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TrailMaster MID XRX Assembly Manual
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TrailMaster MID XRX Assembly Manual

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Summary of Contents for TrailMaster MID 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 GOKARTMASTERS.COM Remove axle straps and discard. Locate headrests and install into seat- backs with seatbelt in between head- rest bars. Push the headrests all the way down into the seat. GOKARTMASTERS.COM GOKARTMASTERS.COM Locate white box with battery. Lay out all hardware on a clean work bench.
  • Page 4 GOKARTMASTERS.COM GOKARTMASTERS.COM Place bar on front pin above head- Install with washer into front of bar light. from the outside. 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.
  • Page 5 GOKARTMASTERS.COM GOKARTMASTERS.COM Install bolt, washers and nut at rear of Locate 4 large bolts, 6 cup washers bar. and 2 nuts. GOKARTMASTERS.COM GOKARTMASTERS.COM Repeat steps 16-19 for the other top Place the side bar onto the passen- bar. ger’s side of the go-kart. GOKARTMASTERS.COM GOKARTMASTERS.COM Locate the passenger side bar.
  • Page 6 GOKARTMASTERS.COM GOKARTMASTERS.COM It is necessary to tap the plastic cap Install the second washer and nut on all the way onto the bar. Use a plastic the bottom bolt. or rubber mallet or a block of wood with a standard hammer. NOTE: DO NOT TIGHTEN THE HARDWARE.
  • Page 7 GOKARTMASTERS.COM GOKARTMASTERS.COM Locate 4 large bolts and 4 chrome Locate the short rear bar. cupped washers. 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.
  • Page 8 GOKARTMASTERS.COM GOKARTMASTERS.COM Tighten ALL of the bar bolts previ- Place the fuel tank onto the rear rack ously installed with a 10mm & 12mm with decal to the rear. wrenches. GOKARTMASTERS.COM GOKARTMASTERS.COM Locate the fuel tank. Install the 4 bolts and nuts into the tank.
  • Page 9 GOKARTMASTERS.COM GOKARTMASTERS.COM Locate the end of the fuel hose on top Turn fuel valve to ‘ON’ position. of the engine. 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.
  • Page 10 GOKARTMASTERS.COM GOKARTMASTERS.COM Locate one (1) shock. Install bottom shock bolt and nut. 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 47. GOKARTMASTERS.COM GOKARTMASTERS.COM Lift up on the rear rack and align bot-...
  • Page 11 GOKARTMASTERS.COM GOKARTMASTERS.COM At this time, lift the rear of the go-kart Place gray plastic cover over battery. with the help of an assistant. Place the kart on a jackstand. Be safe. Use caution. GOKARTMASTERS.COM GOKARTMASTERS.COM Place the battery pad into battery tray Place rubber battery strap over bat- located behind the passenger’s seat.
  • Page 12 GOKARTMASTERS.COM GOKARTMASTERS.COM Locate the set bolt on the sprocket Place the largest washer and castle hub and tighten securely. nut onto the axle. GOKARTMASTERS.COM GOKARTMASTERS.COM Locate the rear passenger’s side Tighten the castle nut securely and wheel. This is one of the larger align the holes in the axle with the wheels.
  • Page 13 GOKARTMASTERS.COM GOKARTMASTERS.COM Install rubber hubcap over axle nut. Tighten the bolts securely using a 10mm wrench. NOTE: Repeat Steps 68-70 for the driver’s NOTE: Repeat Steps 62-67 for the driver’s side rear fender. side rear wheel. GOKARTMASTERS.COM GOKARTMASTERS.COM Remove bolts from the passenger’s Lift front of go-kart and support with side rear fender mounts with a 10mm jack stands.
  • Page 14 GOKARTMASTERS.COM GOKARTMASTERS.COM Locate passenger’s side front fender. Repeat Steps 73-75 on driver’s side This fender has the longer mounting fender. arm. GOKARTMASTERS.COM GOKARTMASTERS.COM Install the front fender with bolts and Locate passenger’s side top spindle lock washers. Tighten securely with a nut and remove cotter pin.
