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Summary of Contents for TrailMaster MINI XRX
- Page 2 GOKARTMASTERS.COM GOKARTMASTERS.COM Move carton to a clean location with 3 Remove metal crating and unpack all or more feet of room around the unit. parts. GOKARTMASTERS.COM GOKARTMASTERS.COM Remove outer cardboard from crate. Place parts out on the floor and take inventory making sure of proper quan- tities.
- Page 3 GOKARTMASTERS.COM Remove axle straps and discard. Lay out all hardware on a clean work bench. Take inventory per hardware list. GOKARTMASTERS.COM GOKARTMASTERS.COM Locate white box with battery. Locate one of the long cage bars. GOKARTMASTERS.COM GOKARTMASTERS.COM Place bar on front pin above head- See Battery Fill Procedure Instruction light.
- Page 4 GOKARTMASTERS.COM GOKARTMASTERS.COM Place rear of bar onto pin at rear be- It may be necessary to align the hole hind seat. in the bar with a screwdriver. GOKARTMASTERS.COM GOKARTMASTERS.COM Locate 2 long bolts, 4 nuts & 8 Install a second cup washer and the chrome cup washers.
- Page 5 GOKARTMASTERS.COM GOKARTMASTERS.COM Place the side bar onto the passen- Repeat steps 16-19 for the other top ger’s side of the go-kart. bar. GOKARTMASTERS.COM GOKARTMASTERS.COM Turn the plastic cap with a pair of pli- Locate the passenger side bar. ers to align the side bar to the top bar.
- Page 6 GOKARTMASTERS.COM GOKARTMASTERS.COM Install the top bolt & washer first. Repeat steps 20-27 for the driver’s Start the threads but do not tighten. side bar. GOKARTMASTERS.COM GOKARTMASTERS.COM Now, install the bottom bolt and Locate the top bar weldment assem- washer from the front. bly.
- Page 7 GOKARTMASTERS.COM GOKARTMASTERS.COM Install the top bar assembly. Locate 2 long bolts and 2 chrome cupped washers. GOKARTMASTERS.COM GOKARTMASTERS.COM Start each of the 4 bolts with cupped Install the short bar behind the seats. washer into the threads of the top bar. Start the bolts with washers into the threads.
- Page 8 GOKARTMASTERS.COM Locate the fuel tank. Install the 4 bolts and nuts into the tank. NOTE: On some models, the fuel tank is already installed on the engine. Check tank mounting hardware to insure tight. Proceed to Step 46. GOKARTMASTERS.COM GOKARTMASTERS.COM GOKARTMASTERS.COM Locate 4 long bolts and nuts and fuel Tighten with a 10mm &...
- Page 9 GOKARTMASTERS.COM GOKARTMASTERS.COM Place the fuel hose clamp onto the Now, it’s time to install the rear hose and push the hose onto the fuel shocks. Remove the metal shipping filter that’s already attached to the fuel tank. bar from the passenger’s side shock mounts. NOTE: SAVE THE BOLTS &...
- Page 10 GOKARTMASTERS.COM GOKARTMASTERS.COM Place the top shock eye into the Tighten top and bottom shock bolts bracket with the spring up. Reinstall with wrenches. bolt and washer that was removed in Step 46. GOKARTMASTERS.COM GOKARTMASTERS.COM Lift up on the rear rack and align bot- Repeat Steps 48-52 for the driver’s tom shock eyelet with the bracket on side rear shock.
- Page 11 GOKARTMASTERS.COM GOKARTMASTERS.COM Place rubber battery strap over bat- Place the battery pad into battery tray tery hook to the front of the battery located behind the passenger’s seat. tray first. Then, pull the strap over the battery and place it on the rear hook of the battery tray.
- Page 12 GOKARTMASTERS.COM GOKARTMASTERS.COM Install the cotter pin into the axle nut. Place the wheel onto the rear axle. Bend one end of the cotter pin over the end of the axle. Clip off other end with cutters. GOKARTMASTERS.COM GOKARTMASTERS.COM Place the largest washer and castle Install rubber hubcap over axle nut.
- Page 13 GOKARTMASTERS.COM GOKARTMASTERS.COM Make sure the hole in the spindle Locate passenger’s side top spindle lines up with the castle nut. nut and remove cotter pin. NOTE: Save cotter pin. GOKARTMASTERS.COM GOKARTMASTERS.COM Reinstall cotter pins. Bend and cut off Locate passenger’s side bottom spin- excess.
- Page 14 GOKARTMASTERS.COM GOKARTMASTERS.COM Locate the front passenger’s side Check tire pressure in all 4 tires. Set wheel and place it on the passenger’s to 10 PSI. You will need a low pres- side front axle. The tread on top should point sure gauge to check the tire pressure.
- Page 15 GOKARTMASTERS.COM GOKARTMASTERS.COM Locate the three (3) small bolts and Tighten bolts securely with two (2) nuts. 10mm wrenches. GOKARTMASTERS.COM GOKARTMASTERS.COM Locate the steering wheel. Install the plastic steering wheel cap by snapping it into place. GOKARTMASTERS.COM GOKARTMASTERS.COM Install the steering wheel with the center If the steering wheel is not straight spoke facing down &...
- Page 16 GOKARTMASTERS.COM GOKARTMASTERS.COM Remove plastic cap from the bot- Pull steering wheel and shaft out of tom of the plastic case with a screw- the gear. You may need to bump the driver. steering wheel gently. GOKARTMASTERS.COM GOKARTMASTERS.COM Make sure the front wheels are Hold the gear in place with your straight ahead and determine which finger.
- Page 17 GOKARTMASTERS.COM GOKARTMASTERS.COM Reinstall the nut securely. Reinstall The front wheel should be in a the plastic cap by simply pushing it straight line with the rear wheel or into place. parallel. NOTE: The front of the go-kart is wider than the rear.
- Page 18 GOKARTMASTERS.COM GOKARTMASTERS.COM Hold the rod with a 10mm wrench Hold the rod with a wrench and and loosen the outer jam nut tighten the jam nuts securely. (standard thread). GOKARTMASTERS.COM GOKARTMASTERS.COM Repeat Steps 92-100 for the driv- Now, loosen inner er’s side.
- Page 19 Locate the foam padding and cables with a 12mm wrench. place it on the top outside bars of the go-kart. NOTE: This is ONLY on the Mini XRX-R GOKARTMASTERS.COM GOKARTMASTERS.COM Cut and remove all strings on can- Remove air filter nut and cover.
- Page 20 GOKARTMASTERS.COM GOKARTMASTERS.COM You’re almost done! Just a few It is highly recommended to use pre-drive items to inspect, and a fuel additive or fuel stabilizer you will be ready to ride your new go-kart. such as Seafoam or Stabil. Follow manufactur- er's instructions on the bottle.
- Page 21 GOKARTMASTERS.COM GOKARTMASTERS.COM There should ALWAYS be some- Pull the choke control out firmly one seated in the driver’s seat and hold. before starting the go-kart. GOKARTMASTERS.COM GOKARTMASTERS.COM ALWAYS engage the parking Push the red Start Button. brake before starting the go-kart. GOKARTMASTERS.COM GOKARTMASTERS.COM Insert ignition key and turn to the...
- Page 22 GOKARTMASTERS.COM Turn the key to ’OFF’ or push the stop button and hold to turn the go-kart engine off.
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