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Summary of Contents for Hammerhead UM250IIR 2005

  • Page 3: Table Of Contents

    OWNER' S MANUAL Page 1. FOREWORD ------------------------------------------------------------------------------------------ 1 A FEW WORDS ABOUT SAFETY ------------------------------------------------------------- 2 IMPORTANT SAFETY INFORMATION------------------------------------------------------- 3 SAFETY LABELS----------------------------------------------------------------------------------- 5 ARE YOU READY TO DRIVE?----------------------------------------------------------------- 6 IS YOUR VEHICLE READY TO DRIVE?----------------------------------------------------- 7 SAFE DRIVING PRECAUTIONS--------------------------------------------------------------- 8 P.D.I.---------------------------------------------------------------------------------------------------- 10 SPECIFICATIONS---------------------------------------------------------------------------------- 11 OPERATION---------------------------------------------------------------------------------------- 13 SERVICE INSTRUCTIONS--------------------------------------------------------------------- 17...
  • Page 4 Thank you for purchasing our kart. We hope you will enjoy it. Before you start to operate the kart, please read through this Owner's Manual carefully as it contains important safety and maintenance information. Failure to follow the warnings contained in this manual can result in serious injuries or death. Be sure to follow the recommended maintenance schedule and service your kart accordingly.
  • Page 5: A Few Words About Safety

    A FEW WORDS ABOUT SAFETY In order to keep everyone safe, you must take responsibility for the safe operation of your 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.
  • Page 6: Important Safety Information

    IMPORTANT SAFETY INFORMATION Your kart will provide you with many years of use and pleasure. Providing you take responsibility for your own safety and that of any one else using your kart or near to the kart when it is being used and understand the challenges you can meet while driving.
  • Page 7 IMPORTANT SAFETY INFORMATION Drive within Your Limits Pushing limits is another major cause of 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 drive safely. Don't Drink and drive Alcohol and driving don’t mix.
  • Page 8: Safety Labels

    Safety Labels This section presents some of the most important information and recommendations to help you drive your kart safely. Please take a few moments to read these pages. The labels should be considered permanent parts of the kart. If a label comes off or becomes hard to read, contact your dealer for a replacement.
  • Page 9: Are You Ready To Drive

    ARE YOU READY TO DRIVE ? Before each drive, you need to make sure that you and your 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 kart, and adjustments to make for your comfort, convenience, or safety.
  • Page 10: Is Your Vehicle Ready To Drive

    ARE YOU READY TO DRIVE? Additional Driving Gear 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. Driving pants with knee and hip pads, a driving jersey with padded elbows, and a chest/shoulder protector.
  • Page 11: Safe Driving Precautions

    SAFE DRIVING PRECAUTIONS Off-Road Use Only Your kart and its tires are designed and manufactured for off-road use only, not for use on paved surfaces. Driving on paved surfaces can affect the kart handling and control. You should not drive your kart on paved surfaces. When driving off-road, also remember to always obey local off-road driving laws and regulations.
  • Page 12 SAFE DRIVING PRECAUTIONS Use Kart on Unfamiliar or Rough Terrain Before driving in a new area, always check the terrain thoroughly. Don't drive fast on unfamiliar terrain or when visibility is limited (it's sometimes difficult to see obstructions like hidden rocks, bumps, or holes in time to react).
  • Page 13 P.D.I. (Post Delivery Inspection and assembly) a)  Install RR. Shocks and tighten the nuts. b)  Install Ball Head, Tie Rod, tighten the Castle Nut and insert the cotter Pin. c)  Install Dust Seals, align the Ball Head Bolt, Knuckle Support to the square hole on the Lower A-Arm.
  • Page 14: Specifications

