Prime Karts XL-4 Assembly And Maintenance

Hide thumbs Also See for XL-4:

Manual (12 pages)

page of 26

/ 26
Bookmarks

Quick Links

Download this manual

PRIME Karts XL-4 and XL-4 PRO Assembly and Maintenance

For 2025 PRIME Karts models:

XL-4

XL-4 PRO

- Ranger

- Charger

- Trailblazer

- Agri-Trac

- Blizzard

- PK Diesel

- Baja

- Nitro

- XL-4 PRO

- Stinger

custom graphics

- Stealth

- Daisy

PRIME Karts XL-4 Stealth model shown

Scan QR for link to assembly

and maintenance guide

Need help?

Do you have a question about the XL-4 and is the answer not in the manual?

Questions and answers

Summary of Contents for Prime Karts XL-4

Page 1 PRIME Karts XL-4 Stealth model shown - Baja - Nitro - XL-4 PRO - Stinger custom graphics Scan QR for link to assembly and maintenance guide - Stealth - Daisy PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 2 Thank you for your purchase of the PRIME Karts XL-4 series pedal kart! These step-by-step instructions will guide you through the assembly and set up of your new PRIME Kart so you can be safely riding in no time. PRIME Karts assembly must be performed by an adult.
Page 3 Tools needed: - 13mm wrench - 17mm wrench - 19mm wrench - Adjustable wrench - Phillips screwdriver - Rubber hammer - 5mm Allen wrench (PRO model only) PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 4 - Seat bracket - Seat - Hand brake - Steering shaft - Rear drive axle - Rear coast axle - Back Bumper PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC *ONLY FOR XL4 PRO model)
Page 5 - Front connection hardware cup lines up with the outer plate. Reinstall and tighten the 2 bolts that were removed. PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 6 Thread the short bolt (DD from hardware set) in the bottom hole. Tighten both bolts. PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 7 Once the axle is fully engaged, the (see F1). bearing carrier will be flush with the fender bracket Reinstall and tighten the 2 bottom bolts. (see F2). PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 8 LEFT fender bracket assembly set and tighten mounting holes line over the left side of the with a 13mm wrench hand brake rod end. PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 10 Once both rear wheels are hub and axle are lined up, a rubber hammer can be on the axles, reinstall the axle used to seat the wheel. bolts and tighten PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 11 Once the bolt is through both the seat and seat bracket, install the washer and nut then tighten using a PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC 13mm wrench...
Page 12 If the bolt will not go all the way in as shown, move the install nut and tighten with 19mm wrenches. inner tube forward until the bolt fully engages and tighten. PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 13 13mm assembly, reinstall hardware and tighten. wrench. NOTE: Make sure steering brace faces forward as shown in the picture. PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 14 Tighten using (2) 19mm head and the inside tab.). Tighten wrenches (or 19mm and each bolt with a 13mm wrench adjustable wrench.) PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 15 Phillips steering brace. Reinstall the bolts that were removed in end connection and screwdriver. step 17 and tighten using a 13mm wrench. tighten. PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 16 Slide the wheel over the front axle and reinstall wheel. Reinstall the bolt in the center of the steering wheel and the axle bolt and tighten. tighten. PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 17 The XL-4 PRO model includes a PRIME place using a rubber hammer. hammer. Karts visibility flag. With the standard XL-4 model, the visibility flag is optional. PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 18 Allen wrench and a 13mm wrench. Install the and tighten using a shorter bolts (nut and washer on top side) and 5mm Allen wrench and tighten all hardware. a 13mm wrench. PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 19 PRIME Karts XL-4 and XL-4 PRO set up and safety check Now that your new PRIME Karts XL-4 is assembled, there are a few maintenance and safety checks that will need to be performed before riding it for the first time.
Page 20 PRIME Karts XL-4 and XL-4 PRO safety guidelines • The XL-4 and XL-4 PRO are designed for riders from 8 years old through adult with a max weight limit of 275# (350# for the XL-4 PRO). It is the rider or supervising adults responsibility to determine if the PRIME XL-4 is appropriate for the rider including safety gear such as a helmet •...
Page 21 PRIME Manufacturing Group, LLC overhaul manual. If you have questions, please 9235 Roe St contact PRIME Karts or your authorized dealer. Pensacola, FL 32514 Phone: 850-475-0450 Email: info@primekarts.com PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 22 6 months 80 hours Inspect Steering Alignment 6 months or as needed 20 hours Grease Front Axles and Steering Shaft Yearly 100 hours Lubricate Chains Yearly 100 hours PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 23 If it is too tight, the kart will be hard to pedal and components will Inspect the tires and wheels for damage, wear and wear prematurely cracking. Replace immediately if needed. PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 25 Use general purpose grease and a grease gun to add grease to the fittings. Wipe off excess grease when complete. PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
Page 26 If they are not, turn ONLY the drag bar rod to move that wheel in or out. Repeat on the opposite side until the measurement is the same, inside to inside tire for the front and back. Once the alignment is set, re-tighten the (4) jam nuts. PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...

This manual is also suitable for:

Xl-4 pro