Owners Manual

Parts Manual
READ THIS MANUAL CAREFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION.

SZ250DI

MINIMUM RECOMMENDED OPERATOR AGE:

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FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for off-road use only. USA only: It does not confirm to federal motor vehicle safety standards, and operation on public streets, roads, or highways is illegal

SZ50DI Limited Warranty

The warranty policy applies to those cases where the new seller vehicle is unloaded from its shipping container, set up and delivered by authorized dealer, and under normal use and service is found to have defects in parts or workmanship under the following terms and conditions. This warranty covers the engine and engine related components for a period of 90 days. This warranty does not apply to any part, which in opinion of seller was defective because of improper maintenance, improper assembly, alterations, abuse, negligence or accident. Should warranty service be required on your SZ50DI during the 90 days warranty period, please contact your nearest authorized dealer for repairs.

What is not covered under this warranty?

This warranty does not cover any seller vehicle that has been subjected to: a. This warranty does not cover any seller vehicle in any way so to adversely affect its safety or reliability. b. Renting c. Disassembly, adjusting, or repairing of the vehicle in any way so as to adversely affect its safety or reliability. d. Competition or racing The warranty does not cover loss of use of the seller vehicle, loss of time, inconvenience, or other consequential damage which includes, but is not limited to, loss or damage to persons or property or any expense of returning any damaged units to the seller distributor or its authorized dealer. Seller has the right to make changes without notice.

CONTENTS
OWNERS MANUAL ............................................................................................................ 4 FOREWORD.................................................................................................................. 4 A FEW WORDS ABOUT SAFETY ................................................................................. 5 IMPORTANT SAFETY INFORMATION.......................................................................... 6 SAFETY LABELS .......................................................................................................... 8 ARE YOU READY TO DRIVE?...................................................................................... 9 IS YOUR VEHICLE READY TO DRIVE? ......................................................................11 SAFE DRINING PRECAUTIONS................................................................................. 13 SPECIFICATIONS ....................................................................................................... 15 OPERATION ................................................................................................................ 16 SERVICE INSTRUCTION............................................................................................ 20 REPAIR........................................................................................................................ 24 PERIODICAL CHECK AND SERVICES ...................................................................... 25 WIRING DIAGRAM...................................................................................................... 26 PARTS MANUAL................................................................................................................ 27 1CRANKCASE ASSY. .............................................................................................. 27 2SIDE COVER ASSY.L ............................................................................................ 29 3RIGHT COVER ASSY ............................................................................................ 30 4CYLINGDER HEAD CASEING ASSY .................................................................... 32 5CYLINGDER HEAD ASSY ..................................................................................... 34 6CYLINGER BODY ASSY........................................................................................ 36 7TIMING CHAIN....................................................................................................... 37 8MAGNETOR ASSY ................................................................................................ 38 9ADMISSION MACHANISM .................................................................................... 39 10CRANK LINK LEVER & PISTON.......................................................................... 40 11SPEED CHANGER............................................................................................... 41 12CLUTCH ASSY .................................................................................................... 42 13GEARBOX COVER ASSY.................................................................................... 43 14TRANSMISSION GEAR ASSY............................................................................. 44 15GEAR SHIFT MACHANISM ................................................................................. 46 16ENGINE OIL PUMP ASSY ................................................................................... 47 17COOLANT PUMP ASSY ...................................................................................... 48 18ELECTRIC STARTER ASSY ................................................................................ 49 19CARBURETOR ASSY .......................................................................................... 50 20FRAME AND FUEL TANK .................................................................................... 51 21SUSPENSION ARM ASSY................................................................................... 53 22STEERING ASSY................................................................................................. 55 23ENGINE RACK..................................................................................................... 57 24ENGINE RACK..................................................................................................... 59 25MIDDLE AXIS ASSY ............................................................................................ 61 26ELECTRICAL ASSY ............................................................................................. 63 27SEAT AND MUD GUARD ..................................................................................... 65 PREPARATION ATTACH INSTRUCTION .......................................................................... 67 ATTACH BATTERY ...................................................................................................... 67
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ATTACH FRONT SHOCK ............................................................................................ 69 ATTACH FRONT TIRE................................................................................................. 70 ATTACH LOOKUM....................................................................................................... 71 ATTACH REAR SHOCK .............................................................................................. 72 ATTACH TRAILING ARM ............................................................................................. 73 ATTACH SEAT AND SAFT BELT ................................................................................. 75 ATTACH THE RADIATOR............................................................................................ 76

OWNERS MANUAL FOREWORD Thank you for choosing our Go-art. We hope you will have fun with it. Before you start operate the Go-Kart, please read through this Owners Manual carefully as it contains important safety and maintenance information. Failure to follow the warnings contained in this manual can result in serious injuries.

Be sure to follow the recommended maintenance schedule and service your kart accordingly. Preventive maintenance is extremely important to the longevity of your Go-Kart.

We hope you will have a pleasant experience with our products and thanks again for choosing US.

A FEW WORDS ABOUT SAFETY

In order to keep everyone safe, you must take responsibility for the safe operation of your Go-Kart. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others. It is not practical or possible to warn you about all hazards associated with operating or maintaining a Go-Kart. You must use your own good judgment. You will find important safety information in a variety of forms, including: Safety Labels - On the Go-Kart. Safety Messages Preceded by a safety alert symbol signal words: WARNING, or CUATION. These signal words mean: and one of two

Physical harm may result from failure to adhere to the instructions that are described within the WARNING labels. Safety Headings --- such as Important Safety Reminders or Important Safety Precautions. Safety Section --- such as Go- Kart Safety. Instructions --- how to use this Go Kart correctly and safely. This entire manual is filled with important safety information----please read it carefully.

IMPORTANT SAFETY INFORMATION

Your Go-Kart will provide you with many years of service and pleasure. Providing you take responsibility for your own safety and understand the challenges you can meet while driving. There is much that you can do to protect yourself when you drive. Youll find many helpful recommendations throughout this manual. The following are a few that we consider most important. Follow the Age Recommendation It is strongly recommended that no one under the age of 16 be permitted to drive this Go-Kart without adult supervision. Always Wear a Helmet Its a proven fact: helmets significantly reduce the number and severity of head injuries. Always wear an approved motorcycle helmet. We also recommend that you wear eye protection, sturdy boots, gloves, and other protective gear. Drive Off-Road Only Your Go-Kart is designed and manufactured for off-road use only. The tires are not made for pavement, and the Go-Kart does not have turn signals and other features required for use on public roads. If you need to cross a paved or public road, get off and walk your Go-Kart across. Take Time to Learn & Practice Even if you have derived other Go-Kart, take time to become familiar with how this Go-Kart works and handles. Practice in a safe area until you build your skills and get accustomed to this Go-Karts size and weight. Because many accidents involve inexperienced or untrained drives, 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. Drive within Your Limits Pushing limits is another major cause of Go-Kart accidents. Never drive beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, fatigue, and inattention can significantly reduce your ability to make good judgments and driver safely. Dont Drink and drive Alcohol and driving dont mix. Even one drink can reduce your ability to respond to changing conditions, and your reaction time gets worse with every additional drink. So dont drink and drive, and dont let your friends drink and drive either.
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Never run your Go- Kart indoors. The exhaust from the engine contains a tasteless, odorless and poisonous gas called carbon monoxide. Keep away from moving parts of the Go-Kart The operator of the Go-Kart should never place their hands or other parts of their body near any moving part of the Go-Kart. Failure to adhere to this warning will cause physical harm to your body. Skidding or Sliding The terrain surface can be a major factor affecting turns, Skidding 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 you speed low and drive carefully.

SAFETY LABELS
This section presents some of the most important information and recommendations to help you drive your Go-Kart safely, Please a few moments to read these pages. The labels are considered permanent parts of the Go-Kart. If a label comes off or becomes hard to read, contact your dealer for warning labels replacements.

ARE YOU READY TO DRIVE?

Before each drive, you need to make sure you and your Go-Kart are both ready to drive. To help get you prepared, this section discusses how to evaluate your driving readiness, what items you should check on your Go-Kart, and adjustments to make for your comfort, convenience, or safety. Before you drive your Go-Kart for the first time, we urge you to: Read this owners manual and the labels on your Go-Kart carefully. Make sure you understand all the safety messages. Know how to operate all the controls. Have adult present if under 16 years old. Before each drive, be sure: You feel well and are in good physical and mental condition. You are wearing an approved motorcycle helmet (with chin strap tightened securely), eye protection, and other protective clothing. You dont have any alcohol or drugs in your system. Protective Apparel For your safety, we strongly recommend that you always wear an approved motorcycle helmet, eye protection, boots, gloves, long pants, and long-sleeved shirt or jacket whenever you drive. Although complete protection is not possible, wearing proper gear can reduce the chance of injury when you drive. The following suggestions will help you choose the proper driving gear. Helmets and Eyes Protection Your helmet 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 in any helmet you buy. Always wear a face shield or goggles to protect your eyes and help your vision.

Operating this Go-Kart without wearing an approved motorcycle helmet, eye protection, and protective clothing could increase your chances of head and/or eye injury, possibly death in the event of severe accident. Always wear approved motorcycle helmet that fits properly and wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket and long pants.

