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Summary of Contents for Go Kart 500
- Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. 500 Go-kart OWNER’S MANUAL 4 × 4 This Go-kart should not be ridden by anyone under 16 years of age.
- Page 2 INTRODUCTION Congratulations on your purchase of the 500GO-KART. With the purchase of this GO-KART, you can now appreciate the high degree of craftsmanship. This manual will provide you with a good basic understanding of the features and operation of this GO-KART. This manual includes important safety information.
- Page 3 INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.
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Page 4: Important Notice
IMPORTANT NOTICE This GO-KART is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this GO-KART on any public street, road or highway. This GO-KART complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. -
Page 5: Table Of Contents
TABLE OF CONTENTS Introduction……………………………………………………………………………………1 SAFETY………………………………………………………………………………………2 Features and Controls…………………………………………………………………………20 Component Locations…………………………………………………………………………20 Indicator and warning lights…………………………………………………………………22 Switch…………………………………………………………………………………………23 Seats……………………………………………………………………………………………24 Seat Belts………………………………………………………………………………………24 Seat Belt Inspection……………………………………………………………………………25 Fuel cap …………………………………………………………………………………26 Ignition Switch ………………………………………………………………………………27 Gear Selector…………………………………………………………………………………28 Brake Pedal……………………………………………………………………………………29 Throttle Pedal…………………………………………………………………………………29 OPERATION…………………………………………………………………………………30 Vehicle brake-in period………………………………………………………………………30 Pre-ride inspection……………………………………………………………………………32... - Page 6 Safe operation practices………………………………………………………………………33 Starting the engine……………………………………………………………………………34 Stopping the engine……………………………………………………………………………35 Braking…………………………………………………………………………………………35 Parking the vehicle……………………………………………………………………………35 New operator driving procedures……………………………………………………………36 Driving with a passenger………………………………………………………………………38 Driving on slippery surface……………………………………………………………………39 Driving uphill…………………………………………………………………………………41 Driving on a side hill…………………………………………………………………………42 Driving downhill………………………………………………………………………………43 Driving through water…………………………………………………………………………43 Driving over obstacles…………………………………………………………………………44 Driving in reverse………………………………………………………………………………45 Parking on an incline…………………………………………………………………………46...
- Page 7 MAINTENANCE………………………………………………………………………………47 Periodic maintenance chart …………………………………………………………………47 Engine oil ……………………………………………………………………………………50 Transmission (main gearcase)………………………………………………………………54 Spark plugs……………………………………………………………………………………55 Constant variable transmission (CVT)system ………………………………………………56 Filter system …………………………………………………………………………………58 Cooling system …………………………………………………………………………………60 Throttle system ………………………………………………………………………………61 Carburetor ……………………………………………………………………………………63 Brakes…………………………………………………………………………………………65 Steering wheel inspection ……………………………………………………………………67 Shock spring adjustment ……………………………………………………………………67 Tires……………………………………………………………………………………………68 Vehicle immersion……………………………………………………………………………69...
- Page 8 Battery…………………………………………………………………………………………70 Clearing and storage…………………………………………………………………………73 SPECIFICATIONS……………………………………………………………………………75 Circuit Diagram, Wiring Diagram and troubleshooting chart ……………………………81...
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Page 9: Introduction
INTRODUCTION Failure to follow the warnings and safety precautions contained in this manual can result in severe injury or death. Your vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. -
Page 10: Safety
SAFETY Equipment Modifications Your vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed. - Page 11 SAFET Safe Riding Gear protective clothing for comfort and Always wear appropriate clothing when riding this vehicle. Wear to reduce the chance of injury.
- Page 12 SAFETY Safe Riding Gear Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Eye Protection Do not depend on eyeglasses or sunglasses for eye protection.
- Page 13 SAFETY Safety Warnings Failure to operate this vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Be sure to read all of the following warnings about driving hazards and how to avoid them. These warnings are provided for your safety. Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident.
- Page 14 SAFETY Safety Warnings Rider Height Some riders may be too tall to ride safely in this vehicle. Do not operate or ride in this vehicle if the clearance between the top of your helmet and the overhead cab frame is less than 2 inches (5 cm). Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk...
- Page 15 SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of serious injury in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield).
