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Masters of motion Fun Kart Owner's/Operator's Manual

Clutch and torque converter models
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FUN KART
Owner's/Operator's Manual
Clutch and Torque Converter Models
WARNING: Read Engine Owner's Manual, Vehicle Operator's Manual and any Supplements
Carefully and View "Operations
and Safety" Video Before Operating Vehicle.
- Assembly
• Operation
• Maintenance
• Warranty
THIS VEHICLE
IS FOR OFF-ROAD
USE ONLY.
THIS VEHICLE
IS NOT DESIGNED
FOR USE ON RENTAL TRACKS
OR RACING.
BEFORE OPERATING
THIS VEHICLE, THE OWNER AND EACH OPERATOR
MUST UNDER.
STAND THIS VEHICLE WAS NOT DESIGNED
OR MANUFACTURED
TO MEET SPECIFICATIONS
FOR USE ON PUBLIC ROADS, STREETS,
HIGHWAYS, AND THOROUGHFARES+THE
OWNER
AND EACH OPERATOR
MUST READ AND UNDERS'fAND
ALLTHE
INSTRUCTIONS
FOR PROP-
ER ASSEMBLY
AND SAFE OPERATION,
AS WELL AS THE INSTRUCTIONS
CONCERNING
THE
ENGINE AND ALL OTHER PORTIONS
OF THE VEHICLE. CHILDREN
MUST BE OF AGE 8 OR
OLDER AND SUPERVISED
BY AN ADULT AT ALL TIMES WHEN USING THE FUN-KAR I.
Part Number 12834
1/1/03

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Summary of Contents for Masters of motion Fun Kart

  • Page 1 FUN KART Owner's/Operator's Manual Clutch and Torque Converter Models WARNING: Read Engine Owner's Manual, Vehicle Operator's Manual and any Supplements Carefully and View "Operations and Safety" Video Before Operating Vehicle. - Assembly • Operation • Maintenance • Warranty THIS VEHICLE IS FOR OFF-ROAD USE ONLY.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SAFETY ................Important Rules for Safe Operation ............. Terminology ............... Qualifications for Fun-Kart Users ............Consumer Responsibility for Safe Use and Maintenance of Fun-Karts ......MANGO POWERSPORTS, LIMITED WARRANTY ........COMBINATION LAP AND SHOULDER BELT RESTRAINT SYSTEM ......
  • Page 3 Chassis a ndSteering ............Decals ..............-..Brake Service..............DiscBrake..............Band/Drum Brake.............. Throttle C able..............Inspection ..............Throttle C able Housing A djustment ..........Battery ................Light B ulbs ..............Replacement Bulbs .............. Head/Tail Light F use.._............Replacement Fuse .............

  • Page 4: Safety

    SAFETY -[his is the safety alert symbol. When you see _1_ WARNING: Indicates a potentiai hazard this symbol on your machine or in this manual, be which could result in severe personal injury or death. alert to the potential for personal injury. _Read and follow all instructions in this ,_1_ CAUTION: Indicates a potential hazard which...
  • Page 5 _1= WARNING: Be sure the passenger restraint WARNING: Operator (and any passenger) of this Fun-Kart MUST always wear a properly system is properly adjusted and fastened at all fitting motorcycle type helmet approved by times during operation. agencies such as the Department of If the passenger restraint system is not properly Transportation (DOT), Safety Helmet Council used by the operator and/or passenger, loss of...
  • Page 6 WARNING: ALWAYS SLOW DOWN when ,_k WARNING: Excessive Fun-Kart speed is turning. potentially dangerous to operator, passengers and others. • High-speed turning can cause loss of control, possible Fun-Kart turn-over and/or possible WARNING: Check fuel supply before each operator and/or passenger injury. use.
  • Page 7 WARNING: Read and keep all supplied CAUTION: NEVER operate Fun-Kart while printed material. under the influence of alcohol, drugs or medication of any kind. Supplements to this Operator's Manual contain updated information relative to your specific Fun- • Such operation is dangerous to yourself and/or Kart model.

  • Page 8: Terminology

    Terminology Axle Guard - a device, which covers the drive agencies such as the Department ef axle on Fun-Karts, so that the possibility of injury Transportation (DOT), Safety Helmet Council of resulting from hand, hair, loose clothing or body America (SHCA) or Snell Memorial Foundation part contacting the axle is reduced.