Additional Driving Wear In addition to a helmet and eye protection, we also recommend: Sturdy off-road motorcycle boots to help protect your feet, ankles, and lower legs. Off-road motorcycle gloves to help protect your hands.
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Driving pants with knee and hip pads, a driving jersey with padded elbows, and a chest/shoulder protector. Drive Training Developing your driving skills is an on-going process. Even if you have derived other Go-Karts, take time to become familiar with how this Go-Kart works and handles. Practice driving the Go-Kart in a safe area to build your skills. Do not drive in rough terrain until you get accustomed to the Go-Karts controls, and feel comfortable with its size and weight.

Operating Go-Kart without proper instruction could increase your risk of an accident, which could lead to serious injury or death.

Attempt supporting with your hands to the ground when the Go-cart turning over could lead to serious injury or death. Never support with your hands to ground when the Go-cat will turn over.

Age Recommendation It is strongly recommended that no one under the age of 16 be permitted this Go-Kart without adult supervision.

A child driving a Go-Kart that is not recommended for his/her age could lose Go-Kart control and result in severe injury or death. A child under 16 should have adult supervision when operate on the Go-Kart.

No Alcohol or Drugs Alcohol, drugs and Go-Karts dont mix. Even a small amount of alcohol can impair your ability to operate a Go-Kart safely. Likewise, drugs-even if prescribed by a physician-can be dangerous while operating a Go-Kart. Consult your doctor to be sure it is safe to operate a vehicle after taking medication.

Operating this Go-Kart after consuming alcohol or drugs can seriously affect your judgment, cause you to react more slowly, affect your balance and perception, and could result in serious injury or death. Never consume alcohol or drugs before or while operating this Go-Kart.

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IS YOUR VEHICLE READY TO DRIVE?

Before each drive, it is important to inspect your Go-Kart and make sure any problems you find are corrected. A pre-drive inspection is a must, not only for safety, but because having a breakdown, or even a flat tire, can be a major inconvenience. If your Go-Kart has overturned or has been involved in a collision, do not drive it until your dealer has inspected your Go-Kart, There may be damages or other problems you cannot see.

Improperly maintaining this Go-Kart or failing to correct a problem before driving can cause a crash in which you can be seriously hurt or dilled. Always perform a pre-drive inspection before every drive and correct any problems.

Pre-drive Inspection Check the following items before you get on the Go-Kart:

Engine Oil Check the level and add oil if needed. Check for leaks. 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 damages or excessive wear. Nuts & Bolts Check the wheels to see that the axle nuts are tightened, Use a wrench to make sure all accessible nuts; bolts, and fasteners are tight. Under body & Exhaust System Check for and remove any dirt, vegetation or other debris that could be fire hazard or interfere with the proper operation of the Go-Kart. Air Cleaner Housing Drain Tube Check for deposits in the drain tube. If necessary, clean the tube and check the air cleaner housing.

Leaks, Loose Parts Walk around you Go-Kart and look for anything that appears unusual, such as a leak or loose cable.

Lights Make sure the headlight; brake light and taillight are working properly.

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Throttle Check the free play 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 rear brake pedal several times, check for proper brake pedal free play. Make sure there is no brake fluid leakage. Engine Stop Button When 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 the cable housing for wear. Check the fittings for looseness. Replace or tighten as needed. Tie rod Check the tie rod housing for wear. Check the fittings for looseness. Replace or tighten as needed.

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SAFE DRINING PRECAUTIONS

Off-Road Use Only You Go-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 Go-Kart on pavement.

Operating this Go-Kart on paved surfaces may seriously affect handling and control of the Go-Kart, and may cause the vehicle to go out of control. Never operate the Go-Kart on any paved surfaces, including sidewalks, driveways, parking lots and streets.

When driving off-road, also remember to always obey local off-road driving laws and regulations. Obtain permission to drive on private property. Avoid posted areas and obey no trespassing signs. You should never drive your Go-Kart on public streets, roads or highways, even if they are not paved. Drivers of street vehicles may have difficulty seeing and avoiding you, which could lead to a collision. In many states it is illegal to operate Go-Karts on public streets, roads and highways.

Operating this Go-Kart on public streets, roads or highways can cause collision with other vehicle. Never operate this Go-Kart on any public streets, roads or highways, even dirt or gravel one.

Keep Hands and Feet on Controls Always keep both hands on the steering wheel and both feet on the foot controls. When driving your Go-Kart. It is important to maintain your balance and to control of the Go-Kart. Removing hands or foot away from the controls can reduce your ability to react control of the kart.

Removing hand from Steering wheel or feet from foot controls during operation can reduce your ability to control the Go-Kart or could cause you to lose your balance and fall off the Go-Kart. Always keep both hand on the steering wheel and both feet on the foot controls of your Go-Kart during operation.

Control Speed Driving at excessive speed increases the chance of an accident. In choosing
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a proper speed, you need to consider the capability of your Go-Kart, the terrain, visibility and other operating conditions, plus your own skills and experience.

Operating this Go-Kart at excessive speeds increases your changes of losing control of the Go-Kart, which can result in an accident. Always drive at a speed that is proper for your Go-Kart, the terrain, visibility and other operating conditions, and your experience.

Use Care on Unfamiliar or Rough Terrain Before driving in a new area, always check the terrain thoroughly. Dont drive fast on unfamiliar terrain or when visibility is limited. (Its sometimes difficult to see obstructions like hidden rocks, bumps, or holes in time to react).

Failure to use extra care when Operating this Go-Kart on unfamiliar terrain could result in the Go-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 Go-Kart.

Never drive past the limit of visibility. Maintain a safe distance between your Go-Kart and other off-road vehicles. Always exercise caution and use extra care on rough, slippery and loose terrain.

Failure to use extra care when operating on excessively rough, slippery or loose terrain could cause loss of traction or vehicle control, which 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 Go-Kart on such terrain. Always be especially cautious on these kinds of terrain.

Do Not Perform Stunts You should always operate your Go-Kart in a safe and reasonable manner. When driving, always keep all four wheels on the ground.

Attempting wheelies, and other stunts increases the chance of an accident, including an overturn. Never attempt stunts, such as wheelies or jumps. Dont try to show off.

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SPECIFICATIONS
DIMENSIONS
Overall Length---------------------------------------------------------------------------------------98 in. (2500mm) Overall Width ---------------------------------------------------------------------------------------- 59 in. (1500mm) Overall Height --------------------------------------------------------------------------------------- 64 in. (1630mm) Wheelbase -------------------------------------------------------------------------------------------- 78 in. (1980mm) Front Track ------------------------------------------------------------------------------------------ 53 in. (1350mm) Rear Track -------------------------------------------------------------------------------------------60.6 in. (1540mm) Ground Clearance ----------------------------------------------------------------------------------- 11.8 in. (300mm)

ENGINE
Type ------------------------------------------------------------------------------------------ Liquid-cooled. 4-Stroke Bore x Stroke -------------------------------------------------------------------------------------------- 72mm60mm Displacement ------------------------------------------------------------------------------------------------------ 244 cc Corrected compression ratio ------------------------------------------------------------------------------------ 9.2:1 Carburetor ----------------------------------------------------------------------- KEI HIN; No. VE 14CEQKY Output Power ---------------------------------------------------------------------------------------16.75hp/7500rpm Maximum Torque ------------------------------------------------------------------------------- 17.6/5500Nm/r/min Starting ----------------------------------------------------------------------------------------------------------- Electric Ignition -------------------------------------------------------------------------------------------------------------- C.D.I. Lubrication -------------------------------------------------------------------------------------------- Force & Splash Transmission ---------------------------------------------------------------------------- Automatic (C.V.T system) Spark Plug ---------------------------------------- DPR5EA-9 (NGK), DPR6EA-9 (NGK), DPR7EA-9 (NGK) Plug gap ------------------------------------------------------------------------------------------------------ 0.6-0.7mm Fuel type --------------------------------------------------------------------------------------------- RQ90 (unleaded) Lubricate oil ---------------------------------------------------------------------------------------------- SAE-10W/30

CAPACITIES
Maximum load ---------------------------------------------------------------------------------- Double Seats/400Ibs Fuel tank ------------------------------------------------------------------------------------------------------------ 16.0L Engine oil ----------------------------------------------------------------------------------------------------------1000ml Coolant -------------------------------------------------------------------------------------------------------------1800ml Starting ---------------------------------------------------------------------------------------------------------------- <5s Climbing ---------------------------------------------------------------------------------------------------------- 20-25 Battery ---------------------------------------------------------------------------------------------------------- 12V 9Ah Head Light ---------------------------------------------------------------------------------------------------- 12V 15W Tail Light ------------------------------------------------------------------------------------------------- 12V 10W/5W Fuse ------------------------------------------------------------------------------------------------------------------- 10A Brake Track --------------------------------------------------------------------------------------- < 7m @ 20miles/h Top speed ---------------------------------------------------------- 40 miles/h (or limited as customers require)

CHASSIS
Front, Rear brake --------------------------------------------------------------- Hydraulic disc, right foot control Front tire --------------------------------------------------------------------------------------------------------- 218-10 Rear tire ------------------------------------------------------------------------------------------------------- 2210-10 Front Suspension ----------------------------------------------------------------------- Independent Dual A-Arm Rear Suspension ------------------------------------------------------- Trailing Arm/Double Oil Damped Shock Restraint System ----------------------------------------------------------------------------- Dual 4-point Harness Final Drive Chain --------------------------------------------------------------------------- (KMC) O-Ring Chain

TIRE PRESSURE
Front ----------------------------------------------------------------------------------------- 15kpa 0.5kg/c 2.2psi Rear ----------------------------------------------------------------------------------------- 20kpa 0.20kg/c 2.9psi

WEIGHT
Net Weight -----------------------------------------------------------------------------------------------340kg/ 750 lbs

WARRANTY
Parts and workmanship ------------------------------------------------------------------------------------- 90 Days

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OPERATION
AOperation controls

WARNING-Do not attempts to start or operate the engine until completely familiar with the location and use of each control necessary to operate this vehicle. The operator must know how to stop this machine before starting and driving it. a. Throttle The right foot pedal is the throttle that controls the Go-Kart speed. As the engine speed increased above idle, the clutch automatically engages and moves the vehicle forward. To disengage the clutch at any time, allow the throttle to return to the idle position. (See Fig. 1)

Each time prior to starting the engine, check the throttle assembly to ensure that when 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 throttles 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.