    Specifications DIMENSIONS Overall Length-------------------------------------------------------------------------- 87 in. (2210mm) Overall Width--------------------------------------------------------------------------- 53.5 in. (1346mm) Overall Height-------------------------------------------------------------------------- 56.6 in. (1438mm) Wheelbase------------------------------------------------------------------------------ 66.1 in. (1680mm) Front Track------------------------------------------------------------------------------ 45.7 in. (1160mm) Rear Track------------------------------------------------------------------------------- 42.7 in. (1085mm) Ground Clearance--------------------------------------------------------------------- 8.5 in. (215mm) ENGINE Type--------------------------------------------------------------------------------------- Water cooled. 4-Stroke Engine capacity------------------------------------------------------------------------ 250cc Bore / Stroke---------------------------------------------------------------------------- 72mm x 60mm Displacement--------------------------------------------------------------------------- 244ml...
  • Page 15 Specifications Brake Track------------------------------------------------------------------------------- < 7 m@20miles/h Top speed----------------------------------------------------- 75 km/h(or limited as customers require) CHASSIS Front, Rear brake--------------------------------------------------------- Hydraulic disc, left foot control Front tire-------------------------------------------------------------------------------------------------- 20 x 7-8 Rear tire---------------------------------------------------------------------------------------------- 22 x 10 -10 Front Suspension---------------------------------------------------------------- Independent Dual A-Arm Rear Suspension------------------------- Full Independent Rear Suspension/Oil Damped Shocks Restraint System-----------------------------------------------------------------------Dual 4-point Harness Final Drive----------------------------------------------------------------------------------------------CV-Shafts TIRE PRESSURE...
  • Page 16: Operation

    Operation A. Operation controls WARNING - Do not attempt to start or operate the engine until complete 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.
  • Page 17 Operation B. Pre-Drive Inspection a.  Check the engine oil level is between the bottom of the dipstick and the "0" mark. Check for leaks. Add oil if required. b.  Check the Fuel Level. Add fuel as necessary and do not overfill. Check for leaks. Ensure the fuel filler cap is securely fastened.
  • Page 18 Operation Component locations Figure 2...
  • Page 19 Operation C.  Passengers The vehicle is designed for two people only. The combined maximum weight of the driver and the passenger should not exceed 200kg or 440lbs. D.  S eat Adjustment The seat should be securely fastened in the position which gives the operator best control of the foot pedals, steering wheel, and the remote stop button.
  • Page 20: Service Instructions

    OPERATION F. Starting and Operating Instructions a.  Before starting the engine, the driver must be seated properly in the kart with the seat belt on. b.  Practice in the kart in an open space at the beginning to learn how to start, turn and stop the vehicle.
  • Page 21 SERVICE INSTRUCTIONS B. Engine Lubrication You must change the oil in the crankcase after the first 5 hours of operating (See Fig. 7) and after every 10 hours of use thereafter. This will insure proper lubrication of the internal parts and prevent costly repairs due to excessive wear.
  • Page 22 SERVICE INSTRUCTIONS a.  Warm up the engine (5~10min) b.  Tighten the air screw gently. Back it 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 air screw counter clockwise slowly and observe the RPM of the engine, stop adjusting as the RPM reaches the top speed.
  • Page 23: Repair

    SERVICE INSTRUCTIONS H. Storage Instruction In the event your kart is not to be operated for a period in excess of 30 days or at the end of each driving season prepare for storage as follows: a.  Drain the fuel tank and carburetor by allowing the engine to run out of fuel. b. ...
  • Page 24 REPAIR B. Rear Wheel Replacement Do not disassemble the castle nuts when you replace the rear wheels and hub assembly. Remove the cotter pin and then 24mm nut. Then slide off the wheel and hub assembly. It is only necessary to remove the 4 lug nuts to remove the wheel. Tighten the nuts after replacing the wheels.
  • Page 25 Figure 13...
  • Page 26: Periodical Check And Services

    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 of Service
 Monthly Quarterly Yearly Initial service Items (first week) Tire pressure/wear Brake performance Tightness of screws Air cleaner Carburetor...
  • Page 27 WIRING DIAGRAM...
  • Page 28: Parts Manual

