Download
Share
Print this page
  1. Manuals
  2. Brands
  3. Prime Karts Manuals
  4. Utility Vehicle
  5. TRACKER XXL-4
  6. Assembly and maintenance

Prime Karts TRACKER XXL-4 Assembly And Maintenance

Hide thumbs Also See for TRACKER XXL-4:

Advertisement

Quick Links

Download this manual
PRIME Karts XXL-4 TRACKER Assembly and Maintenance
For 2025 PRIME Karts models:
XXL-4
TRACKER
Scan QR for link to PRME Karts resource page
for assembly/ maintenance guide and parts list
PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC

Advertisement

loading
Need help?

Need help?

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

Questions and answers

Related Manuals for Prime Karts TRACKER XXL-4

Summary of Contents for Prime Karts TRACKER XXL-4

  • Page 1 PRIME Karts XXL-4 TRACKER Assembly and Maintenance For 2025 PRIME Karts models: XXL-4 TRACKER Scan QR for link to PRME Karts resource page for assembly/ maintenance guide and parts list PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 2 Thank you for your purchase of the PRIME Karts XXL-4 TRACKER 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 Box 2 also include front graphics plate that has been removed to show other contents of the box Note the direction of the arrow on box #1 PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 4 - Drive wheels (plus front spare) - Steering wheel - Steering shaft - Grab handle assembly - Right rear drive assembly - Left rear drive assembly - Front graphics plate PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 5 Slide (I) left hand brake assembly through the top left hole in (D) rear frame connector. Lift the back of the silver parking brake cam to expose the top hole PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 6 (D) rear frame connector. Thread the (2) bolts in the top holes and the (2) nuts on to the bottom studs. DO NOT TIGHTEN. Repeat this on (T) the right side. PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 7 NOTE: The spare wheel will not have a busing or bearings back. Slide the left (J) brake into the right brake arm (I). Install the washers and lock nuts and tighten. PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 8 PRIME Karts XXL-4 Tracker Assembly Instructions Install (N) rear fenders Install (C) seat frames to (M) seats Lift the parking brake handle and slide the fender side slot on the fender support bracket. A rubber hammer can be used to tap the fender into place.
  • Page 9 (S) and (T). Install bolt (GG), flat washer and lock nut. position and stand the rear drive assemblies up so DO NOT TIGHTEN. they are resting on the back of the seat. PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 10 EACH left crank arm, the pedal marked R will be installed on each right crank. The pedal marked L will thread into the left crank arm counterclockwise. The pedal marked R will thread into the right crank arm clockwise PRIME Karts XL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 11 13mm wrench. Slide the end connection into the right side end connection tube and line up the holes. Using a 6mm Allen wrench, thread the bolt that was removed into the end connection and tighten. PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 12 (R) bracing rod. Reinstall the nut and bolt and tighten using a 5mm Allen wrench a 13mm wrench. Install the bolt and washer into the end of (R) through the end connection and tighten with a 13mm wrench. PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 13 (E) connector tube. Thread the bolt from the bottom into the end connection and tighten using a 6 mm Allen wrench. Install the flat washer and lock nut and tighten using a 19mm wrench. PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 14 Tighten all hardware for components assembled to this point. 1. Rear frame assembly to connector tubes (2 bolts and lock nuts) 2. Bracing rod mounting bolts (4). 3. Right and left rear assemblies to rear frame connector (4 bolts, 4 nuts) PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 15 Remove the nut and bolt from the pivot tube spacer bushing and remove the busing from the tube. Next, Install (FF) front pivot bushing over (G) front pivot tube. PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 16 (FF) front pivot bushing over the end of (G) front pivot tube. Slightly lift (K) front axle assembly again and slide the pivot spacer busing over the end. Reinstall the bolt, washer and locknut and tighten using a 13mm wrench and 5mm Allen wrench. PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 17 The bolt must be completely threaded in. If the bolt will not completely thread in, slightly pivot (K) front axle assembly until the bolt threads completely. PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 18 Reinstall the washer and lock nut using Reinstall the axle bolt and washer and tighten using a 17mm wrench. a 13mm open end wrench and a 17mm PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 19 Reinstall the bolt Zurk grease fitting is facing down. Reinstall the bracket bolts and and washer and tighten using a 13mm wrench. washers but DO NOT TIGHTEN PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 20 Repeat this with (DD) front plate mounting bracket screws and tighten the 4 screws with a Phillips screwdriver. Tighten the 4 (DD) mounting bolts with a 5 mm Allen wrench. PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 21 (P) steering wheel. Using a rubber hammer, tap the steering wheel cap until it is seated. PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 22 PRIME Karts XXL-4 Tracker 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. 1. Set the seat position (1-6) for the rider’s height. To adjust the seat, simply pick it up and move it to the appropriate square hole.
  • Page 23 • ABOVE ALL, USE COMMON SENSE AND KNOW YOUR LIMITS or the limits of those being supervised Have fun and enjoy your new PRIME Karts XL-4 series pedal kart! PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 24 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 XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 25 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 XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 26 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 XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 27 PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 28 Use general purpose grease and a grease gun to add grease to the fittings. Wipe off excess grease when complete. PRIME Karts XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...
  • Page 29 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 XXL-4 Assembly and Maintenance l © 2025 PRIME Manufacturing Group, LLC...