BRAKE PEDAL b. Brake The brake is located on the left side of the kart (See Fig. 1). Applying pressure to the pedal draws the brake caliper around the brake pump at the rear wheel and slows or stops the kart.

THROTTLE PEDAL

Figure 1
IGNITION START SWITCH HORN BUTTON FORWARD NEUTRAL RIGHT TURN REVERSE

c. Start engine Insert the key into key-switch, turn the key clockwise, and release the key when the engine starts. The engine will warm up within 5 minutes and the engine choke will close automatically and operate at normal RPM (Warning: Dont crank starter more than 5 seconds at one time). (See Figure 2)
HIGHT BEAM HEADLIGHT

LEFT

DIPPED BEAM HEADLIGHT 16

FOG LAMP

PARKING

WARNING

LEVER OF MODE FOR LIGHT SIGNLE

STEERING

Figure 2

WARNING

Figure 3
BPre-Drive Inspection

Perform this pre-drive inspection everyday before driving vehicle. If not performed, serious damage to the vehicle or personal injury may result.

d. Check for Engine Oil Level. Check for leaks, add oil if required. e. Check for Fuel Level. Add fuel as necessary and do not overfill. Check for leaks. f. Check for Brakes. Depress the rear brake pedal several times, and then check for proper brake pedal free play. Make sure there is no brake fluid leakage. Adjust if necessary. g. Check Tires. Check tires condition and pressure. The pressure on both Front and Rear tire is 15kpa and 20kpa. h. Check Drive Chain. Check for drive chains condition and tension. Lubricate if necessary. i. Check Throttle. Check for smooth operation. Assure throttle snaps back to idle. j. Check Engine Stop Button. Perform engine stop button test. Repair as necessary. k. 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. l. Check Roll Cage Bar. Ensure all protective roll cage bar are in place before operating the Go-Kart. m. Check Brake Light. Check for proper operation. n. Check Wheels. Check for tightness of wheel nuts and axle nuts; check that axle nuts are secured by cotter pins. o. Check Steering. Check for free operation for any unusual looseness in any area.

Always follow rules for safe operation and wear a helmet.

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Component locations

RADIATOR STEERIHNG WHEEL

SAFTY BELT

FUEL TANK

FLAG POLE BRACKET

BRAKE PEDAL

THROTTLE PEDAL

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CPassengers

The vehicle allows for two riders only. Combine maximum weight of driver And the passenger should not exceed 180kg or 400Ibs.
DSeat 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.

Figure 4

a. Pull seat adjustment handle upward to disengage seat slide. b. Move seat to desired position. c. Be sure seat adjustment handle snaps back into place and that seat is locked into position.

Before attempting to adjust the seat ensure that engine of the Go-Kart is stopped.

Never operate this Go-Kart when the provided seat is not securely fastened, to do so could result in a strong possibility of severe personal injury or loss of life. Before attempting to adjust the seat ensure that engine of Go-Kart is stopped.

EShift Adjustment

a. Press down the shift lever to the L position so that the unit can move forward at low speed, press the lever to H position so that the unit can move forward at high speed, Pull back the shift to N position so that the unit cant move because of in the neutral, pull back the lever to R so that the unit can move backward. (See Fig. 5) b. Loosen nut #1(RHD) and #2(LHD). Adjust nut #3 can adjust the mesh status inside reverse gear box. Make sure the shift lever can be on the four positions (H, L, N, ADJUSTING R) cleanly. Then tighten the nuts #1, # 2.

NUT ADJUSTING NUT

ADJUSTING NUT #3

Figure 5

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Never engage the shift lever when the Go-kart is in motion Only engage the shift lever when the Go-kart is at a full stop Give a slight throttle and loosen throttle, then engage shift from neutral to shift. The shift lever must be on neutral and pull parking lever when leave the Go-kart

FParking Adjustment a. Press down the reverse lever to the

F position so that the unit can move forwards; pull back the lever to P so that the unit can park. (See Fig. 6) Adjust Nut #1; Make sure cable is not too tight or too loose. Adjust Nut #2 accordingly to adjustment of Nut #1.Figure 6
G Starting And Operating Instructions

ADJUSTING NUT ADJUSTING NUT

a. Before starting the engine, be sure that the driver is seated properly in the Go-Kart and tighten the seatbelt. Figure 6 b. Testing the Go-Kart in an open place at the beginning to learn how to start, turn and stop. c. Operate the Go-Kart slowly until you are familiar with it. d. The turning radius of this Go-Kart is small and agile, so the centrifugal force is very high when turning at high speed. Slow down to a more controllable speed when turning to prevent the Go-Kart from rolling over. e. To prevent vehicle from rolling over, be sure to only turn the vehicle at a slow more controllable speed. Heel on the ramp of the main board when turning, Keep your leg rely on the foot pedal, you can feel the kart is stable because of the gravity is adjusted and wont roll over.

SERVICE INSTRUCTION
A Service Air Cleaner Service air cleaner every 80 hours. Service more often under dusty conditions. a. Remove cleaner cover 1 b. Remove air cleaner element 2 (See Fig. 7) c. Check the paper filter, if the filter is dusty, please replace with a new one.

Figure 7

B. Engine Lubrication You must change the oil in the crankcase after the first 5 hours of operating of your new engine (See Fig. 9) and after 10 hours of use thereafter. That will insure
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proper lubrication of internal parts and prevent costly repairs due to excessive wear.

Never operate this Go-Kart when the provided seat is not securely fastened, to do so could result in a strong possibility of severe personal injury or loss of life.

a. Remove fill plug located on rear side of engine. Tip kart backwards slightly by blocking up the front end and drain oil into suitable container. b. Replace fill plug and tighten securely. Place kart in a level position. c. Refill crankcase (approximately 1000 ml) to top of filler neck with SAE 10W/30 oil. Use same grade of oil as used originally. d. Check oil level before each use of dart or after each 10 hours of operation. Add oil to bring up to proper lever. Do not mix various grades of oil.

Figure 8

C. Engine Coolant You should check the coolant for lack. If lack, you need to refill coolant into the radiator (approximately 1800 ml) or reserve coolant. The lack of coolant will cause engine overheat. This can cause engine damage. D. Spark Plug a. Remove the spark plug and inspect it each time you change the oil. (Use a spark plug wrench) The electrodes should be kept clean and free of carbon. The presence of carbon or excess oil will greatly reduce proper engine performance. If possible, check the spark plug gap (area between electrodes) using a wire feeler gauge. This specification is 0.025~0.030. b. Before installing spark plug coat threads lightly with graphite grease if possible, to ensure easy removal next time the spark Figure 8 plug needs inspection. c. It is advisable to replace the spark plug at least once a year to insure easy starting and good engine performance. E. Carburetor Adjustment Never make unnecessary adjustments. The factory recommended settings are correct for most applications. Its not necessary to disassemble the screw unless the carburetor needs to be replaced. Prepare a 50r/w tachometer before
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adjustment. a. Warm up the engine (5~10min) b. Tighten the airscrew gentle. Back out 2-3/8 turns counter clockwise. c. Connect the tachometer; adjust the throttle to limit the idle speed. The standard value is (1400RPM). d. Turn the airscrew counter slowly and observe the RPM of the engine, stop adjusting as the RPM reaches the top speed. e. Adjust the screw and adjust the idle speed to an ideal value. f. Repeat step 4 and 5 until the rotate speed of engine stables.

Figure 9 F. Cleaning Instructions Keep your kart clean. With a clean rag, wipe off and dirt and oil from around controls. Wipe off any spilled fuel and oil. Keep the engine clean of foreign object and be sure to check that air intake fan is free of debris for proper cooling. G. Kart Lubrication Lubricate vehicle every 90 days of use, Apply several drops of oil in specific points. H. Chain Lubrication
To increase chain life, it should be lubricated with a spray on type chain lubricant.

