place the bottom eye hole of the shock into the shock mounts on the top a arms and insert bolt b Place the top eye hole of the shock into the shock mount located on the frame and insert bolt c Tighten bolts vvith 15mm and 17mm vvrench REAR VVHEEL AND CAP a In the hardware box you will find 4 chrome wheel caps The larger set vvill be used on the rear Also get out 8 acorn shaped lug nuts b Slide the wheel cap into the center hole of the wheel from the back c Place the vvheel assembly into position by aligning the holes in the vvheel vvith the lugs on the front hubs d Tighten the lug nuts with a 15mm socket With the wheels off the ground you may not be able to tighten the lugs completely Lomer the kart and tighten the lug nuts completely 48 SET UP INSTRUCTIONS INTERCEPTOR GTR 250 16 STUMP GUARD AND TRAILER HITCH a Place the stump guard under the rear suspension box under the rear sprocket b Align the 4 holes of the stump guardvvith the holes on the frame c Be sure all bolts a
58. n Breather Tube 8213 3032 Drain Tube Assy 8213 3033 Tube Clip E5 8213 3034 Change SW Assy 8200 3193 8257 3014 Cylinder Stud Bolt B Spring Fixed Catch CO COOl N O O ASIWN 8200 3404 Screvv Fixing 8200 0193 Drain Plug Bolt 12mm 8200 0591 Drain Plug VVasher 12mm 8200 3507 Drain Plug Washer 14mm 8100 0160 Flange Bolt SH 6x12 8100 0162 Flange Bolt SH 6x18 8200 3112 Flange Bolt SH 6x50 8200 3114 Flange Bolt SH 6x70mm 8213 3035 Sted Ball 12 I NIA INITIO la DS A JA IN i a sech al GTR 250 PARTS MANUAL FIG 6 R CRANK CASE Fig 6 R CRANK CASE REF PART NO DESCRIPTION QTY 8213 3120 R Crank Case Comp 8213 3121 Wave Washer E06 8240 3101 Crank Case Gasket 8213 3036 Cam Chain Setting Plate 8213 3037 Star Reduction Gear Comp 8213 3038 Sta Reduction Gear Shaft 8213 3039 Start Motor Assy 8200 3192 Cylinder Stud Bolt A 8200 0304 Dowel Pin 8x14 8200 3110 Flange Bolt SH 6x10 8100 0164 Flange Bolt SH 6x22 8100 0169 Flange Bolt SH 6x55 CO CO INI OD G 5 CN gt RO NR UZS RN RO sech ia a l ai _ air FIG R CASE COVER GTR 250 PARTS MANUAL Fig 7 R CASE COVER REF PARTS NO DESCRIPTION QTY 8213 3040 R Case Cover Comp 8213 3041 Clamp E7 8213 0040 Tappet Adj Hole Cap Assy 8213 0041 Oil Filter Screen 8257 0011
59. n one drink can reduce your ability to respond to changing conditions and your reaction time gets vvorse vvith every additional drink So don t drink and drive and dont let your friends drink and drive either Do not operate this kart if you are taking any prescriptions Do Not Operate this Kart at Night Lower visibility at night can greatly reduce a driver s judgment Driving at night is dangerous and will increase the possibility of an accident Never Run Your Kart Indoors The exhaust from the engine contains carbon monoxide a polsonous gas vvhich is tasteless amp odorless Carbon monoxide kills Keep Away from Moving Parts of the Kart Never place your hands or any other body part near any moving part of the kart Failure to adhere to this warning may cause physical harm to your body Skidding or Sliding The terrain s surface can be a major factor affecting turns Skidding in a turn is more likely to occur on slippery surfaces such as snow ice mud and loose gravel If you skid on ice you may lose all directional control To avoid skidding on slippery terrain keep your speed low and drive carefully This section presents some of the most important information and recommendations to help SAFETY LABELS you drive your kart safely Please take a fevv moments to read these pages The labels should be considered permanent parts of the kart If a label comes off or becomes hard to read contact your dealer for vvarning label r