    Parts Manual Fig. 1 CYLINDER COMP. CYLINDER COMP. REF NO. PART NO. DESCRIPTION REQ’D NO. 172MM-023100 CYLINDER COMP 172MM-023002 CYLINDER SEAL 152MI-023300 TENSIONER 152MI-023003 SPRING SEAT FLANGE BOLT 152MI-023002 SPRING 152MI-023004 TENSIONER SEAL 172MM-023007 WATER INFLOW RUBBER TUBE 172MM-023009 WATER TUBE SHEATH QC/T621-1999-B24 WIRE CLAMP 152MI-023009...
  • Page 29 Fig. 2 CYLINDER COVER ASSY. (1)
  • Page 30 PARTS MANUAL CYLINDER COVER ASSY.(I) REF NO. PART NO. DESCRIPTION REQ’D NO. 172MM-021009 OIL TUBE CLIP 172MM-021001 CYLINDER COVER 172MM-021006 PLATE 152MI-021011 CYLINDER COVER SEAL 172MM-021100 INLET ROCKER SHAFT 172MM-021200 EX ROCKER SHAFT 172MM-021400 OUTER OIL TUBE 152MI-021001 RUBBER RING 172MM-021431 OIL TUBE HOLDER 152MI-021003...
  • Page 31 Fig. 3 CYLINDER COVER ASSY.(2)
  • Page 32: Cylinder Cover Assy.(1)

    PARTS MANUAL CYLINDER COVER ASSY.(2) REF NO. PART NO. DESCRIPTION REQ’D NO. 172MM-022100 CYLINDER COVER ASSY. 172MM-022700 EX. TUBE FLANGE 152MI-022014 CAMSHAFT COVER 172MM-022008 EX. TUBE NUT 172MM-022010 CYLINDER COVER SEAL 172MM-022900 CARBURETOR RELAY SEAT 172MM-022500 INLET TUBE CLAMP 152MI-022810 TEMPERATURE RETAINER 152MI-022803 UPPER TEMPERATURE RETAINER COVER...
  • Page 33 Fig. 4 CRANKCASE ASSY.
  • Page 34: Crankcase Assy

    PARTS MANUAL CRANKCASE ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. 172MM-011200 CRANKCASE, R. 152MI-011010 HANGER OUTER BUSH 152MI-011008 O-RING 15.8x2.4 152MI-011009 HANGER INNER BUSH 152MI-011013 O-RING 7.5 x 1.5 172MM-011003 CRANKCASE SEAL 172MM-011100 CRANKCASE, L. 172MM-011014 BRAKE SHOE SHOCK ABSORPTION WASHER 172MM-011400 INNER OIL TUBE 172MM-011002...
  • Page 35 Fig. 5 Right Side Cover Assy...
  • Page 36: Right Side Cover Assy

    PARTS MANUAL RIGHT SIDE COVER ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. RUBBER HOSE (LINKED WITH CYLINDER COVER) 172MM-013013 RUBBER HOSE (LINKED WITH RIGHT SIDE 172MM-013100 COVER) 172MM-013015 RUBBER HOSE (LINKED WITH AIR CLEANER) 172MM-013016 RUBBER HOSE CLIP 172MM-013002 RIGHT SIDE COVER 172MM-013008 PLATE...
  • Page 37: Crankshaft Con'rod & Piston Assy

    PARTS MANUAL Fig. 6 CRANKSHAFT CON'ROO & PISTON ASSY. CRANKSHAFT CON’ROD & PISTON ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. 172MM-041000 CON’ROD ASSY. 172MM-040008 THE FIRST PISTON RING 172MM-040009 THE SECOND PISTON RING 172MM-042000 OIL RING ASSY. 172MM-040005 PISTON 172MM-040007 PISTON PIN 152MI-040011...
  • Page 38: Valve Trannyassy.(1)