- Page 16 SAFETY Safety Warnings Carrying a Passenger Never carry a passenger until you have operated this vehicle for at least four hours. Carrying Multiple Passengers Carrying more than one passenger in this vehicle can affect the operator’s ability to steer and operate the controls, which increases the risk of loss of control and accident or overturn.
- Page 17 SAFETY Safety Warnings Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, your skills and your passenger’s skills. Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or overturn.
- Page 18 SAFETY Safety Warnings Jumps and Stunts Exhibition driving increases the risk of an accident or overturn. DO NOT do power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving. Driving Downhill Improperly Driving down a hill improperly could cause loss of control or overturn.
- Page 19 SAFETY Safety Warnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in the owner's manual. Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause an overturn.
- Page 20 SAFETY Safety Warnings Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. Travel slowly and use extra caution when operating on unfamiliar terrain.
- Page 21 SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.
- Page 23 SAFETY Safety Warnings Operating Through Water Operating through deep or fast-flowing water can cause loss of traction, loss of control, overturn or accident. Never operate in fast-flowing water or in water that exceeds the floor level. Always follow proper procedures for operating in water as described in the owner's manual.
- Page 24 SAFETY Safety Warnings Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems. Operating on Frozen Bodies of Water Operating on frozen bodies of water can result in the vehicle and/or riders falling through the ice.
- Page 25 SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Never allow a child to refuel or handle gasoline. ● Always stop the engine when refueling. ● Always refuel outdoors or in a well ventilated area. ●...
- Page 26 SAFETY Safety Warnings Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touches hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass.
- Page 27 SAFETY Safety Labels and Locations Warning Label WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER allow vehicle to be operated: Without all occupants first viewing and understanding safety ● warning labels. With more than one passenger. ●...
- Page 28 SAFETY Safety Labels and Locations Warning Label WARNING Operation of this vehicle by children age 16 and under increases the risk of severe injury or death. NEVER permit children age 16 and under to operate or ride in this vehicle. WARNING VEHICLE OVERTURN could cause severe injury or death.
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Page 29: Features And Controls
FEATURES AND CONTROLS Component Locations... - Page 30 FEATURES AND CONTROLS Component Locations...
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Page 31: Indicator And Warning Lights
FEATURES AND CONTROLS Indicator and warning lights (1)Speedometer (2)Fuel indicator (3)Left turning indicator (4) Right turning indicator (5)Parking indicator light (6)Fuel warning light (7)Water temperature warming light (8)Battery conditional warming light (9) High beams indicator (10)Gear indicator (11)Mileage indicator (12)Tachometer (13)Coolant temperature warming light... -
Page 32: Switch
FEATURES AND CONTROLS Switch 1. Low beams/High beams turn“ / ” 2. Light switch“ / ” ● 3. Turning switch“ / ● / ” 4. Horn switch“ ” 5. Starter (choke) 6. Warning indicator light switch“ ” 7. Driver model turn switch... -
Page 33: Seats
FEATURES AND CONTROLS Seats Driver’s Seat Adjustment 1. Lift the seat latch lever 1 located under the right front edge of the driver’s seat. 2. While holding the lever upward, slide the seat forward or rearward to the desired position, then release the lever. -
Page 34: Seat Belt Inspection
FEATURES AND CONTROLS The position of the shoulder strap can be adjusted Tip: to the height of the operator. 2. Push the latch plate into the buckle until it clicks. 3. Press the red release latch on the buckle to release the seat belt. -
Page 35: Fuel Cap
FEATURES AND CONTROLS Fuel Cap Never allow a child to refuel or handle gasoline. The fuel tank filler cap is located on the left-hand side of the vehicle behind the operator seat. When refueling, always use unleaded gasoline. -
Page 36: Ignition Switch
FEATURES AND CONTROLS Ignition Switch (1) Turn the key switch to “ST”position. The engine can be started only at this position and the key can not be removed. (2) Turn the key switch to “ON” position, the engine will turn off. When turn the key switch to “OFF”... -
Page 37: Gear Selector
FEATURES AND CONTROLS Gear Selector Low gear H: High gear N: Neutral R: Reverse The gear selector is located between the seats. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving. -
Page 38: Brake Pedal
FEATURES AND CONTROLS Always set the parking brake whenever the vehicle is left unattended. Tip: Operating the vehicle while the parking brake is engaged could cause an accident resulting in serious injury or death. It could also result in driveline or engine damage. Always be sure to disengage the parking brake before operating the vehicle. -
