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Summary of Contents for TrailMaster Challenger 150UTV-X
- Page 1 TrailMaster Challenger 150UTV-X Set up instruction Version: 2.0 2017/05/14 This set up instruction guides our customer to set up the go kart TrailMaster Challenger 150UTV-X step by step to ensure a correct assembly for safe driving.
- Page 2 CHALLENGER150X P. D. I 1. Check the components after opening the box. 1.1 Battery (pic.1): type YTX12-BS (12V10Ah), includes one battery, one battery liquid, two bolts and nuts for installation. 1.2 Steering wheel (1 pc) 1.3 Owner’s manual (1pc) 1.4 Hardware bag (3pc)
- Page 3 CHALLENGER150X P. D. I 1.4.1 Bag 1: Hub cover 4pcs, zip tie 10 1.4.2 Bag 2: battery box (1pc), battery strap (1pc), bolt M8X55 (4pc), bolt M8X60 (2pc), bolt M8X30 (8 pc), bolt M6X16 (6pc), bolt M6X30 (2 pc), screw M6X16 (6 pc), bolt M6X12 (3 pc), washer∮6 (6 pc), cotter pin 3X40 (2pc), R-washer (12 pc), self-locking nut M8 (18pc), nut M6 (6 pc), bolt M8X16 (10 pc) 1.4.3 Bag 3: Steering wheel cover (1pc), cable for headlight (1pc), clamps...
- Page 4 CHALLENGER150X P. D. I 1.5 Head rest 2pc (Not on the new sport seat) 1.6 Rear roll cage bar 1pc 1.7 Front roll cage bar 1pc...
- Page 5 CHALLENGER150X P. D. I 1.8 Front light cover (lights are pre-installed) 1pc 1.9 Top headlights mounting bar 1pc 1.10 Front wheel left and right 1of each 1.11 Front wheel left and right 1of each...
- Page 6 CHALLENGER150X P. D. I 1.12 Rear shock 1pc 1.13 canopy top 1pc, side net door left and right 1 of each, bar cushions 1.14 Top headlight mounting parts 1 set...
- Page 7 CHALLENGER150X P. D. I 1.15 Side mirror 1 set (The mirror in the box can be different!) 1.16 Rear mirror 1 pc 1.17 Front metal bumper 1pc 1.18 Windshield 1pc (already installed) 1.9 Front lights mounting bar 1pc...
- Page 8 CHALLENGER150X P. D. I 2. Assembly： 2.1 Assemble the rear shocks: take down the bolts from the shocks; lift the rear swing arm to let the top of shock into the fixing seats of frame, use 37-44NM torque to fix the shocks attached the frame. (Note: 1NM = 0.74 lb ft): 2.2 Assemble the rear wheels (pic.18): screw the castle nut M16x1.5 tightly with 98-103NM, then open the cotter pin 3X40 for fixing, cover...
- Page 9 CHALLENGER150X P. D. I 2.3 Assemble the front shocks: Take down the bolt on the shocks, attach the shock to the front lower suspension arm, and fix the bolt with 37-44NM torque: 2.4 Assemble the front wheel: Take down the tire bolts on the hub, set up the front wheel on the right position of hub, fix the tire bolts with 37-44NM torque, put on the hub cover.
- Page 10 CHALLENGER150X P. D. I 2.5 Front bumper mounting bracket assembly: assemble the front bumper mounting bracket on the UTV frame using GB5789 M6x16 bolts, PLEASE DO NOT TIGHT THE BOLTS AT THIS STEP. 2.6 Set up the top headlights wire: open the right side of front hood cover as displayed in the picture, put the wire through the hole on the front hood cover where the front roll cage bar mount rod is, connect the plugs...
- Page 11 CHALLENGER150X P. D. I 2.7 Install the front light cover: attach the front light cover on the frame and install it on the frame with M6X16 bolts and M6 nuts. 2.8 Plug the headlight and turn lights’ wire: plug the wires with the connecting sockets;...
- Page 12 CHALLENGER150X P. D. I the nut 2.11 Install the front roll cage bar: put the front roll cage bar into the mount posts on the frame, put in the M8x60 bolt, R-washer, windshield bracket and tighten the M8 nut to fix.
- Page 13 CHALLENGER150X P. D. I 2.12 Install the rear roll cage bar: put the rear roll cage bar onto the mount posts of the frame, fix it using M8x55 bolt, R-washer and M8 nut. 2.13 Joint the front and rear roll cage: joint the roll cages and connect them with M8x30 bolt and M8 nut.
- Page 14 CHALLENGER150X P. D. I 2.15 Install the seat back head rest (No this step with new sport seat!) 2.16 Install the rear mirror: take off the M5 bolt, O-ring. Put the O-ring on the rear mirror mount plate of the frame, then use M5x25 and ∮5 spring washer to install the rear mirror on the frame.
- Page 15 CHALLENGER150X P. D. I 2.18 Install the side net doors 2.19 Install the battery, battery cover: put the battery liquid into the battery body, close the battery cover. Put the cushion plate into the battery mount box. Connect the battery wires to the battery poles “+ to +; - to –”, cover them.
- Page 16 CHALLENGER150X P. D. I 2.20 Install the side mirrors: install the side mirrors on the windshield brackets (see. 2.11), fix them with a M10 self-locking nut, and adjust the mirrors. (The mirror in the box can be different!) 2.21 Install the top light mount bar, top lights and windshield: 2.21.1 Install the top light mounting piece onto the top light mounting bar, install the top lights on the mounting piece 2.21.2 Install the top light mounting bar onto the frame, fix it using...
- Page 17 CHALLENGER150X P. D. I brackets using M8X30 bolt and M8 nut 2.21.6 Connect the top light wiring with the top lights 2.22 Install the front metal bumper, insert the bar end covers...
- Page 18 CHALLENGER150X P. D. I Before driving please make sure that all of the hardware on the UTV are tightened; please read the user manual of TrailMaster Challenger 150UTV-X carefully, you will be given with important safety information and advices. Thanks a lot for choosing TrailMaster Challenger 150UTV-X.
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