  • Page 9: Consumer Responsibility For Safe Use And Maintenance Of Fun-Karts

    Consumer Responsibility for Safe Use and Maintenance of Fun-Karts Fun-Karts shall not be modified from the n. That tires are in good condition, inflated manufacturer's original design and configuration. properly, and have sufficient tread remaining; Fun-Karts shall not be used to perform racing, stunt riding, jumps, spin-outs, donuts or other o.
  • Page 10 b. Passengers (intwo-seat Fun-Kart) shall d. Persons with any mental or physical remain s eated witharms andlegsinside the conditions, which may make them Fun-Kart ata!ltimes during Fun-Kart susceptible to injury or impair their physical operations; dexterity or mental capabilities to recognize, understand, and perform all of the safety c.

  • Page 11: Mango Powersports, Limited Warranty

    MANCO POWERSPORTS LIMITED WARRANTY LIMITED WARRANTY Manco PowerSports (hereinafter referred to as "Manco') hereby warrants to the original purchaser that the frame and components of the new Manco vehicle will be free from defects in materials and workmanship. The period of the warranty is thirty (30) days from the date of purchase for the component parts (except as noted below), and for a period of ninety (90) days from the date of purchase for the frame.

  • Page 12: Combination Lap And Shoulder Belt Restraint System

    COMBINATION LAP AND SHOULDER BELT RESTRAINT SYSTEM COMBINATION LAP AND SHOULDER BELT Find the long strap of the restraintsystem (1A and 1B) and pull it across the shoulder, chest RESTRAINT SYSTEM USE AND and lap inserting the metal tongue (2), on the MAINTENANCE strap, into the buckle (3) until it is securely latched.
  • Page 13 Combination Lap and Shoulder Belt Restraint System 5. Adjust the shoulder part of the belt (1A) by pulling Inspection: down on the free end of the shoulder belt (6). Make sure that all of the webbing has been 1. Each time before operating the kart: unwound from the web winder (4) and that the Inspect the webbing of the restraint system(s) belt is snug across the shoulder and chest with...
  • Page 14 The web winder(s) and or webbing may require _1_ WARNING:The proper functioning of the periodic cleaning to ensure that they wind up the web winder(s) and plastic sleeves on the belts webbing located above the adjuster. That can be are critical to minimizing the possibility of the accomplished by flushing them out with water and belts being outside the kart and becoming drying.

  • Page 15: Safety Flag

    SAFETY FLAG WARNING: The Safety Flag is added to this kart for off-road visibility ONLY. It is provided, and required, for increased visibility, especially on hilly terrain and is required by law in many states. ASSEMBLY INSTRUCTIONS Attach Safety Flag to the back of the headrest mounting strap using the bolt provided in the parts bag for mounting the Headrest Pad.

  • Page 16: Pre-Ride Inspection

    PREoRIDE INSPECTION Before riding the FumKart, inspect all operating Inspect the Fun-Kart before each riding to make sure controls and parts, it is in proper working order. Allow the engine to cool before adding oil or refueling. _1= WARNING: If proper inspection is not performed, serious injury or death can result.

  • Page 17: Engine Stopped Inspections

    Engine Stopped Inspections (See Figure 1) INSPECTION PROCEDURE ACTION ITEM Refer to Engine Owner's Manual. Engine Oil Level Add oil if required Check for leaks. Tighten filler cap securely. 2. I Refer to Engine Owner's Manual. Fuel Level Add fuel as necessary. DO NOT refuel a hot engine.

  • Page 18: Engine Started Inspections

    ITEM ACTION INSPECTION PROCEDURE Brush Bars Make sure all brush bars are in Replace damaged bars or fasieners and place and securely attached. tighten as necessary. Steering Make sure steering turns freely, Lubricate/Adjust as necessary, See MAINTENANCE-CHASSIS. Check for proper "toe-in" of Lubricate/Adjust as necessary, See wheels.

  • Page 19: Operation

    OPERATION Brake (2) _1_ WARNING: Prior to operating the Fun-Kart, review the assembly instructions to make sure The brake is controlled by the left side foot pedal. the Fun-Kart has been assembled properly. Push the pedal to apply the brake. Operating Controls (See...

  • Page 20: Clutch

    the clutch bearing in two or three hours of operation. The brake pedal is latched by pushing down the Slipping can occur by riding at slow speeds with high brake pedal and raising the latch so its notch (a) fits engine RPM such as trying to climb hills, pulling on the pedal bushing (b).