    PARTS MANUAL Fig. 7 VALVE TRANNY ASSY.(1) VALVE TRANNY ASSY.(1) REF NO. PART NO. DESCRIPTION REQ’D NO. 152MI-022500 VALVE TAPPET SEAL 172MM-022300 VALVE CAM 152MI-021007 ROCKER 172MM-022001 INLET VALVE 172MM-022005 EX. VALVE 172MM-022002 OUTER VALVE SPRING 172MM-022003 INNER VALVE SPRING 152MI-022005 SPRING VALVE DISC 152MI-022001...
  • Page 39 PARTS MANUAL VALVE TRANNY ASSY.(2) Fig. 8 VALVE TRANNY ASSY.(2) REF NO. PART NO. DESCRIPTION REQ’D NO. 172MM-022200 TIME CHAIN 172MM-023200 TENSIONER (LOWER) 172MM-023001 CHAIN GUIDE PLATE (UPPER) GB96-85-6-D. Zn BIG WASHER GB/T5781-2000 HEX FLANGE BOLT M6 x 12...
  • Page 40: Left Side Cover Assy

    PARTS MANUAL Fig. 9 LEFT SIDE COVER ASSY. LEFT SIDE COVER ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. 172MM-012001 LEFTSIDE COVER 172MM-012007 LEFT SIDE COVER SEAL 172MM-012004 PLATE 172MM-012003 FLANGE BOLT 152MI-012200 SHOCK ABSORPTION BLOCK ASSY. 152MI-011007 DOWEL PIN 010 x 16 OIL DISCHARGE BOLT VISION HOLE 172MM-012008 GBT818-2000-...
  • Page 41: Water Pump Assy

    PARTS MANUAL WATER PUMP ASSY. Fig. 10 WATER PUMP ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. 172MM-080004 WATER PUMP IMPELLER 152MI-081000 WATER SEAL 172MM-080003 WATER PUMP HOUSING 172MM-080002 WATER PUMP HOUSING SEAL 172MM-080001 WATER PUMP SHAFT 152MI-013009 FLANGE BOLT M6 x 40 152MI-02017 FLANGE BOLT M6 x 25 GBT893 1-86-19...
  • Page 42: Carburetor Comp

    PARTS MANUAL F i g . 11 CARBURETOR COMP. CARBURETOR COMP. REF NO. PART NO. DESCRIPTION REQ’D NO. 172MM-100000 CARBURETOR COMP...
  • Page 43: Oil Pump Assy

    ARTS MANUAL OIL PUMP ASSY. Fig. 12 OIL PUMP ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. 152MI-071000 OIL PUMP ASSY. 152MI-071002 OIL PUMP 152MI-071003 OIL PUMP COVER PLATE 152MI-071001 OIL PUMP SHAFT 152MI-070001 OIL PUMP SPROCKET 152MI-073000 OIL PUMP CHAIN 152MI-071004 INNER OIL PUMP ROTOR 152MI-071005...
  • Page 44: Clutch Assy

    PARTS MANUAL Fig. 13 CLUTCH ASSY. CLUTCH ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. 172MM-052500 OUTER WHEEL CLUTCH 172MM-052400 DRIVEN DISC 172MM-052003 SIDE DISC 172MM-052006 CLUTCH RETURN SPRING 172MM-052600 CENTRIFUGAL BLOCK GB/T8931-86-28 CIRCLIP 172MM-052700 DRIVE BELT 172MM-052300 DRIVEN WHEEL 172MM-052100 MOVABLE DRIVEN WHEEL 172MM-052002...
  • Page 45: Electric Starter Assy

    PARTS MANUAL Fig.14 ELECTRIC STARTER ASSY. ELECTRIC STARTER ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. 172MM-090001 DOUBLE GEAR 172MM-092000 DRIVEN GEAR 172MM-091000 DOUBLE-GEAR 172MM-090007 FIX PLATE 172MM-093000 START MOTOR 152MI-080013 FLANGE BOLT M6’22 172MM-090008 FLANGE BOLT M6*14...
  • Page 46: Reduction Box Assy