I. Chain Adjustment Check the chain adjustment after first two hours of use. Readjust if it has more than 1/2 flex. (See figure 12) a. Loosen NUT M12X1.5 ADJUSTING NUT #1, and ADJUSTING NUT #2. b. Rotate ADJUSTING BOLT #1 and ADJUSTING BOLT #2,the BEARING BLOCK will move forwards and backwards, so the chain will become loose and tight. Repeat this procedure until chain is at proper tension. c. Tighten NUT M12X1.5 ADJUSTING NUT #1, and ADJUSTING NUT #2.
NUT M12X1.5 NUT M12X1.5

ADJUSTING NUT ADJUSTING BOLT #1 ADJUSTING BOLT #2 ADJUSTING BOLT #2

Figure 10
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J. Adjustment of Front and Rear Shock There are five adjustable positions on each shock. The default position is in the middle set by manufacture (See Fig.11) Use a round nut wrench as you adjust the shock, the tension of shock spring will increase as you screw to left, decrease as you screw to the right. K. Storage Instruction In the event your kart is not to be operated for periods in excess of 30 days or at the end of each driving season prepare for storage as follows: a. Drain fuel tank and carburetor by allowing engine to run out of fuel, or use a fuel stabilizer. b. Lubricate engine cylinder by removing the spark plug and pour one ounce of clean lubricating oil through the spark plug hole into the cylinder. Crank the engine slowly to spread oil and replace spark plug. c. Do not save or store gasoline over winter. Using old gasoline, which has deteriorated from storage, will cause hard starting and affect engine performance.

LEFT ROTATE

RIGHT ROTATE

SPRING ADJUSTMENT CAM

Figure 11

Do not drain fuel while engine is hot. Be sure to move Go-Kart outside before draining fuel.

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REPAIR
A. Front Wheel Replacement Do not disassemble the castle nuts when you replace the front wheels. It is only necessary to tighten the nuts so that the wheel turns freely on the axle with minimum end play. (See Fig. 13) Tighten the nuts after replacing the wheels.

Figure 13 B. Rear Wheel Replacement Do not disassemble the castle nuts when you replace the front wheels. It is only necessary to tighten the nuts so that the wheel turns freely on the axle with minimum end play. (See Fig. 14) Tighten the nuts and put on the cotter Pin after replacing the wheels.

Figure 14 C. Front Wheel Alignment a. The front wheels should be toe-in from 1/8 to 1/4. To check for alignment, measure distance A and B between the centerline (CL) of the wheels. The proper toe-in dimension A should be 1/8-1/4 greater than dimension B. b. To adjust the alignments, loose the lock nuts on both sides of Front Tie Rods. To make Dimension B smaller, scare the rod to the left. Adjust the rod to right direction to make Dimension B larger. After adjusted to desired length, tighten the lock nut against the rod end. Recheck the dimensions for proper alignment.

24

PERIODICAL CHECK AND SERVICES

The maintenance intervals in the following table are based upon average driving conditions. Driving in unusually dusty areas, require more frequent servicing. Time Items service of Initial service (First week) I I I Monthly Quarterly Yearly

Tire pressure/wear I Brake performance I Tightness of screws I Air cleaner C I Carburetor I A C Spark plug C, A Drive chain I I C, A, L Brake oil I Replace gearbox oil I R Replace coolant I R Chassis C, I L Fuel switch/fuel tank I C Battery I Valve clearance of A engine A: adjust C: clean I: inspect, clean or replace if necessary. L: lubricate R: replace

25

Turning signal,Rear R before

Horn button Ignition switc h

Combination switch Alternator 14V 12A

coil,ign

Headlight NB U
caution Change Left direction Right

OFF Fog light Head- Low light light Far light Super light

WIRING DIAGRAM

W YG L P N K NR

Function Display

B YG

Turning signal,Rear R behind

UW

Tail lamp/ the brake light

26
R K

Headlight

Turning signal,Rear L before U UW B BW

Fuse 20A

Turning signal,Rear L behind

BNR
B

B NB

Horn
88 o C

Brakes light switch

Water temperature Swich

Radiator fan

Flasher

Gear switch

Start relay

Start motor

Battery 12V9Ah

Wire's colour symbol

12

RS---red/grey B---black R---red U---blue RU---red/blue P---purple S---grey W---white YG---yellow/green L---Cambridge blue N---brown K---pink NB---brown/black NR---brown/red UW---blue/white RB---red/black GY---green/yellow SB---grey/black BR---black/red Y---yellow WG---white/green GB---green/black WR---white/red BW---black/white

PARTS MANUAL 1CRANKCASE ASSY.

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

P/N
172MM-C-011100 172MM-C-011200 172MM-011001 172MM-011002 172MM-011004 152MI-021005 172MM-011005 172MM-B-011006 172MM-011400 152MI-021019 152MI-011017 1P52MI-011018 1P52MI-A-011006 152MI-011010 152MI-011008 152MI-011009 GB/T 276-1994 6304 172MM-060002

ENGLISH
CRANK CASE ASSY.L CRANK CASE ASSY.R SEAL 28X40X8 SEAL RING.INNER OIL PIPE. STUD A.CYLINGDER LOCATING PIN 10x14 STUD B.CYLINGDER SEAL WASHER.CRANK CASE INNER OIL PIPE ASSY BOLT M6X12 BOLT M6X60 BOLT M6X70 BOLT M6X105 OUTER SLEEVE.EAR "O" RING FOR SEAL INNER SLEEVE.EAR BEARING 6304 BALL BEARING 22X50X14

Qty
1 1 1 2 3 4 1 1 1 1 5 3 1 2 4 2 1 1

27

1CRANKCASE ASSY.

No. 19 20 21 22 23 24 25 26 27 28

P/N
GB/T 9877-1988 FB33X35X5 GB/T 276-1994 6201 GB/T 276-1994 620-RS 172MM-B-068001 CF188-068002 CF188-068003 GB/T308-1989 3/8 152MI-130004 172MM-B-011300 172MM-B-011400 152MI-023010

ENGLISH
OIL SEAL FB 33X35X5 BEARING 6201 BEARING 6202-RS HOLLOW BOLT M14X1.5 WASHER 14.4X22X1 SPACE SPRING STEEL BALL "O" RING FOR SEAL13.5X1.4 ODOMETER SENSOR SEAL CAP BOLT M6X20

Qty
1 1 1 1

1 1 1 1 1 1 1

28

2SIDE COVER ASSY.L

No. 1 2 3 4 5 6 7 8

P/N
172MM-B-012001 172MM-B-012002 GB/T818-2000 M6X12 172MM-B-012005 152MI-013008 152MI-021005 172MM-B-012003 152MI-021018

ENGLISH
SIDE COVER.L AIR DAMPER SCREW BOLT BOLT LOCATING PIN 10x14 SEAL WASHER.LEFT SIDE COVER BOLT

Qty
1 1 3 7 2 2 1 1

29

3RIGHT COVER ASSY

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

P/N
172MM-013013 172MM-013100 172MM-013015 172MM-013016 172MM-013002 172MM-013008 172MM-013012 172MM-013007 152MI-013100 172MM-013006 172MM-013001 172MM-013019 152MI-021008 172MM-013031 172MM-013028 152MI-021009 172MM-013030 172MM-013005 152MI-021014 152MI-08008 QC/T621-1999-A10

ENGLISH
AIR PIPE.CYLINDER HEAD COVER BREATH PIPE.RIGHT SIDE COVER BREATH PIPE.AIR FILTER CLAMP.BREATH PIPE SIDE COVER.R PRESS PLATE.CABLE SEAL WASHER.RIGHT SIDE COVER CAP.OIL FILTER OIL FILTER CORE SPRING METER.ENGINE OIL 3-WAY CAP.OBSERVATION HOLE.UPPER BOLT "O" RING 30X3.35 SEAL RING.CAP "O" RING 18X3.35 OUTLET BOLT WAHER 12 LOCATING PIN 8x14 CLAMP 12

Qty
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2

30

3RIGHT COVER ASSY

No. 22 23 24 25 26 27 28

P/N
QC/T621-1999-A12 172MM-013010 172MM-013009 152MI-013009 172MM-013026 152MI-071007 1P52MI-011018

ENGLISH
CLAMP 10 BREATH FAUCET WATER OUTLET FAUCET BOLT M6X40 PROTECTION PIPE BOLT M6X28 BOLT M6X70

Qty
4 1 1 3 1 1 3

31

4CYLINGDER HEAD CASEING ASSY

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

P/N
172MM-021009 172MM-021001 172MM-021006 152MI-021011 172MM-021100 172MM-021200 172MM-021400 152MI-021001 172MM-021431 152MI-021003 152MI-021004 152MI-021015 152MI-021013 152MI-021008 152MI-021016 152MI-021012 152MI-021014 152MI-021009 152MI-021010 GB/T818-2000-M5X16-DCr GB/T848-85-6-DCr 152MI-021005 BOLT M6X12 BOLT M6X25 152MI-013010

ENGLISH
CLAMP.OIL PIPE COVER.CYLINDER HEAD STOP PLATE SEAL WASHER. AXIS.SWING ARM.INLET AXIS.SWING ARM.OUTLET OIL PIPE ENGINE.OUTER RUBBER RING.OIL PIPE MOUNT.OIL PIPE SHOCK ABSORB RUBBER STRIP REAMED BOLT A M8X25 REAMED BOLT M12X1.25 REAMED BOLT M8X25 REAMED BOLT A M8X28 CAP.OBSERVATION HOLE.UPPER WASHER 8 EAR WASHER SEAL.OBSERVATION HOLE.UPPER SEAL RING.SWING ARM AXIS CRUCIFORM SLOT SCREW SMALL WASHER LOCATION PIN 10X14 BOLT M6X12 BOLT M6X25 BOLT M6X50