60. ne ground e Malfunction of spark plug e Spark plug fouled Check for sparks 7 sparks no spark at Malfunction of CD set e Malfunction of AC generator e Ignition coil is in open or short circuited Ignition coil leads open or short circuited Malfunction of main svvitch Cylinder compression Lovv compression e Piston ring seized pressure normal pressure or no pressure e Malfunction of cylinder valves e Worn cylinder and piston ring e Cylinder gasket leak Re start by follovving the starting e Sand hole in compression parts procedures Perform cylinder compression pressure test There are some signs of Malfunction of throttle valve operation Air sucked into intake manifold ignition nut engine can not be started Incorrect ignition timing Remove the spark plug again and check it Dry spark plug Wet spark plug e Fuel level in carburetor too high Malfunction of throttle valve operation e Throttle valve opening too wide Remove carburetor after 30 minutes and connect a hose onto fuel rich circuit then blow the hose with air Blowing is normal Blowing clogged e Malfunction of automatic by starter 41 TROUBLE SHOOTING CHARTS B Engine Runs Sluggish Speed does not pick up lack of power Check and Adiustment Fault Condition Probable Causes V Try gradual acceleration and check engine speed e Air cleaner clogged e d 5 End b Poor fuel supply e L
61. ne Muffler Air Cleaner Rear Svving Arm Rear Housing VVire Harness Electrical Trail Board Tool Kit VVarning Stickers Stickers O 00 O 13 15 16 18 20 25 26 31 40 41 46 Fig 1 Fig 2 Fig 3 Fig 4 Fig 5 Fig 6 Fig 7 Fig 8 Fig 9 Fig 10 Fig 11 Fig 12 Fig 13 Fig 14 Fig 15 Fig 16 Fig 17 Fig 18 Fig 19 Fig 20 Fig 21 Fig 22 Fig 23 Fig 24 Fig 25 Fig 26 Fig 27 Fig 28 Fig 29 INDEX Services Manual General Information Service Maintenance Information Lubrication System Fuel System Cylinder Head Valve Cylinder Pistion Type Belt Driving System Kick Starter Final Driving Mechanism Alternator Crankshaft Crankcase Cooling System Electrical Equipment LA 2 1 Sal 4 1 sal 6 1 1 8 1 21 10 1 12 1 VVARRANTY arter A Better Built Machine CARTER RARTS LIMITED VVARRANTY REGISTRATION ALL UNITS MUST BE REGISTERED VVITHIN 10 DAYS OF PURCHASE OR THE VVARRANTY IS VOID To register your product complete the VVarranty Registration form Fax or mail the vvarranty registration form vvith a copy of the sales receipt to Carter A vvarranty registration form MUST be on file vvith Carter before a vvarranty claim can be processed VVARRANTY PERIOD The vvarranty period starts from the date that the unit is sold to the first retail purchaser for all Carter products During the vvarranty coverage period vve vvill cover vvarranty parts and labor only Parts repaired an
62. ng Set 8213 3056 Piston 8213 3057 8213 3058 Piston Pin Connecting Rod 8213 3059 Conn Rod Assy 8213 3060 Balance Shaft Drive Gear 8213 3061 R Crank Side Plate O OI INI O AJIA WIN a 8213 3062 Crank Pin O 8213 3063 8213 0095 Piston Pin Clip 17mm Woodruff Key 25x14x4 8222 3012 Connecting Rod Bearing PK32x41x17 8 8200 3704 Oil Seal TC 27x42x7 8222 3017 Radial Ball Bearing 6207 8222 3010 Radial Ball Bearing TMB306JR2C3 FIG 10 GTR 250 PARTS MANUAL AC GEN FLYVVHEEL 3 8 22 5 4 e Ss 9 GA 3 15 1 KG _ 82 mm gt a 4 dd Fig 10 AC GEN FLYVVHEEL 8240 3103 R Cover Gasket 8213 3064 Starting Clutch Gear Comp 8213 3065 One VVay Clutch Assy 8213 3066 AC Gen Flyvvheel Set 8213 3067 Flywheel Comp 8213 3068 Stator Comp 8200 0214 Flange Nut 14mm 8200 0551 Thrust VVasher 14x28x2 8200 3701 Oil Seal TC 12x22x5 8200 0403 Pan Screvv 5x16 8200 3403 Pan Screvv 6x40 8200 0304 Dovvel Pin 8x14 8200 3804 Circlip In 32mm 14 8222 3015 Radial Ball Bearing 6201LUC3 15 8100 0175 Socket Bolt 8x20 10 O O IO 901 BE WIN NI OIN a Sd X A dai da GTR 250 PARTS MANUAL FIG 11 BALANCE SHAFT PS 4 amp Se S a i XX 2 vn ME 9 L y 5 5 A m er as iA q l 2 b A 3 J