    PARTS MANUAL REDUCTION BOX ASSY. Fig. 15 REDUCTION BOX ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. 172MM-062000 VENTILATION PIPE 172MM-060009 REDUCTION BOX CAP 172MM-061000 REDUCTION CASE CAP SEAL 172MM-060001 CHIEF SHAFT 172MM-060003 SECONDARY SHAFT 172MM-060006 SECONDARY GEAR SHAFT 172MM-060007 OUTPUT SHAFT 172MM-060008 OUTPUT GEAR...
  • Page 47: Gearbox Assy

    PARTS MANUAL GEARBOX ASSY. Fig. 16 GEARBOX ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. 172MM-051004 SLIDE BLOCK 172MM-051005 DRIVE WHEEL 172MM-051003 DRIVE WHEEL BUSH 172MM-051100 MOVABLE DRIVE WHEEL 172MM-051200 CENTRIFUGAL ROLLER 172MM-051001 DRIVE WHEEL CAP 172MM-051002 SLOPE PLATE GB3452 1-82 O-RING GB9074 14-88 FLANGE BOLT...
  • Page 48: Magneto Comp

    PARTS MANUAL MAGNETO COMP. Fig. 17 MAGNETO COMP. REF NO. PART NO. DESCRIPTION REQ’D NO. 172MM-094000 CLUTCH 172MM-033000 IGNITION COIL 172MM-013008 WIRE PLATE 172MM-031000 FLYWHEEL 172MM-032000 STATOR GB/T70 1-2000 INNER HEX FLANGE BOLT M8 X 18 172MM-040001 NUT M16x 1 172MM-040002 WASHER 16.3x30x2 152MI-030002...
  • Page 49: Frame Group

    Fig. 18 FRAME GROUP...
  • Page 50 PARTS MANUAL FRAME GROUP REF NO. PART NO. DESCRIPTION REQ’D NO. 6.000.061 C.B.C. CROSS BAR. FR (B.R.S.) 8.070.034 C.B.C. BAR CAGE (B.R.S.) 8.080.033 C.B.C. CROSS BAR, RR (B.R.S.) 8.070.035 C.B.C. BAR, L./R. SIDE (B.R.S.) 2.000,045 FRAME COMP. (B.R.S.) 8.010.047 R-WASHER 9.908.050N SOCKET BOLT M8 x 1.25 x 50 9.908.055N...
  • Page 51: Steering Shaft Assy

    Fig. 19 STEERING SHAFT ASSY.
  • Page 52 PARTS MANUAL STEERING SHAFT ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. 7.010.041 STEERING BOLT COVER 9.100.612 BOLT STRAP M6x12 8.030.024 SPINDLE BRACKET 7.020.038 STEERING WHEEL STEERING SHAFT 6.000.122 7.010.026 STEERING SHAFT BUSH 9.700.020 SPECIAL WASHER Φ20 9.700.120 CIRCLIP Φ20 9.100.825 BOLT M8 x 25 9.400.008...
  • Page 53: Front Suspension Arm Assy

    Fig. 20 FRONT SUSPENSION ARM ASSY.
  • Page 54 PARTS MANUAL FRONT SUSPENSION ARM ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. STRUT AND SPINDLE SUPPORT, R. 2.000.028 9.108.105 BOLT-WASHER M8 x 1.25 x 105 8.010.015 UPPER SUSPENSION ARM COLLAR 7.010.003 UPPER SUSPENSION ARM BUSH 4.000.004 UPPER SUSPENSION ARM 9.220.008 LOCKING FLANGE NUT M8 9.800.012...
  • Page 55: Full Shifting Assy

    FULL SHIFTING ASSY. Fig.21...
  • Page 56 PARTS MANUAL FULL SHIFTING ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. 9.110.020 BOLT-WASHER M10x20 9.110.100 BOLT-WASHER M10 x 100 6.000.240 GEAR BOX SUSPENSION ARM 8.010.168 COLLAR #1 9.112.230 BOLT-WASHER M12x1.25x230 6.000.239 PIVOT ARM SHIFT C 7.020.068 CUSHION BUSH 9.220.012 LOCKING FLANGE NUT M12 8.010.167 COLLAR #2...
  • Page 57: Rear Cargo Rack/ Seat/ Belt