Qty
1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 2 1 2 1 2 2 3 1 3

32

4CYLINGDER HEAD CASEING ASSY

No. 26 27 28 29 30

P/N
152MI-021018 172MM-021404 172MM-021002 172MM-021300 172MM-021008

ENGLISH
BOLT M6X55 SHOCK ABSORB SLEEVE BREATH PIPE FAUCET MOUNT.AIR FILTER BLOCKING

Qty
1 1 1 1 1

33

5CYLINGDER HEAD ASSY

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

P/N
172MM-022100 172MM-022700 152MI-022014 172MM-022008 172MM-022010 172MM-022900 172MM-022500 152MI-022810 152MI-022803 152MI-022021 172MM-022601 172MM-022400 152MI-022017 172MM-022800 152MI-022600 GB/T6191-1986-M6X18-DCr 172MM-022007 152MI-022012 152MI-022013 152MI-022804 172MM-022009 152MI-022020 152MI-021005

ENGLISH
CYLINDER HEAD FLANGE.EXHAUST BEARING COVE.CAM AXIS NUT.EXHAUST SEAL WASNER.CYLINDER HEAD CARBURETOR SEAT UNIT CLAMP UNIT.AIR INLET PIPE THERMOSTAT THERMOSTAT SHELL.UPPER RUBBER PIPE1.CARBURETOR THERMOSTAT SHELL.LOWER SPARK PLUG BOLT M6X25 SEAL WASHER. BREATH WATER TEMP SENSOR SOCKET HEAD SCREW DOUBLE-SCREW BOLT WASHER 8 CAP NUT M8 "O" RING 14.8X1.9 "O" RING 31X2 BOLT M6X22 LOCATION PIN 10X14

Qty
1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 2 2 4 4 1 1 2 2

34

5 CYLINGDER HEAD ASSY

No. 24 25 26 27 28 29

P/N
QC/T621-1999-A6.5 152MI-090005 152MI-023008 152MI-022017 GB/T848-85-6-DCr 152MI-022021

ENGLISH
STEEL RING CLAMP BOLT M6X16 BOLT M6X18 BREATHE PIPE.CARBURETOR SMALL WASHER SCREW BLOCKAGE

Qty
2 2 1 1 1 1

35

6CYLINGER BODY ASSY

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

P/N
172MM-023100 172MM-023002 152MI-023300 152MI-023307 152MI-023306 152MI-023004 172MM-023007 172MM-023009 QC/T621-1999-B24 152MI-023305 GB/T848-85-6-DZN 152MI-021005 152MI-023008 152MI-080013

ENGLISH
CYLINDER SEAL WASHER.CYLINDER TENSIONER UNIT BOLT.SPRING SEAT SPRING.TENSION SEAL WASHER.TENSIONER RUBBER PIPE.WATER INLET JACKET.WATER PIPE STEEL BAND CLAMP WASHER 8.5 SMALL WASHER LOCATION PIN 10X14 BOLT M6X18 BOLT M6X22

Qty
1 1 1 1 1 1 1 1 2 1 1 2 2 1

36

7TIMING CHAIN

No. 1 2 3 4 5

P/N
172MM-022200 172MM-023200 172MM-023001 GB96-85-6-DZn GB/T5781-2000-M6X12-DZn

ENGLISH
CHAIN UNIT TENSION PLATE CHAIN GUIDE PLATE BIG WASHER BOLT

Qty 1 1 1 1 1

37

8MAGNETOR ASSY

No. 1 2 3 4 5 6 7 8 9 10

P/N
172MM-094000 172MM-033000 172MM-013008 172MM-031000 172MM-032000 GB/T70.1-2000-M8X18 172MM-040001 172MM-040002 152MI-030002 152MI-060002

ENGLISH
FREE-WHEELING CLUTCH TRIGGER COIL CABLE PRESS BAND FREE-WHEELING STATOR UNIT SOCKET HEAD SCREW NUT M16X1 WASHER16.3X30X2 BOLT M5X16 BOLT M6X30

Qty 1 1 1 1 1 3 1 1 2 3

38

9ADMISSION MACHANISM

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

P/N
152MI-022500 172MM-022300 152MI-021007 172MM-022001 172MM-022005 172MM-022002 172MM-022003 152MI-022005 152MI-022001 152MI-022006 NTN: 16002 GB894.A-1-86-15 172MM-022310 172MM-022301

ENGLISH
SEAL.VALVE ROD CAM UNIT SWING ARM INTAKE VALVE EXHAUST VALVE VALVE SPRINGL.OUTTER VALVE SPRINGL.INNER PAN.VALVE SPRING SEAT.VALVE SPRING CLAMP.VALVE BALL BEARING AXIS RETAINER RING CHAIN PULLY CAM AXIS

Qty
2 1 2 1 1 2 2 2 2 4 2 1 1 1

39

10CRANK LINK LEVER & PISTON

No. 1 2 3 4 5 6 7 8 9

P/N
172MM-A-041000 172MM-040008 172MM-040009 172MM-042000 172MM-040005 172MM-040007 152MI-040011 152MI-040010 152MI-040006 172MM-040006 GB/T119-2000-2X14

ENGLISH
CRANK LINK UNIT PISTON RING PISTON RING OIL RING PISTON PISTON PIN JOINT.OIL CHANNEL JOINT SPRING WOODRUFF KEY STOP RING.PISTON PIN PIN

Qty
1 1 1 1 1 1 1 1 1 2 1

40

11SPEED CHANGER.

No. 1 2 3 4 5 6 7 8 9 10 11 12

P/N
172MM-021007 172MM-021006 172MM-A-051005 172MM-A-051003 172MM-A-051100 172MM-A-051200 172MM-A-051004 172MM-A-051002

ENGLISH
NUT M14X1.5 WASHER14.5X30.2 DRIVE WHEEL PAN SLEEVE.DRIVE WHEEL PAN MOVABLE DRIVE PAN OFFCENTER ROLLER SLIDING BLOCK PUSH PAN

Qty
1 1 1 1 1 6 3 1

41

12CLUTCH ASSY

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

P/N
172MM-052008 172MM-A-052500 172MM-052005 172MM-A-052400 172MM-A-052200 172MM-A-052600 172MM-A-052006 172MM-A-052003 GB/T896-1986-9 172MM-052310 GB/T893.1-1986-28 GB/T278-1989-1060902 172MM-A-052300 172MM-A-052001 172MM-A-052104 172MM-A-052100 GB/T3452.1-1992-46.2X1.8 172MM-A-052007 172MM-A-052004 172MM-A-052009 172MM-A-052002 172MM-B-053000

ENGLISH
BOLT M12X1.25 OUTTER WHEEL DISC THIN NUT M30X1 DRIVE PAN UNIT DAMPING RUBBER BLOCK CLUTCH BLOCK RELEASE SPRING SIDE PAN SPLIT WASHER NEEDLE BEARING RETAINER RING.HOLE BEARING DRIVEN PAN UNIT GALLOWS ROLL GREAS SEAL.DRIVEN PAN MOVABLE DRIVEN PAN "O" SEAL RING SEAL BUSHING CLUTCH SPING SLEEVE GUIDE PIN COG BELT

Qty
1 1 1 1 3 3 3 1 3 1 1 1 1 4 2 1 2 1 1 1 4 1

42

13GEARBOX COVER ASSY

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

P/N
172MM-C-060001 172MM-C-060002 172MM-013005 152MI-021014 172MM-B-069000 GB/T 276-1994 6202-RS GB/T 276-1994 6201 GB/T 276-1994 6203 GB/T 276-1994 6305-RS 172MM-B-011107 172MM-B-011111 1P52MI-A-011007 CF188-332004 CF188-332003 172MM-C-060003 CF188-310028 152MI-080008 172MM-C-060007 172MM-C-060006 GB5787-86 M6X40-DCr 152MI-080012 CF188-065002 172MM-B-011113 GB/T 819-2000

ENGLISH
COVER.GEARBOX PAPER WASHER.GEARBOX BOLT M12X1.5.OIL OUTLET WASHER12 SHIFT DISPLY SWITCH BALL BEARING BALL BEARING BALL BEARING BALL BEARING BOLT M8X48 BOLT M8X30 BOLT M8X55 "O" RING 19X2.5 BOLT.OIL INLET OIL SEAL 32X62X7 JOINT.AIR PIPE LOCATION PIN 8X14 PAPER WASHER. CHAIN PULLY COVER BOLT BOLT M6X32 OIL SEAL SD 15X25X5 OIL STOP CHIP SCREW M4X12

Qty
1 1 1 1 1 1 1 1 1 3 5 2 1 1 1 1 2 1 1 3 3 1 1 2

43

14TRANSMISSION GEAR ASSY

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20

P/N
172MM-B-067000 GB/T89431-1986 20 172MM-B-067000 172MM-B-067001 172MM-B-060001 172MM-B-062000 172MM-B-062006 172MM-B-062002 NTN: K16X20X10 172MM-B-062009 172MM-B-062001 172MM-B-062007 GB/T894.1-86-24 K24X28X10 172MM-B-062003 172MM-B-062005 172MM-B-062004 172MM-C-063000 172MM-C-063002 172MM-C-063005