  • Page 15 GOKARTMASTERS.COM GOKARTMASTERS.COM Tighten both nuts securely with a Locate outer steering joints and tight- 17mm wrench. en the nut securely using a 12mm socket on the nut and a 12mm wrench on the top. GOKARTMASTERS.COM GOKARTMASTERS.COM Make sure the hole in the spindle Locate the front passenger’s side lines up with the castle nut.
  • Page 16 GOKARTMASTERS.COM GOKARTMASTERS.COM Place the washer and castle nut onto Make sure that the brake fluid is be- the axle and tighten securely with a tween the ‘MIN’ & ‘MAX’ levels on the 19mm socket. brake master cylinder reservoir. GOKARTMASTERS.COM GOKARTMASTERS.COM Add brake fluid, if necessary, to the Install cotter pin and bend.
  • Page 17 GOKARTMASTERS.COM GOKARTMASTERS.COM Locate throttle cable mount and Locate the steering box clamps and make sure nuts are snug with two (2) tighten all four (4) bolts and nuts se- 10mm wrenches. Tighten gently. curely with 8mm & 10mm wrenches. NOTE: Plastic connector should be next to the metal clamp.
  • Page 18 GOKARTMASTERS.COM GOKARTMASTERS.COM Install the steering wheel with the center If the steering wheel is not spoke facing down & the front wheels straight when the front wheels are straight forward. pointing straight, locate the plastic gearcase on the steering box. NOTE: If the steering wheel does not line up cor- rectly with the front wheels, continue mounting the steering wheel as close as possible.
  • Page 19 GOKARTMASTERS.COM GOKARTMASTERS.COM Remove steering shaft nut with Turn the steering wheel straight 17mm socket. and push the shaft back down into the gear. GOKARTMASTERS.COM GOKARTMASTERS.COM Reinstall the nut securely. Rein- Pull steering wheel and shaft out stall the plastic cap by simply of the gear.
  • Page 20 GOKARTMASTERS.COM GOKARTMASTERS.COM Stand approximately 10 feet in Adjust the passenger tie rod ac- front of the go-kart and look at the cordingly to align the wheel. front passenger wheel in relationship to the rear passenger wheel. GOKARTMASTERS.COM GOKARTMASTERS.COM Hold the rod with a 10mm wrench The front wheel should be in a and loosen the outer jam nut straight line with the rear wheel...
  • Page 21 GOKARTMASTERS.COM GOKARTMASTERS.COM Now, adjust the wheel in or out For final front end alignment pro- by turning the rod. cedure, the front wheels should turn toward each other approximately 1/4” to 1/2”. GOKARTMASTERS.COM GOKARTMASTERS.COM Hold the rod with a wrench and Measure across the front wheels tighten the jam nuts securely.
  • Page 22 GOKARTMASTERS.COM GOKARTMASTERS.COM Using electrical tape, tape the Then, attach the side and connect padding in place at the ends and the Velcro. center. GOKARTMASTERS.COM GOKARTMASTERS.COM Locate fabric top and install on go Attach the rear flaps. -kart GOKARTMASTERS.COM GOKARTMASTERS.COM Repeat Steps 109-116 for the driv- Remove air filter nut and cover.
  • Page 23 12mm wrench. gine behind the driver’s seat. With the go-kart sitting on level ground, the NOTE: This is ONLY on the Mid XRX-R oil level should be to the top of the threads. If not, fill with 10W30 oil.
  • Page 24 GOKARTMASTERS.COM GOKARTMASTERS.COM It is highly recommended to use There should ALWAYS be some- a fuel additive or fuel stabilizer one seated in the driver’s seat such as Seafoam or Stabil. Follow manufactur- before starting the go-kart. er's instructions on the bottle. GOKARTMASTERS.COM GOKARTMASTERS.COM If there is no passenger in the go-...
  • Page 25 GOKARTMASTERS.COM GOKARTMASTERS.COM Pull the choke control out firmly Turn the key to ’OFF’ or push the and hold. stop button and hold to turn the go-kart engine off. GOKARTMASTERS.COM Push the Start Button. GOKARTMASTERS.COM It may be necessary to run the engine on choke or partial choke for 30 seconds to 1 minute to warm up the engine.

This manual is also suitable for:

Mid xrx-r