    REAR CARGO RACK / SEAT / BELT Fig. 22...
  • Page 58 PARTS MANUAL REAR CARGO RACK/ SEAT/ BELT REF NO. PART NO. DESCRIPTION REQ’D NO. 9.090.005 TAIL LIGHT BULB 21W/5W 12V 6.000.144 TAIL LIGHT 9.210.006 LOCK NYLON NUT M6 2.000.046 REAR CARGO RACK (B.R.S.) 6.000.111 REAR SIDE REFLECTOR ® 8.010.171 LUG NUT 7.020.032 TUBE COVER 6.000.241...
  • Page 59: Air Cleaner/ Radiator/ Battery/ Muffler Assy

    FIG.23 AIR CLEANER/ RADIATOR/ BATTERY/ MUFFLER ASSY.
  • Page 60 PARTS MANUAL AIR CLEANER/ RADIATOR/ BATTERY/ MUFFLER ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. 7.090.035 AIR CLEANER DUCT 7.090.036 AIR CLEANER CLAMP 7.090.037 AIR CLEANER CASE COMP. 7.090.038 AIR CLEANER ELEMENT 7.090.039 AIR CLEANER COVER 9.805.003 TAPPING SCREW M5 x 16 7.090.040 AIR CLEANER GAUZE COVER 7.090.041...
  • Page 61: Gear Box Assy

    GEAR BOX ASSY. FIG.24...
  • Page 62 PARTS MANUAL GEAR BOX ASSY. REF NO. PART NO. DESCRIPTION REQ’D NO. 9.040.012 DUST SEAL Φ56x35x 10 9.030.011 BEARING RADIAL BALL E6007 7.090.001 WAHSER Φ45x35x2 7.090.002 KEY STOCK 7.090.003 FINAL SHAFT 7.090.004 FINAL GEAR 9.030.002 BEARINGN RADIAL BALL E6204 7.090.005 WAHSER Φ35 x 20.5 x2 7.090.006 COUNTER GEAR A...
  • Page 63: Rear Suspension Assy

    REAR SUSPENSION ASSY. FIG.25...
  • Page 64 PARTS MANUAL REAR SUSPENSION ASSY REF NO. PART NO. DESCRIPTION REQ’D NO. 7.020.039 RR. HUB COVER 9.500.430 COTTER PIN $4 x 30 9.800.018 CASTLE NUT M18 8.010.118 LUG NUT CAP M10 6.000.143 RIM. RR. 8.010.169 REAR WHEEL HUB 9.710.031 TIRE BOLT Ml Ox 1.25x31 9.030.007 BEARING 6007 8.010.170...
  • Page 65: Wire Harness/Electrical

    WIRE HARNESS / ELECTRICAL...
  • Page 66 PARTS MANUAL WIRE HARNESS / ELECTRICAL REF NO. PART NO. DESCRIPTION REQ’D NO. 9.100.630 BOLT M6 x 30 9.200.006 NUT M6 6.000.250 REGULATE RECTIFIER COMP. 9.600.615 PAN SCREW M6 x 15 9.300.006 WASHER Φ6 9.210.005 LOCKING NYLON NUT M6 7.010.038 SWITCH PANEL COVER 7.010.061 BOLT COVER...
  • Page 67 LABEL. NO LONG HAIR 9.090.011 LABEL. WARNING 9.090.012 LABEL. NO CLIMBING 9.090.013 LABEL. WARNING 9.090.014 LABEL. SEAT BELT 9.090.024 LAB EL. RADIATOR 9.090.016 LABEL. TWISTER 9.090.017 LABEL. WARNING 9.090.025 LABEL. HAMMERHEAD 250 9.090.026 LABEL.HAMMERHEAD 250 R.SIDE 9.090.027 LABEL.HAMMERHEAD 250 L.SIDE...

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