ENGLISH
TRANSITION GEARS ASSY RTAINER RING TRANSITION GEAR TRANSITON GEAR-AXIS MAIN AXIS SECONDARY AXIS ASSY WASHER.15X28X2 DRIVEN GEAR.HIGH SPEED NEEDLE BEARING SLIDING SLEEVE.SHIFT SECONDARY AXIS WASHER 24X33X2 CIRCLIP.AXIS NEEDLE BEARING DRIVEN GEAR.REVERSE DRIVE GEAR.OUTPUT DRIVEN GEAR.LOW SPEED OUTPUT AXIS ASSY WASHER 20X32X2.5 DRIVEN GEAR.OUTPUT

Qty
1 2 1 1 1 1 2 1 2 1 1 2 1 1 1 1 1 1 1 1

44

14TRANSMISSION GEAR ASSY

No.
21 22 23 24 25 26

P/N
CF188-061007 172MM-C-063001 172MM-C-063004 172MM-C-063005 172MM-C-063009 172MM-B-062008

ENGLISH
RETAINER RING.AXIS 25 OUTPUT AXIS CHAIN PULLEY PRESS PLATE.CHAIN PULLEY BOTL M6X12 WASHER 16X28X2

Qty
1 1 2 1 1 1

45

15GEAR SHIFT MACHANISM

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

P/N
172MM-B-066000 172MM-B-066002 172MM-B-066003 172MM-B-066004 172MM-B-066001 172MM-B-066005 CF188-065201 CF188-065203 CF188-065204 CF188-065202 CF188-065204 CF188-065206 151MI-013008 151MI-023010 CF188-065300 172MM-C-065100 172MM-B-066007 172MM-B-066009 172MM-B-066008

ENGLISH
SHIFT DRUM ASSY SHIFT YOKE PIN.SHIFT YOKE SNAP RING.PIN.SHIFT YOKE SHIFT DRUM TOUCH CHIP.SPEED DISPLY WASHER.DRIVEN SECTOR GEAR DRIVEN SECTOR FEAR.SHIFT WASHER 13.5X22X1 DRIVEN SECTOR GEAR-AXIS.SHIFT SPRING.DRIVEN SECTOR GEAR WASHER 6.6X20X2 BOLT M6X35 BOLT M6X20 SWING ARM ASSY.SHIFT DRIVE SECTOR GEAR COMP.SHIFT SHIFT AXIS PRESS SPRING.SHIFT PRESS BUSHING.SHIFT

Qty
1 2 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1

46

16ENGINE OIL PUMP ASSY

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

P/N
151MI-071000 151MI-071002 151MI-071003 151MI-071001 151MI-071001 151MI-073000 151MI-071004 151MI-071005 151MI-070002 151MI-072000 GB878-85-M3X12 151MI-071006 GB894.1-86-10 151MI-021019 151MI-070003

ENGLISH
OIL PUMP ASSY OIL PUMP BODY OIL PUMP COVER OIL PUMP AXIS CHAIN PULLEY.OIL PUMP CHAIN OIL PUMP ROTOR.OIL PUMPL.INNER ROTOR.OIL PUMPL.OUTTER SPACER PLATE A.OIL PUMP SPACER PLATE B.OIL PUMP SCREW LOCATION PIN 4X6.5 RETAINER RING.AXIS BOLT M6X12 BOLT M6X28

Qty
1 1 1 1 1 1 1 1 1 1 1 1 1 1 2

47

17COOLANT PUMP ASSY

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

P/N
172MM-080004 152MI-081000 172MM-080003 172MM-080002 172MM-080001 152MI-013009 152MI-021017 GB/T893.1-1986-19 152MI-080007 152MI-080011 NTN: 6800 172MM-080005 152MI-080008

ENGLISH
IMPELLER.WATER PUMP WATER SEAL ASSY WATER PUMP COVER SEAL WASHER. COVER WATER PUMP AXIS BOLT M6X40 BOLT M6X25 RETAINER RING.HOLE WASHER.7.5X13X1.2 WASHER.6X12X1 NEEDLE BEARING GREAS SEAL 10X20X5 LOCATION PIN 8X14

Qty
1 1 1 1 1 2 2 1 1 1 2 1 2

48

18ELECTRIC STARTER ASSY

No. 1 2 3 4 5 6 7

P/N
172MM-090001 172MM-092000 172MM-091000 172MM-090007 172MM-093000 152MI-080013 172MM-090008

ENGLISH
AXIS.DUPLICATE GEAR DRIVEN GEAR COMP DUPLICATE GEAR COMP MOUNTING PLATE STARTER COMP BOLT M6X22 BOLT M6X14

Qty
1 1 1 1 1 2 1

49

19CARBURETOR ASSY

No. 1

P/N
172MM-100000

ENGLISH CARBURETOR ASSY

Qty
1

50

20FRAME AND FUEL TANK

20 FRAME AND FUEL TANK
19 20 21 22 35 34 33 23 24 32 31 30 29 25 26 27 28 49 44 47 48 39 36 37 38 40 41 42 43 45 46

12

11

13 4 5 67 1 2 3 15 89 10 14 16

17

18

51

20 FRAME AND FUEL TANK NO. PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 GB5787-1986 M12x1.5x60 D250.11.886 GB6177.1-2000 M12X1.5 DI250.01.05.04.00 D250.11.004 D250.11.058 D250.11.001 GB/T95-85 10 GB3632-83 10 GB5782-2000 M10x70 DI250.01.05.02.00 DI250.01.05.03.00 DI250.01.05.00.01 GB6177.1-2000 M10 GB5787-1986 M10x50 DI250.01.05.05.00 GB70-85 M10X30 DI250.01.01.00.00 D250.11.059 D250.11.920 D250.11.804 GB6177.1-2000 M10 S250.11.003 DI250.05.02.00.01 S250.11.903 DI250.05.02.00.02 DS250.11.01.00.09 D250.11.060 174020000 JD0910006 GB/T95-1985 8 GB5787-1986 M8X25 GB6177.1-2000 M8 D250.09.902 DI250.05.01.01.00 GB6177.1-2000 M6 GB5787-1986 M6X20 GB5787-1986 M6X20 D250.09.904 DI250.05.01.00.02 161320000 DI250.05.01.00.03 170720000 D250.09.002 D250.09.008 D250.09.004 D250.11.059 GB5787-1986 M8X20 D250.09.001

DESCRIPTION
FLANGE BOLT NYLON BUSHING FLANGE NUT PROTECTIVE BAR.CANDAL.R T U B E S E A T . N Y L O N ? 32 R-WASHER TUBE SEAT.RUBBER ? 32 PLAIN WASHER SPRING WASHER BOLT PROTECTIVE BAR.REAR PROTECTIVE BAR.CANDAL.L PROTECTIVE BAR.TOP FLANGE NUT M10 FLANGE BOLT M10x50 PROTECTIVE BAR.FRONT SOCKET HEAD SCREW M10X30 MAIN FRAM TUBE.BREATHER CAP.FUEL TANK FUEL TANK FLANG NUT M10 RUBBER BAND SUPPORT.FUEL TANK VALVE ASSY.FULE TUBE.FUEL.#1 FILTER.FUEL TUBE.FUEL.#2 HOSE CLAMP RUBBER BUSH.BODY PLAIN WASHER 8 FLANG BOLT M8X25 FLANG NUT.LOCK M8 RADIATOR FAN ASSY RADIATOR FLANG NUT M6 FLANG BOLT M6X20 RUBBER BUSH.RADIATOR CAP.RADIATOR TUBE.CARBURETOR.#1 CLAMP 13 TUBE.TRANSITION CLAMP 10 TUBE.OUTLET.RADIATOR TUBE.CABURETOR.#2 TUBE.SUB WATER TANK SUB WATER TANK FLANG BOLT M8X20 TUBE.INLET.RADIATOR

Q'TY
4 4 4 1 2 2 2 2 2 2 1 1 2 4 4 1 2 1 1 1 1 4 2 2 1 1 1 1 4 2 4 2 2 2 1 6 6 2 1 1 4 1 2 1 1 1 1 2 1

52

21SUSPENSION ARM ASSY

21 SUSPENSION ARM ASSY
41 40 39 42

38

35 34 33 32 31 15 30 16 17 28 27 26 25 24 20 19 18 21 22 23 29

36

37

13

14

12 11 10 5 6 7 8 9

3 4

53

21 SUSPENSION ARM ASSY No. PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 DS250.02.02.00.00 DS250.02.00.00.04 DI250.04.01.01.00 DS250.02.00.00.02 GB5787-1986 M12x1.5x85 JD2682000 JD0268001 DS250.02.00.00.01 GB6177.1-2000 M12X1.5 GB3632-83 16 GB6172.1-2000 M16X1.75 DS250.02.00.00.05 GB5787-1986 M12x1.5x45 DI250.02.00.00.01 GB5787-1986 M10X1.25x60 JD0256100 GB6177.1-2000 M10X1.25 GB/T6179-1986 M12 GB/T91-2000 2.5X30 DS250.02.00.00.03 GB5787-1986 M8X15 GB3632-83 8 DI250.04.01.02.00 JD0360008 GB13871-1992 FB 47x28x7 GB/T276-1994 6204 JD0360007 GB/T5783-2000 M6X15 JD0360150 DI250.02.00.00.02 JD0360200-EU JD0360006 GB/T95-1985 16 GB/T93-1987 16 GB/T9459-1988 M16X1.5 A GB/T91-2000 4x40 JD0360010 JD0760000 JD0760800 GB/T95-1985 10 GB/T93-1987 10 GB/T923-1988 M10x1.25