  • Page 21: Operating Instructions

    Operating Instructions Before operating the Fun-Kart, be sure to read and Use a tire pressure gauge during the. removal or follow all the WARNINGS, CAUTIONS and addition of air as necessary to achieve proper tire instructions on the preceding pages. pressures.

  • Page 22: Seat Adjustment

    BRAKE TEST WARNING: DO NOT use the parking brake unless the following test is satisfactorily _!1_ WARNING: DO NOT operate this Fun-Kart performed. unless the brake is working properly. 1. Set parking brake and clear a path ahead of the Fun-Karl.

  • Page 23: Passenger Restraint System And Handhold

    MKOO4A Figure 4. Seats with Seat Slides & Fixed Seats Passenger Restraint System and Handhold WARNING: Passengers must keep all parts (See Figure 5) of their body within the seat and frame. Failure to do so could result in personal injury. WARNING: A passenger is only permitted in specially designated DOUBLE SEAT KARTS.

  • Page 24: Operation

    MK005B MK065A Figure 5. Passenger Restraint System and Handhold Operation CAUTION: Person starting the engine should STARTING note direction of engine exhaust flow. Failure to keep clear of exhaust flow may cause skin and 1. Make sure properly functioning parking brake is eye irritation.

  • Page 25: Turning

    STOPPING WARNING: DO NOT operate Fun-Kart if the Release the throttle to return the engine speed to idle. engine stop switch is not functional. Apply the brake pedal to stop the Fun-Kart's motion. RUNNING Turning (See Figure 6) Operate the Fun-Kart in a large, level, open space in order to learn to start, steer and stop properly.

  • Page 26: Slippery Surfaces And Skids

    1. If the front wheels tend to skid in mud, sand or Therefore, when turning, the inside wheel may lose snow, you may be able to improve control by traction slightly. The new rider must learn to shift releasing the throttle and allowing the Fun-Kart to weight and control the throttle to allow the rear tires coast through the turn.

  • Page 27: Maintenance

    MAINTENANCE Tool List CAUTION: When making repairs or 10 mm combination wrench for battery cable adjustments to the Fun-Kart which do not involve bolts. engine adjustments, the spark plug wire must be disconnected and kept away from the spark plug 3/8"...

  • Page 28: Engine Service

    Drive Components WARNING: All Iocknuts must have full thread Chains (See Figure 8) engagement. For any Iocknut to function properly, threads must extend completely through and at The Fun-Kart may be equipped with one or more least three threads beyond the Iocknut. chains to drive the rear wheels.
  • Page 29 LUBRICATION INSPECTION Use proper lubricants. Remove guards covering drive components. Install new guards if damaged. [CO__MP_ONENT !LUBRICANT At the center point between the two sprockets, push and pull the chain and note total flex. If flex RollerChains / Spray-on graphite based chain lubricant is more than 1/2", adjust chain.
  • Page 30 ADJUSTMENT 4. Be sure clutch (2) and drive wheel sprockets (3) are aligned. CLUTCH KARTS (See Figure 9) 5. Securely tighten the four engine bolts. 6. Recheck chain tension. Refer to INSPECTION. 1. Remove guards covering drive components. 2. Loosen, but do not remove, the four engine 7.
  • Page 31 INSTALLATION CHAIN REPLACEMENT (See Figure 10) 1. Install new chain. REMOVAL 2. Slide the pin portion of the master link (3) in to 1. Remove guards covering drive components. each end of chain to be connected. 2. Rotate drive wheel to place master link (3) in 3.

  • Page 32: Clutch

    If the clutch starts "slipping" see your dealer for Clutch (SeeFigure 11) maintenance. Oiltheclutch bearing a fter each ride, using 30W motor oil. © MKO09 Figure 11. Oiling the Clutch Bearing...

  • Page 33: Torque Converter

    If any of these conditions exist on the Kart, the Torque Converter (See Figure 12) torque converter components and/or the drive chain NOTE: it is recommended that torque converter must be serviced immediately. Both clutch and driven maintenance beyond inspection and belt replacement pulleys must be disassembled and cleaned be performed by your dealer.