63. ng vvheelies jumps and other stunts increases the chance of an accident including an overturn Never attempt stunts such as vvheelies or jumps Don t try to shovv off GENERAL INFORMATION MODEL IDENTIFICATION FRAME NUMBER The frame number or VIN is stamped on the upper firevvall of the frame behind the seat VIN NUMBER LOCATION ENGINE NUMBER The engine number is located on the lovver front left side of the engine case FUEL RECOMMENDATIONS Be sure to use the specified fuel FUEL Gasoline should be 92 octane or higher Unleaded gasoline is recommended Engine oil should be SAE 10VV 30 BREAK IN PROCEDURE For the first 2 hours of riding do not exceed 2 3 throttle Vary Engine speed for the first 5 hours Never hold engine at full throttle for long periods of time Bi A a VIN NUMBER LOCATION SPECIFICATIONS DIMENSIONS Overall Length 90 in 2286mm Overall Width 62 in 15748mm Overall Height 63 in 1600mm Wheelbase 68 in 1727mm Front Track 47 1 in 1060mm Rear Track
64. r and clothing Keep arms legs and feet inside kart Do not use alcohol or drugs ARE YOU READY TO DRIVE Before each drive make sure you and your kart are both ready to drive This section discusses hovv to evaluate your driving readiness vvhat items you should check on your kart and adiustments to make for your comfort convenience or safety Before you drive your kart for the first time vve urge you to m Read this ovvner s manual and the labels on your kart carefully m Make sure you understand all the safety messages m Knovv hovv to operate all the controls m Have an experienced adult present if operator is not experienced in this kart Before each drive be sure m YOU vvear your seat belt at all times vvhile driving your kart m You feel vvell and are in good physical and mental condition m You are wearing an approved motorcycle helmet with chin strap tightened securely eye protection and other protective clothing You don t have any alcohol or drugs in your system Protective Apparel For your safety we strongly recommend that you always wear an approved motoreycle helmet eye protection boots gloves long pants and long sleeved shirt or jacket vvhenever you drive Although complete protection is not possible vvearing proper gear can reduce the chance of injury vvhen you drive The follovving suggestions vvill help you choose the proper driving gear Helmets and Eye Protection Your helme
65. r excess oll will gently reduce proper engine performance f possible check the spark plug gap area between electrodes using a wire feeler guage This specification is 0 8 0 9mm clean dint or carbon washer b Before installing the spark plug coat threads lightly with graphite grease if possible to ensure easy removal in the future proclea c It is advisable to replace the spark plug at least once a vear to insure easy starting and good engine performance 28 SERVICE INSTRUCTIONS F Cleaning Instructions Keep your kart clean VVith clean rag vvipe off dirt and oil from around controls VVipe off any spilled fuel and oil Keep the engine clean of foreign objects and be sure to check that air intake fan is free of debris for proper cooling G Drive Chain Hovv to Tighten Chain a On this unit in order to tighten the chain the entire engine must be slid forvvard DRIVE CHAIN b Loosen the engine plate bolts 2 front and 2 rear c Loosen air box bolts 4 total d Loosen muffler bolts 2 total e Slide engine forward and tighten all bolts NOTE When pushing the engine forward the front engine mount will try and tilt forward This will cause the engine to return to its original position FRONT PLATE BOLTS once force is removed You will need to tap the bottom of the engine plate to keep it from tilting Check gear positions after adjusting chain How to Lubricate