DESCRIPTION
LOWER A-ARM.R UNIVERSAL JOIN.R FRONT BRAKE CALIPER.R KNUCKLE.R FLANGE BOLT M12x1.5x85 SEAL,LOWER A-ARM30*40*10 BUSH.LOWER A-ARM.FR SPACER.LOWER A-ARM FLANGE NUT M12X1.5 SPRING WASHER 16 THIN NUT M16X1.75 UNIVERSAL JOIN.L FLANGE BOLT M12x1.5x45 SHOCK ABSORBER.FR FLANGE BOLT M10x1.25X60 UPPER A-ARM FLANGE NUT M10X1.25 SLOTTED NUT M12 COTTER PIN 2.5X30 KNUCKLE.L FLANGE BOLT M8X15 SPRING WASHER 8 FRONT BRAKE CALIPER.L BUSH 3.FRONT KNUCKLE GREASE SEAL FB 47x28x7 BALL BEARING 6204 BUSH 2.FRONT KNUCKLE BOLT M6X15 DISC.FRONT BRAKE KNURLED BOLT HUB.FRONT WHEEL BUSH 1.FRONT KNUCKLE PLAIN WASHER 16 SPRING WASHER 16 SLOTTED NUT M16X1.5 COTTER PIN 4x40 HUB COVER.FRONT WHEEL TIRE,FR,AT21X8-10 RIM,FRONT WHEEL PLAIN WASHER 10 SPRING WASHER 10 CAPPED NUT M10X1.25

Q'TY
1 2 4 1 4 8 8 4 8 4 5 1 4 2 4 2 4 4 4 1 4 4 1 2 2 2 2 12 2 8 2 2 2 2 2 2 2 2 2 8 8 8

54

22STEERING ASSY
22 STEERING ASSY
1 2 3 4 5 6

9 8 10

11

12

13

40 43 42 45 46 44 38 37 36 34 33 35 41 39

14

15 16

32 31

30

17 29 18 19 20

22

21

28 27 26

23

25 24

55

22 STEERING ASSY No. PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 GB70-85 M4x16 DI250.03.01.00.01 DI250.03.01.00.02 GB819-85 M6x20 DI250.03.00.00.02 DI250.03.01.00.03 D250.03.905 GB822-2000 M6X20 GB6177.1-2000 M6 DS250.03.01.00.00 GB5787-1986 M10X1.25x25 GB3632-83 8 GB5782-2000 M8x25 DS250.03.02.00.03 DS250.03.02.00.02 DS250.03.02.00.05 DS250.03.03.00.00 D250.03.006 D250.03.007 GB6177.1-2000 M10x1.25 D250.03.006 DS250.03.03.00.02 DS250.03.03.00.01 DS250.03.00.00.02 GB/T848-1985 10 GB/T93-1987 10 GB/T9457-1988 M10 GB/T91-2000 2X25 GB5787-1986 M10x1.25x25 GB/T93-1987 4 GB/T822-2000 M4X5 DI250.04.01.01.00 GB6177.1-2000 M8 GB5787-1986 M8X25 DI250.04.01.00.05 GB/T6172.1-2000 M8 DS250.04.01.00.03 GB/T91-2000 2X25 GB/T882-1986 6x40 DS250.04.01.00.03 DS250.04.01.00.02 DS250.04.01.00.01 D650.07.01.00.05 GB/T91-2000 2.5X25 GB/T882-1986 8X50 DS250.04.02.00.01

DESCRIPTION
SOCKET HEAD SCREW M4x16 PLASTIC COVER.STEERING WHEEL RUBBER COVER.STEERING WHEEL CRUCIFORM SLOT SUNK SCREW M6x20 RUBBER WASHER STEERING WHEEL COMBINED SWITCH CRUCIFORM SLOT PANHEAD SCREW M6X20 FLANGE NUT M6 STEERING COLUMN FLANGE BOLT M10x1.25 x25 SPRING WASHER 8 BOLT UPPER UNIVERSAL SHAFT SPRING STEEL SHEET LOWER UNIVERSAL SHAFT STEERING GEAR NYLON COVER.L BRACKET.STEERING GEAR FLANGE NUT M10x1.25 NYLON COVER.R BALL JOINT TIE ROD BALL JOINT.TIE ROD PLAIN WASHER 10.SMALL SPRING WASHER 10 SLOTTED NUT M10 COTTER PIN 2x25 FLANG BOLT M10x1.25x25 SPRING WASHER 4 CRUCIFORM SLOT PANHEAD SCREW M4X5 MASTER CYLINDER FLANG NUT M8 FLANG BOLT M8X25 PUSH SHAFT.MASTER CYLINDER THIN NUT M8 T BLOCK COTTER PIN 2X25 PIN 6x40 PIN BRAKE PEDAL SPRING.PEDAL RETURN PEDAL PAD COTTER PIN PIN 8X50 THROTTLE PEDAL

Q'TY
1 1 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

56

23ENGINE RACK
23 ENGINE RACK
3 2 1 5 7 8 9 10 6 4

11

15 16 13 12 18 19 20 17 22 21 22 23 14

24

25 26

27

28

29

30 32 33 31

39 38 36 37

34 35

57

23 ENGINE RACK No. PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 GB6177.1-2000 M10X1.25 D650.04.01.00.01 DI250.08.01.00.00 GB6177.1-2000 M12X1.5 DI250.08.00.00.01 GB5787-1986 M10X1.25X20 GB5787-1986 M12X1.5X115 DI250.08.02.00.00 GB6170-86 M12 GB5785-86 M12X1.5X80 GB5785-86 M12X1.5X80 DI250.05.02.00.04 JD0900011 DI250.05.02.00.03 GB5787-1986 M8X25 GB5787-1986 M8X45 GB6177.1-2000 M8 DI250.05.02.00.01 GB6177.1-2000 M18 DI250.05.02.01.01 DI250.05.02.01.02 DI250.05.02.00.01 D250.00.037 GB6177.1-2000 M6X15 D250.08.009 GB/T91-2000 3X25 D250.08.005 D250.08.004 GE12E DI250.05.03.03.00 GB/T95-1985 8 DI250.05.03.00.01 DI250.05.03.04.00 DI250.05.03.00.02 GB/T95-1985 6 GB5787-1986 M6X20 GB5787-1986 M6X50 DI250.05.03.00.03 GB5787-1986 M8X30

DESCRIPTION
FLANG NUT M10X1.25 ENGINE RUBBER BUMPER ENGINE MOUNT.REAR FLANG NUT M12X1.5 SPACER.ENGINE FLANG BOLT M10X1.25X20 FLANG BOLT M12X1.5X115 ENGINE RACK NUT M12 BOLT M12X1.5X80 BOLT M12X1.5X105 MUFFLER RUBBER BUMPER STEEL BUSH.BODY MUFFLER MOUNT FLANG BOLT M8X25 FLANG BOLT M8X45 FLANG NUT M8 MUFFLER FLANG NUT M8 CLAMP.UPPER CLAMP.LOWER EXHAUST PIPE SEAL.EXHAUST PIPE FLANG NUT M6X15 BUSH1.SHIFT LEVER COTTER PIN 3X25 BUSH2.SHIFT LEVER SPRING.SHIFT LEVER KNUCKLE BEARING GE12E SHIFT LEVER PLAIN WASHER 8 SPRING SHEET.SHIFT LEVER PUSH AND PULL FUNICULUS SWINGING ARM.SHIFT PLAIN WASHER 6 FLANG BOLT M6X20 FLANG BOLT M6X50 MOUNT.PUSH AND PULL FUNICULUS FLANG BOLT M8X30

Q'TY
5 4 1 3 1 1 1 1 2 2 2 2 2 2 2 2 4 1 2 1 1 1 1 2 1 2 1 1 1 1 1 2 1 1 1 1 2 1 1

58

24ENGINE RACK
24 TRAILING ARM ASSY

33

34

35

32 31 27 28 29 30

26 25 13 11 9 10 15 4 5 12 24 22 21 23

14

3 2

20 7 6 19 1 16 18 17 8

37

36

59

24 TRAINLING ARM ASSY No. PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 DI250.09.02.00.00 DI250.07.01.00.01 DI250.07.01.00.02 DI250.07.01.00.03 DI250.07.01.00.04 DI250.07.01.00.00 GB9877.1-1988 FB32X47X8 GB/T5787-86 6005 GB6177.1-2000 M8X15 GB/T93-1987 8 DI250.04.03.02.00 GB6177.1-2000 M12X1.5 DI250.09.00.00.03 GB5787-1986 M12X1.5X60 DI250.09.01.00.00 GB6177.1-2000 M10X1.25 D650.02.01.00.01 D650.02.01.00.02 GB5787-1986 M10X1.25X80 DI250.04.01.02.00 GB2673-1986 M6 20 DI250.04.01.00.04 DI250.09.00.00.01 DI250.09.00.00.06 DI250.02.00.00.02 DI250.09.00.00.05 D250.06.011 DI250.07.04.00.01 GB/T91-2000 4X30 JD0360010 D250.00.037 JD0780000 GB/T95-1985 10 GB/T93-1987 10 GB/T923-1988 M10x1.25 DI250.04.03.01.00 DI250.04.01.03.00