  • Page 34: Chassis A Ndsteering

    Weekly, grease the steering spindles and brake Chassis and Steering linkage assembly (if equipped with grease fittings) as LUBRICATION (See Figure 13) shown. Use multi-purpose grease and a standard grease gun. Grease should be added until it is Every two or three hours of use lubricate the coming out of the ends of the spindles and the brake following items with several drops of automotive SAE linkage assembly.
  • Page 35 2. Loosen t hefour jamnuts (1)onthetie rods(2) FRONT WHEELALIGNMENT (SeeFigure 14) andmove them away fromthetie rodends. ThisFun-Kart is equipped withthreaded t ierodsso 3. Rotate bothtierodsequally t oadjust " toe-in." thefrontwheel a lignment may beadjusted. Thefront Make surethewheels a rebothpointed straight wheels should be"toed-in"...
  • Page 36 WHEELREPLACEMENT 2. Jack up the Fun-Kart to raise the wheel off the ground. TheFun-Kart may beequipped w ithspindle a nd/or 3. Remove spindle nut and replace wheel. lugmounted w heels, Usethefollowing p rocedure for wheel r eplacement. 4. Install spindle nut finger tight. 5, Lower the Fun-Karl to the ground.
  • Page 37 4. Install lug nuts (cone side towards wheel) finger LUG MOUNTED WHEELS (See Figure 16) tight. 1. With the Fun-Kart on the ground, loosen all lug 5. Lower Fun-Kart to the ground. nuts (1). 6. Tighten tug nuts in a criss-cross pattern to 80 ft Ib 2.

  • Page 38: Decals

    3. Check that the caliper assembly (1) slides freely Decals in the mounting bracket (2) and caliper actuator lever (3) moves freely. Clean and lubricate as _1_ WARNING: Safety decals must be replaced if required. they become unreadable or detached from the 4.
  • Page 39 MK013a MK013b Figure 17. Disk Brake...
  • Page 40 BRAKEPADREPLACEMENT (SeeFigure 18) high temperature grease and replace the actuator pin into the brake housing spherical end first. WARNING: Do not perform maintenance of Place the backing plate into the brake housing then place the new brake lining on top of the brake rotor, pads or calipers until the parts have backing plate.

  • Page 41: Band/Drum Brake

    The brake rod (1) can be shortened by removing Band/Drum Brake the hex head bolt that holds the brake rod (2) on the brake pedal (3), reassembling the bolt in the WARNING: DO NOT operate this Fun-Kart if rear hole of the brake rod and tightening the nut. the brake system wig not properly stop the Fun- Kart.
  • Page 42 BAND REPLACEMENT (See Figure 20) _1_ WARNING:The guard(s) must be in place to 1. Remove the guard covering the brake band. protect the rider(s) from the rotating parts of the Fun-Kart. DO NOT operate the Fun-Kart without 2, Remove cotter pin (1) and clevis pin (2) from the the guards securely in place.

  • Page 43: Throttle Cable

    Throttle Cable 4. Screw the rear jam nut (1) against the frame. 5. Tighten the front jam nut (2) securely. Inspection 6. Make sure the engine throttle linkage is in the idle position and the throttle pedal is against the rear The throttle cable hQusing may need to be adjusted stop.

  • Page 44: Battery

    Battery (See Figure 22) _b_ WARNING: The battery may generate explosive gases after filled with acid and during 1. Disconnect battery cables. charging or use. Keep flammable materials away 2. Remove the wing nuts (1) and lift off the battery from the battery.

  • Page 45: Light Bulbs

    Light Bulbs Head/Tail Light Fuse If both the head light and tail light are n_)tworking To replace the head or tail light bulb, remove the check and replace the fuse if necessary. Locate the screws and lens from the housing. To remove the inline type fuse holder on the wiring harness between bulb, push bulb in and rotate counterclockwise.

  • Page 46: Storage

    STORAGE In the event the Fun-Kart won't be operated for a Removal from storage: After Fun-Kart has been in period in excess of 30 days or at the end of each storage, re-read Operator's Manual, Engine riding season prepare it for storage by following the Operator's Manual and perform storage instructionsin your Engine Operator's assembly/maintenance as necessary.

  • Page 47: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE SCHEDULE The maintenance intervals shown in the following schedule are based upon average riding conditions, Karts subjected to severe use, ridden in wet or unusually dusty areas require more frequent servicing. See Engine Owner's Manual for additional requirements, Check Each Ride 1.
  • Page 48 MKOigA MK019B Figure 23. Maintenance...

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