Page 39: Operation
OPERATION Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Vehicle Break-in Period The break-in period for your new vehicle is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. -
Page 40: Vehicle Brake-In Period
OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline. Never allow a child to handle gasoline. 2. Check the oil level. See page 51. Add the recommended oil as needed to maintain the oil level in the safe operating range. -
Page 41: Pre-Ride Inspection
OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Brake Ensure proper operation... -
Page 42: Safe Operation Practices
OPERATION Safe Operation Practices 1. Complete the New Operator Driving Procedures outlined on pages 36-37. 2. Do not ride at night or when visibility is poor (rain, fog, dusk). Your vehicle doesn't have lights that are designed for driving in these conditions. 3. -
Page 43: Starting The Engine
OPERATION Starting the Engine 1. Sit in the driver's seat and fasten the seat belt. 2. Place the transmission in neutral. Set the parking brake. 3. Apply the brakes. 4. Do not press the throttle pedal while starting the engine. 5. -
Page 44: Stopping The Engine
OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Place the transmission in neutral. 3. Set the parking brake. 4. Stop the engine. 5. Turn the fuel valve off. Braking 1. Release the throttle pedal completely. (When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking.) 2. -
Page 45: New Operator Driving Procedures
OPERATION New Operator Driving Procedures 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Review the section of this owner’s manual about starting the engine, stopping the engine, braking and parking (pages 34-35). - Page 46 OPERATION 9. Set the parking brake. 10. Place the transmission in neutral. 11. Start the engine. 12. Apply the brakes and shift into gear. 13. Release the parking brake. 14. Check your surroundings. Make sure the area is clear of people and obstacles. 15.
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Page 47: Driving With A Passenger
OPERATION Driving with a Passenger 1. Complete the New Operator Driving Procedures outlined on Pages 36-37. 2. Perform the pre-ride inspection. See page 3. Do not carry a passenger until you have at least four hours of driving experience with this vehicle. 4. -
Page 48: Driving On Slippery Surface
OPERATION 7. Never allow a passenger to ride on the back of the vehicle. Allow a passenger to ride only in the passenger seat. 8. Make sure the passenger is wearing appropriate riding gear, including an approved helmet and eye protection. - Page 49 OPERATION Follow these precautions when driving in slippery conditions: 1. Slow down before entering slippery areas. 2. Be alert, watch the path ahead and avoid quick turns, which can cause skids. 3. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.
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Page 50: Driving Uphill
OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending a hill. 2. Avoid steep hills (25° maximum). 3. Drive straight uphill. 4. Never climb hills with excessively slippery or loose surfaces. 5. Drive at a steady rate of speed. Never press the throttle suddenly. -
Page 51: Driving On A Side Hill
OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Driving on a sidehill improperly cause loss of control or overturn. If crossing a hill is unavoidable, follow these precautions: 1. Drive slowly and use extreme caution. 2. -
Page 52: Driving Through Water
OPERATION Driving Through Water Your vehicle can drive through shallow water. Make sure the water is no deeper than the floor of the vehicle. Follow these precautions when driving through water: 1. Check water depth. Never drive through water that is deeper than the floor level. -
Page 53: Driving Over Obstacles
OPERATION Driving Over Obstacles Follow these precautions when driving over obstacles: 1. Always check for obstacles before driving in a new area. 2. Look ahead and watch the terrain. Always be alert for hazards such as logs, rocks and low hanging branches. -
Page 54: Driving In Reverse
OPERATION Driving in Reverse Follow these precautions when driving in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttle lightly. Never apply the throttle suddenly. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. -
Page 55: Parking On An Incline
OPERATION Parking on an Incline A rolling vehicle can result in serious injury. Avoid parking on an incline. If parking on an incline is unavoidable, follow these precautions: 1. Place the transmission in neutral. 2. Set the parking brake. 3. Stop the engine. 4. -
Page 56: Maintenance
MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine parts available from your dealer. - Page 57 MAINTENANCE Periodic Maintenance Chart Perform these operations more Perform all services at whichever maintenance interval is reached first. often for vehicles subjected to severe use. I: means inspect clear adjust lubricate or change needed C: means clear; R: means change A: means adjust L: means lubricate...