DESCRIPTION
TRAILING ARM.R BRIDLE.BOOT INNER BOOT BRIDLE.BOOT OUTER BOOT HALF AXLE SEAL FB 32X47X8 BALL BEARING 6005 FLANG NUT M8X15 SPRING WASHER 8 BRAKE CALIPER.HAND BRAKE.L FLANG NUT M12X1.5 SHOCK ABSORBER.REAR FLANG BOLT M12X1.5X60 TRAILING ARM.L FLANG NUT M10X1.25 RUBBER BUSHING.TRAILING ARM STEEL BUSHING.TRAILING ARM FLANG BOLT M10X1.25X80 CALIPER.FOOT BRAKE.L SUNK SCREW M6X20 DISC.REAR BRAKE SPACER 1.REAR WHEEL SPACER 2.REAR WHEEL KNURLED BOLT HUB.BRAKE DISC WASHER.REAR WHEEL AXLE SLOTTED NUT.HALF AXLE COTTER PIN 4X30 HUB COVER.FRONT WHEEL RIM.REAR TIRE AT22X10-10.REAR PLAIN WASHER 10 SPRING WASHER 10 CAPPED NUT M10X1.25 BRAKE CALIPER.HAND BRAKE.R BRAKE CALIPER.FOOT BRAKE.R

Q'TY
1 4 2 4 2 2 4 4 4 4 1 4 2 4 1 4 8 4 4 1 4 2 2 2 8 2 2 2 2 2 2 2 8 8 8 1 1

60

25MIDDLE AXIS ASSY

25 MIDDLE AXIS ASSY

9 16 9 8 7 6 5 4 14 12 3 10 15

11

12 13 17 18 25 24 26 27 28 29 23 33 30 32

20

22 21

31

19

61

25 MIDDLE AXIS ASSY No. PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 DI250.07.00.00.01 GB894.1-86 26 DI250.07.00.00.03 RETAINE RING SN206.1 SN206.2 GREASE CUP GB/T93-1987 10 SCREW BOLT M10X80 TWO-ROW BALL BEARING GB6177.1-2000 M12X1.5 SN206.3 GB5787-1986 M12X1.5X45 DI250.07.00.00.01 DI250.07.02.00.00 GB5787-1986 M10X1.25X35 D650.07.02.01.00 GB5787-1986 M8X30 GB6177.1-2000 M8 GB/T91-2000 3X30 D650.07.02.00.01 GB/T882-1986 8X24 DI250.04.02.00.00 GB6177.1-2000 M6 GB5787-1986 M6X30 DI250.04.03.00.01 DI250.04.03.00.02 DI250.04.03.00.03 GB/T93-1987 6 GB/T95-1985 6 GB/T91-2000 2.5X30 D650.07.02.00.02 DI250.04.03.01.00

DESCRIPTION
SPRING CIR CLIP CIRCLIP FOR AXIS 26 SLEEVE.MID AXIS RETAINER RING SEAL.BEARING BLOCK BEARING BLOCK.UPPER GREASE CUP.BEARING BLOCK SPRING WASHER 10 SCREW BOLT TWO-ROW BALL BEARING FLANG NUT M12X1.5 BEARING BLOCK.LOWER FLANG BOLT M12X1.5X45 CHAIN GEAR.29 TEETH MID AXIS FLANG BOLT M10X1.25X35 PARKING BRAKE LEVER FLANG BOLT M8X30 FLANG NUT M8 COTTER PIN 3X30 JOINT.PARKING BRAKE PIN 8X24 CABLE COMP.PARKING BRAKE FLANG NUT.LOCK M6 FLANG BOLT M6X30 OIL CUP.PARKING BRAKE OIL TUBE.PARKING BRAKE GUARD SPRING SPRING WASHER 6 PLAIN WASHER 6 COTTER PIN 2.5X30 LEVER.PARKING CYLINDER PARKING CYLINDER

Q'TY
2 2 2 4 8 2 2 4 4 2 4 2 4 1 1 4 1 2 2 2 4 2 1 3 1 1 1 1 2 2 1 1 1

62

26ELECTRICAL ASSY
26 ELECTRICAL ASSEMBLY

5 6 11 10 12 7 8

13

14 15

16 17

19 18

63

26 ELECTRICAL ASSEMBLY No. PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 D250.07.900 D250.07.907 D250.07.915 DS250.10.00.00.02 D250..07.909 DS250.10.00.00.05 DI250.10.02.00.00 DI250.10.03.00.00 DI250.10.04.00.00 D250.07.912 GB6177.1-2000 M12X1.5 D250.07.903 D250.07.913 D250.07.802 N6.200 D250.07.904 DI250.10.01.00.00 DI250.10.05.00.00 D250.10.917

DESCRIPTION
TURNING SINGLE.FR SPEED METER VOLTAGE REGULATOR FACE PLATE IGNITION SWITCH BUTTON.HORN FUNCTION DISPLAY 3# FUNCTION DISPLAY 4# FLASHER RELAY.STRAT HEADLIGNT(35/25W) TRAIL LAMP HORN BATTERY(12V,9AH) NYLON CLAMP 6X200 TURNING SINGLE.REAR HAENESS.WIRING COIL.IGN CDI

Q'TY
2 1 1 1 1 1 1 1 1 1 2 2 1 1 8 2 1 1 1

64

27SEAT AND MUD GUARD

27 SEAT AND MUD GUARD

2 4

6 7 8

13

12

14

11

10

16 15

65

27 SEAT AND MUD GUARD No. PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 DS250.08.01.00.03 DS250.08.01.00.02 GB6177.1-2000 M10X1.25 D250.11.005A DI250.11.01.00.07 DI250.11.01.00.06 444.6.20 D250.11.058 GB6177.1-2000 M6 D250.11.005A DS250.11.01.00.05 GB6177.1-2000 M10X1.25 GB5787-1986 M10X1.25X20 DS250.11.01.00.06 DS250.11.01.00.04 DS250.11.01.00.03

DESCRIPTION
SEAT COMP.R SEAT COMP.L FLANG NUT M10X1.25 SAFTY BELT SEAT ADJUSTER.R SEAT ADJUSTER.L SCREW.PHILIPS HEAD M6X20 RUBBER WASHER 6 FLANG NUT.LOCK M6 MUD GUARD SUPPORT.MUD GUARD.REAR.L FLANG NUT M10X1.25 FLANG BOLT M10X1.25X20 SUPPORT.MUD GUARD.REAR.R SUPPORT.MUD GUARD.FR.L SUPPORT.MUD GUARD.FR.R

Q'TY
1 1 8 2 1 1 12 12 12 4 1 8 8 1 1 1

66

PREPARATION ATTACH INSTRUCTION ATTACH BATTERY

1 REMOVE BATTERY FROM GO-KART REMOVE THE BOLT AND THE

REMOVE THE BATTERY CAP

REMOVE THE RUBBER CUSHION

2 REMOVE ALL OF PLUGS BY SCREWDRIVER

PUT OUT SEAL CAP FIX OVERFALL TUBER

ILL THE ELECTROLYTE AS BELOW a) Pull the seal cap out of the plastic bottle

b) Turn over the seal cap 180 degree, fix it on the outlet of plastic bottle

67

b) Cut the inlet of plastic bottle

c) Fill the battery with electrolyte to upper lever by inserting every inlet of the battery

4 5

Put the battery into the box on go-kart. Connect the wire to battery as below picture; red to +, black to -.

RED WIRE

BLACK WIRE

Fix the battery cap, rubber cushion and tighten both bolts and nuts.

Notice; Before use new battery, it need to notice follows; 1- After the battery is filled electrolyte, the new battery need to recharge as the Owners manual said. Otherwise, the new battery will be damaged and cant recharge. 2- The new battery cant overload in use, otherwise it damage forever. 3- The new battery need to maintenance with recharge as the Owners manual said.

68

ATTACH FRONT SHOCK

FRONT SHOCK

FRAME TIE ROD 12345Remove pin, nut, adjust cushion from the bolt on the tie rod. Insert the tie rod into the hole on the front wheel axle. Tighten the nut, insert the pin, then lock the pin. Put the upper hole of the front shock into the groove on the frame. Insert the bolt though the hole on the frame and the hole on the front shock. 6- Tighten the nut.

69

ATTACH FRONT TIRE

The hub to fix the front tire is packed as below:

1- Remove four nuts, four spring washers, four plain washers on the hub. 2- Fix the rim on the hub.

3- Insert the washers, spring washers through bolt on the hub. Tighten four nuts.

Notice: Direction marked on the tire must correspond to the vehicle forward

70

ATTACH LOOKUM

1 3 4

71

ATTACH REAR SHOCK

a) Remove the bolt and the nut

b) Attach the rear shock as below picture:

72

ATTACH TRAILING ARM

73

74

ATTACH SEAT AND SAFT BELT

FIX SAFTY BELT

FIX SEAT

FIX SEAT

FIX SAFTY BELT

75

ATTACH THE RADIATOR

1- Attach the radiator as below pictures. 2- Connect wire from fan motor to main wire. 3- Arrange the main and reserve coolant rubber tube as below picture.

CONNECT WIRE END FROM MAIN WIRE TO FAN MOTOR

76