66. radiator filler cap and by pass hose from the by pass valve Radiator filler cap By pass hose b With the engine running at idle fill the radiator with coolant Fill the radiator until coolant comes out of the by pass valve When ONLY coolant comes out of the by pass valve and there are no air bubbles in the coolant reconnect the by pass hose c Continue to fill the radiator until the coolant level reaches the top of the radiator neck where the cap goes After several minutes of idling the coolant level will drop Refill the radiator to the same level and monitor for several more minutes for air bubbles If the coolant level drops again refill Once the coolant level 1s stable and you no longer see air bubbles screw the radiator cap back on and fill the reservoir to the appropriate level 53 GTR 250 PARTS MANUAL INDEX TO ENGINEER GROUP ACA a e Cylinder Head Comp Cylinder Assembly L Cover Assembly Ho en R Crank CaSO R Case Cover m Movable Drive Face Crank Shaft es AC Gen Flywheel Balance Shaft Mission Case
67. re in place then tighten with lOmm and 12mm wrench d Place trailer hitch plate under trailer hitch mount Align the 2 bolt holes insert the 2 large bolts and vvashers and tighten vvith a 19mm and 21 mm vvrench e Tighten ball with 24mm or adjustable vvrench 17 CARGO RACK a Place a black rubber end cap on each mounting post of the cargo rack There will be 6 in all The black rubber end caps are in the hardvvare box Also remove 6 black anodized bolts and vvashers b Hold the top section of the rack about 1 off the rear frame and start the rear bolts Go ahead and tighten these rear bolts most of the vvay This vvill prevent the heads of the bolts from scratching the frame c Insert the remaining bolts and vvashers and tighten with a 10mm wrench Be sure all bolts are started before tightening 18 TAIL LIGHT a Insert the mounting bolts of the tail light into the tail light bracket located under the cargo rack b Tighten with a 10mm wrench Be sure not to over tighten 19 FRONT FENDERS a Place the fender brackets over each strut above the steering arm b Start each bolt first then tighten with a 10mm and 12mm wrench 49 20 21 SET UP INSTRUCTIONS INTERCEPTOR GTR 250 REAR FENDERS a Behind each seat is a mounting post for the rear fenders b Align the holes and slots of the fender bracket with those of the mounting post c Tighten with 10mm wrench SEATS AND SEAT BELTS a
68. rotective clothing ALL HAIR MUST BE TIED UP AND SECURED AT OR ABOVE SHOULDER LENGTH ALL LOOSE CLOTHING MUST BE SECURED ALL NECKLACES AND SCARVES MUST BE SECURED m NEVER OPERATE THIS GO KART AT EXCESSIVE SPEEDS You increase your risk of losing control if you operate it at speeds too fast for the terrain visibility conditions or your experience m NEVER ATTEMPT WHEELIES JUMPS OR OTHER STUNTS WARNING The vehicle must be stationary and the engine at idle before selecting gears 303115 A WARNING Loss of control collision or getting caught in moving parts can result in serious injuries Adult supervison for under 16 years old MAX LOAD VVear a D O T approved motoreycle helmet 2 00 L B S O N LY Secure long hair and loose clothing Wear protective eye wear and clothing Keep arms legs and feet inside kart Do not use alcohol or drugs 3031107 Fig 28 WARNING STICKERS PART NO DESCRIPTION 503 3000 Label Parking Brake 603 0005 Hot Dot Touch Sticker 503 3014 Label Chain Guard 503 3002 Label No Long Hair 503 3003 Label Warning HAZ 503 3004 Label No Riding 503 3005 Label Warning LOSS 503 3006 Label Seat Belt 503 3012 Label Warning VEH 603 0006 Rear Cargo Max Loading SticRer 1 2 3 4 5 6 7 8 9 1 ik A GTR 250 PARTS MANUAL F G 29 STICKERS Fig 29 STICKERS PART NO DESCRIPTION 603