- Page 59 MAINTENANCE Periodic Maintenance Chart * If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. ** For safety, we recommend that have a qualified dealer perform these operations. 1.If the Odometer indication is large, please repeat this maintenance. Remark 2.If operate this vehicle at special wet or dusty area, you had better shorten the maintenance interval.
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Page 60: Engine Oil
MAINTENANCE 3.If you vehicle often operate on rough terrain ,you must maintenance to maintain your vehicle’s performance. 4.Change every two years , have a qualified dealer perform these operations. Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 48. - Page 61 MAINTENANCE Engine Oil Oil Check Maintain the oil level within the safe range on the dipstick. Do not overfill. 1. Position the vehicle on a level surface. 2. Remove the dipstick. Wipe it dry with a clean cloth. 3. Reinstall the dipstick completely. 4.
- Page 62 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 75.Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase. 1.
- Page 63 MAINTENANCE Engine Oil Oil and Filter Change 9. Install the new oil filter cartridge with an oil filter wrench ,and then tighten it to the specific torque with a torque wrench .Oil filter cartridge tightening torque:17N·m (17m·kgf,12ft·lbf). 10. Reinstall the sealing washer on the drain plug 11.
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Page 64: Transmission (Main Gearcase)
MAINTENANCE Transmission (Main Gearcase) Fluid Check The fill plug is located on the rear of the gearcase. Access the fill plug through the left rear wheel well. Maintain the fluid level at the bottom of the fill plug hole. 1. Position the vehicle on a level surface. 2. -
Page 65: Spark Plugs
MAINTENANCE Spark Plugs Spark Plug Gap/Torque Electrode Gap Plug Tightening Torque 0.8-0.9 mm 12.5 ft. lbs. (17.5 Nm) Using non-recommended spark plugs can result in serious engine damage. Always use our NOTICE company recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. -
Page 66: Constant Variable Transmission (Cvt)System
MAINTENANCE Constant Variable Transmission (CVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure may occur at a high speed. - Page 67 MAINTENANCE CVT Drying There may be some instances when water is accidently ingested into the CVT system. Use the following instructions to dry it out before operating. The drain plug is located on the bottom of the CVT cover. . Remove the drain plug. Allow the water to drain. Reinstall the drain plug. 2.
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Page 68: Filter System
MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 48. Access the air box through the rear decorative board. 1.Remove the air filter fixed card 1 and the cover 2 . 2. - Page 69 Filter Element 3.Screw...
- Page 70 MAINTENANCE Filter Systems Air Filter 5. Clean away any oil or sediments in the air box. 6. Reinstall the filter element and air box cover. Secure the fixed card. NOTICE Never operate the vehicle with the filter element removed. Dirt will enter the engine, causing rapid wear and severe damage to the engine.
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Page 71: Cooling System
MAINTENANCE Cooling system 1.Place the vehicle on a level surface. 2.Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature. 3.If the coolant is at or below the minimum level mark, remove the reservoir cap, add coolant to the maximum level mark, install the reservoir cap. -
Page 72: Throttle System
MAINTENANCE Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for service if throttle problems arise. - Page 73 MAINTENANCE Throttle System Throttle Freeplay Inspection 1. Place the transmission in neutral. Set the parking brake. 2. Start the engine. Allow it to warm up thoroughly. 3. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.5-3 mm).
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Page 74: Carburetor
MAINTENANCE Carburetor Common sense: Install the carburetor, the carburetor must ensure that engine to connect with sealing flange department, in order to avoid leakage, resulting in engine starts hard, no idling or idling unstable failure. 1. Carburetor Idle Adjustment: carburetor factory has been idle mixture screw fine adjustment, the general initial use, the user without the need for any adjustments, so as to avoid unnecessary trouble. - Page 75 MAINTENANCE Carburetor Carburetor/Engine Idle RPM Adjustment If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Place the transmission in neutral. 2. Set the parking brake. 3. Start the engine and allow it to warm up for approximately five minutes. 4.
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Page 76: Brakes
MAINTENANCE Brakes Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before riding. See page 66 for brake fluid information. If you discover any irregularities in brake system operation, including excessive pedal travel, contact your dealer for proper diagnosis and repairs. - Page 77 MAINTENANCE Brakes Brake Fluid Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 3 or DOT 4 brake fluid. After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle.