69. t is your most important piece of driving 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 DOT Department of Transportation sticker on any helmet you buy Alvvays vvear a face shield or goggles to protect your eyes and help your vision N WARNING Operating this go kart vvithout vvearing an approved motoreycle 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 and wear eye protection goggles or face shield gloves boots long sleeved shirt or jachet and long pants ARE YOU READY TO DRIVE Additional Driving Gear In addition to a helmet and eye protection we also recommend m Sturdy off road motoreycle boots to help protect your feet ankles and lower legs m Off road motorcycle gloves to help protect your hands m Driving pants with knee and hip pads a driving jersey with padded elbows and a chest shoulder protector Driver Training Developing your driving skills is an ongoing process Even if you have driven other karts before driving take time to become familiar with how this kart works and handles Practice driving the Rart in a safe area to build your skills
70. time of publication Due to improvements or other changes there may be some discrepancies in this manual Therefore if nevver information is needed in the future please contact the local distributor Distributor reserves the right to make production changes at any time vvithout notice and vvithout incurring any obligation to make same or similar changes to vehicles previously built or sold We hope you will have a pleasant experience with our product Thanks again for choosing our kart Carter Brothers Manufacturing Co nc 1871 U S Highvvay 231 South arter Brundidge Alabama 36010 Phone 800 523 5278 A Better Built Machine INDEX Owner s Manual Warranty About Safety Important Safety Information Safety Labels Are You Ready To Drive Is Your Vehicle Ready To Drive Safe Driving Precautions General Informations Specifications Locations Of Parts Operation Periodical Checks And Services Service Instructions Service Information Wiring Diagram Trouble Shooting Charts Set up Instructions Parts Manual Head Cover Cylinder Head Comp Cylinder Assembly L Cover Assembly L Crank Case R Crank Case R Case Cover Movable Drive Face Crank Shaft AC Gen Flywheel Balance Shaft Mission Case Oil Pump Assembly Cylinder Head Side Cover Assembly Driven Pully Set A I C V Assembiy Carburetor Assembly Frame Group Steering Shaft Assembiy Suspension Arm Assembiy Rear Cargo Rack Seat Belt Engi
71. to specified quantity from the join hole Gear Oil Quantity 650 cc when replacing e Make sure that the join bolt washer can be re used and install the bolt Torque value 3 5 4 5kgf m f Start engine and run engine for 2 3 minutes Turn off engine and make sure that oil level is at correct level Make sure that there is no oil leakage DRAIN BOLT 27 SERVICE INSTRUCTIONS D Carburetor Adjustment Never make unnecessary adjustments The factory recommended settings are correct for most applications N WARNING Air screvv vvas set at factory so no adiustment is needed Note the number of turns it takes to scevv it all the vvay in for ease of installation The parking brake must be used to stop the kart to perform the adjustments THROTTLE VALVE STOPPER SCEVV a VVarm up engine 5 10min b Tighten the air screvv gently Backout 2 turns c Connect the tachometer adjust the throttle to limit the idle speed The standard value is 1700 RPM d Turn the air screw counter clockvvise slowly and observe the RPM of the engine stop adjusting as the RPM reaches top speed e Adiust the screvv and adjust the idle speed to an ideal value f Recheck and readjust the idle speed if necessary AIR ADJUSTMENT SCREVV E Spark Plug a Remove the spark plug and inspect it each time you change the oil Use a spark plug vvrench Keep the electrodes clean and free of carbon The presence of P 0 8 0 9mm carbon o