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Page 78: Steering Wheel Inspection
MAINTENANCE Steering Wheel Inspection 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8"-1.0" (20-25 mm) of freeplay. 4. If there is excessive freeplay or strange noises, or the steering feels rough or catchy, have the steering system inspected by an authorized dealer. -
Page 79: Tires
MAINTENANCE Tires Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth mea- sures 1/8" (3 mm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. -
Page 80: Vehicle Immersion
MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. NOTICE: Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. 1. - Page 81 MAINTENANCE Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult your dealer. Battery CAUTION : Do not try to remove the sealing caps of the battery cells.
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Page 82: Fuse Replacement
MAINTENANCE Battery :A special battery charger (constant voltage/ampere or constant voltage) is required for CAUTION recharging a sealed type battery. using a conventional battery charger may shorten the battery life. Fuse replacement 1.The fuses are under the meter cover. 2. If a fuse is blown, turn off the main switch and the switch of the circuit in question. then, install a new fuse of the specified amperage. - Page 83 MAINTENANCE Battery 1. When the machine is not used for a month or longer, removes the battery and stores it in a cool, dark place. Completely recharge the battery before reinstallation. 2. Always make sure the connections are correct when putting the battery back in the machine. Do not use an improper fuse, because an improper fuse can cause damage to the WARNING...
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Page 84: Cleaning And Storage
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. Before washing the vehicle, locate the CVT inlet and outlet duct. The ducts are located at the rear decorative board and right side of the vehicle. - Page 85 MAINTENANCE Cleaning and Storage Storage Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Drain the fuel system. 2. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug.
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Page 86: Specifications
SPECIFICATIONS MODEL 500GO-KART Dimensions: Overall length 2850 mm (112.2 in) 1600 mm (63.0 in) Overall width Overall height 1500 mm (59.1 in) Seat height 865mm (22.4 in) Wheelbase 2190mm 86.2in Minimum ground clearance 350mm 13.8in Minimum turning radius 4150mm (163.4 in) Basic weight: Mass of whole equipments (Not include 474kg... - Page 87 MODEL 500GO-KART Lubrication system Pressure spray Engine oil: Type Recommended engine oil classification Quantity: Without oil filter cartridge replacement 1.8L(1.90 US qt) With oil filter cartridge replacement 1.9L(2.01 US qt) Final gear case oil: Type GL-4 85W/90 Quantity: Periodic oil change 0.33L(0.35 US qt)
- Page 88 MODEL 500GO-KART Front gear case oil: Type GL-4 85W/90 Quantity: Periodic oil change 0.33L(0.35 US qt) dry element Air filter: Fuel: Type UNLEADED GASOLINE ONLY Fuel tank capacity 32.0 L (8.4Gal) Fuel reserve amount about 4 L (1 Gal) Carburetor: Type/quantity vacuum film MIKUNI...
- Page 89 MODEL 500GO-KART Secondary reduction system Shaft drive Transmission type V-belt automatic Operation Right hand operation High gear 3.514 5.857 Low gear Reverse gear 3.828 Chassis: Frame type Steel tube frame Caster angle 6° Trail Tire: Type Tubeless Size front 25×8.00-12 rear 25×10.00-12 Brake: Front brake...
- Page 90 MODEL 500GO-KART operation Left foot operation Suspension: Front suspension Double wishbone Rear suspension Double wishbone Shock absorber: Front shock absorber Coil spring / oil damper Rear shock absorber Coil spring / oil damper Wheel travel: Front wheel travel 100 mm (3.9 in) Rear wheel travel 120 mm (4.7 in) Electrical:...
- Page 91 MODEL 500GO-KART Tail/brake light 12 V 5 W/21.0 W × 2 Indicator light Neutral indicator light LED × 1 High gear indicator light LED × 1 Low gear indicator light LED × 1 Reverse gear indicator light LED × 1 Coolant temperature warning light LED ×...
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Page 92: Troubleshooting Charts
Troubleshooting charts Starting problems or poor engine performance Clean Fuel tank Fuel tank air vent air vent obstructed Restart the engine The vacuum hose Clean vacuum clogged or leakage hose or replace 1. Fuel There is fuel. Remove the fuel hose Check the No fuel from the fuel pump... - Page 93 Engine overheating Wait until the WARNING engine has cooled. POTENTIAL HAZARD Check the coolant level in the coolant reservoir and/or radiator. Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN Level is low, check the cooling system for You could be burned by hot fluid and Level is OK.
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