72. understand that I must please initial beside each number 1 Always read the Owner s Manual carefully follow the operating procedures described in the Owner s Manual and pay special attention to the warnings contained in the manual and on all labels 2 It ls Recommended that no one under the age of 16 operate the Vehicle 3 Never allow any operation of the Vehicle beforer eading the Owner sManual 4 Never allow more than one operator and one passenger to ride on the Vehicle 5 Never operate the Vehicle after consuming alcohol or drugs 6 Never operate the Vehicle without wearing your seat belt Karts only a proper helmet eye protection and protective clothing 7 Never operate the Vehicle on unsafe terrain or at excessive speeds 8 Never do wheelies jumps or other stunts 9 Never allow anyone to ride on the back or the front of the Kart or the handlebars of the Scooter 10 Never allow the Kart to be driven on a public road of any kind even a dirt or gravel one because you may not be able to avoid colliding with other vehicles Operating your Kart on a public road may be against the law 11 Never operate the Kart on pavement The Kart is not designed to be used on paved surfaces and may be difficult to control 12 Always follow the break in period as described in the Owner s Manual or your engine warranty will be voided 13 Always clean the air filter as described in the Owner s Manual or your engine warranty will be voided 14 Never operat
73. ving pulley spring broken Clutch vveights broken Drive slide shaft gear groove broken Transmission gear damaged Clutch vveights spring broken Clutch outer stuck vvith clutch vveights Connection parts in clutch and shaft vvorn out or burned Drive belt vvorn out or deformed VVeight roller vvorn out Movable drive face shaft vvorn out Driven pulley spring deformed Driven pulley shaft vvorn out Greased in drive belt and driven face Probable Causes Damaged steering bearing Damaged steering shaft bushing Bent rim Improperly installed wheel hub Excessive wheel bearing play Bent swing arm Bent frame Swing arm pivot bushing excessively worn Bent tie rod Incorrect tie rod adjustment Rear tire air pressure incorrect Improper wheel alignment Bent frame TROUBLE SHOOTING CHARTS G Lose Povver Check and Adjustment Raise vvheels off ground and spin by hand Spin freely Check tire pressure Normal Accelerate lightly engine speed can be increased Normal Check ignition timing Normal Test cylinder compression Normal Check carburetor Normal Check spark plug Normal Check for engine overheating Normal Accelerate or run at high speed Normal Fault Condition Abnormal Abnormal Abnormal Abnormal Abnormal Clogged Fouled or discolored Overheating Knocks 45 Probable Causes Brake dragging Drive chain too tight Damag
74. vn 20 B m Pre Drive Inspection N WARNING Perform this pre drive inspection everyday before driving vehicle If not performed serious damage to the vehicle or personal injury may result Check engine oil level Check for leaks add oil if required Check fuel level Add fuel as necessary and do not overfill Check for leaks Check brakes Depress the rear brake pedal several times then check for proper brake pedal freeplay Make sure there is no brake fluid leakage Adjust if necessary Check tires Check tire condition and pressure The pressure on both front and rear tires is 14 psi respectively Check drive chain Check drive chain s condition and tension Lubricate if necessary Check throttle Check for smooth operation Assure throttle snaps back to idle Check engine stop button Perform engine stop button test Repair as necessary Check all nuts bolts and fasteners Check wheels to see that all axle nuts and lug nuts are tightened properly Check and tighten as necessary all other fasteners to specified condition Check occupant protection bar Ensure all occupant protection bars are in place before operating the kart Check brake light Check for proper operation Check wheels Check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins Check steering Check for free operation for any unusual looseness in any area N WARNING Alvvays
75. w M03X6 2 552 3037 Brake Pedal Pad 1 622 0001 Needle Bearing 2617 2 500 1079 Flange Bolt M08x30 2 10 500 1069 Lock Washer M08 2 11 636 6009 Steering Knuckle 1 12 636 6006 Steering Assy 1 13 600 0066 Flange Bolt M08x20 4 14 500 1018 Round Nut M16x1 5 2 15 536 3006 Steering Ball Joint 2 16 500 3003 Hex Nut M10 4 17 536 3007 L Dust Cover Ball Joint 1 18 636 6011 Tie Rod 2 19 536 3009 Tie Rod End 2 20 500 3025 VVasher M10 2 21 500 1071 Lock Washer M10 2 22 500 3004 Castle Nut M10 2 23 500 1090 Cotter Pin 2x20 2 24 536 3010 R Dust Cover Ball Joint 1 25 636 0601 Steering Gear Bracket Blue 2 25a 636 0605 Steering Gear Bracket Sliver 2 25b 636 0606 Steering Gear Bracket Carbon 2 26 558 3036 Throttle Pedal Pad 1 7 600 0100 Throttle Pedal Bolt M08x145 1 28 557 3001 Throttle Pedal Spring 1 29 500 3044 Flange Bolt M08x50 2 30 600 0155 Bolt Brake Pedal 1 31 558 3000 Throttle Pedal Comp 1 32 500 1074 Flange Bolt M05X16 2 33 652 0014 Brake Light Switch 1 34 600 8007 Circlip 20 round 1 35 652 6005 Brake Pedal Comp 1 36 640 6603 Pedal Bushing 4 37 557 3002 R Brake Pedal Return Spring 1 38 500 1073 Nut M08 4 39 634 6003 Spindle Bracket 1 40 500 1043 Flange Lock Nut M08 2 41 636 0002 Brake Master Cylinder 1 42 636 0561 Spindle Pin 2 43 600 3801 Lock Pin 6x22 1 44 500 1079 Flange Bolt M08x30 2 21 FIG 20 SUSPENSION ARM ASSEMBLY A d Mn Fig 20 SUSPENSION ARM ASSEMBLY PART NO GTR 250 PARTS MANUAL DESCRIPTION
76. x16 8200 3001 Bolt M08x45 8240 3401 Muffler Tube Clamp 613 6016 640 6025 Secondary Combust Valve Fixing Base Overflow Pipe A 640 6026 Overflow Pipe B 613 6014 Postcombustion Air Clean 613 6017 Intake Tube 640 6203 Outer Tube 613 6020 Radiator Assy 600 0163 Bolt M10x40 900 3003 Hex Nut M10 8213 3000 Muffler Assy 613 6019 Temperature Controller 8240 3310 Air Clean Inlet Pipe muffler 640 6027 Filler Neck 8240 3501 Drain Tube Clip B SD8 5 8240 3502 Drain Tube Clip A SB12 5 640 6204 Reservoir Tube 640 6028 640 6029 VVater reservoir Cap Left Crank Case Dust Boot Intake NI AA S HS La ta 2 ia ia joa a pe AI A O Aa aa gt 640 6024 Left Crank Case Dust Boot Exaust 24 FIG 23 REAR SWING ARM A res oa o 18 ag NS GTR 250 PARTS MANUAL Fig 23 REAR SWING ARM REF PART NO DESCRIPTION QTY 1 600 9001 Grease Fitting M06 12 2 600 6011 O Ring D434 24 3 637 6404 Rr R Fender Bracket k61 4 600 0110 Cross Bolt M6x16 8 5 600 0523 Flange Bolt M12x45 6 900 3006 Flange Lock Nut M12 16 7 600 0001 Washer Cap black 2 8 63 6403 Rr L Fender Bracket k61 1 9 500 3045 Flange Bolt M08x55 2 10 653 6013 Rr Upp

Carter Brothers Go Kart Interceptor GTR 250 Model 2861 – Live Axle

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Carter Brothers Go Kart Interceptor GTR 250 Model 2861 &ndash; Live Axle

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Carter Brothers Go Kart Interceptor GTR 250 Model 2861 – Live Axle