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Book 2 of 2
MODEL 5210 / AGES 13+ / 24 MPH MAX SPEED
5210 208cc FUN KART
OWNER'S MANUAL / PARTS GUIDE
15362R1
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 UNDERSTAND 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 UNDERSTAND ALL THE INSTRUCTIONS FOR PROPER ASSEMBLY AND SAFE OPERATION, AS WELL AS THE
INSTRUCTIONS CONCERNING THE ENGINE AND ALL OTHER PORTIONS OF THE VEHICLE. CHILDREN MUST BE 13+ YEARS OF AGE FOR THIS VEHICLE AND SUPERVISED BY AN ADULT AT ALL TIMES WHEN USING
THIS FUN KART. SPEED REDUCTION KITS ARE AVAILABLE FOR ALL VEHICLES. THIS VEHICLE IS NOT A TOY.
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Summary of Contents for American Sportworks 5210
- Page 1 Book 2 of 2 MODEL 5210 / AGES 13+ / 24 MPH MAX SPEED 5210 208cc FUN KART OWNER’S MANUAL / PARTS GUIDE 15362R1 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 UNDERSTAND THIS VEHICLE WAS NOT DESIGNED OR MANUFACTURED TO MEET SPECIFICATIONS FOR USE ON PUBLIC ROADS, STREETS, HIGHWAYS AND THOROUGHFARES.
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Page 2: Limited Warranty
American SportWorks (hereinafter referred to as “ASW”) hereby warrants to the original purchaser that the frame components of new ASW fun karts will be free from defects in material and workmanship. The period of warranty is thirty (30) days from date of purchase for the component parts (except as noted below), ninety (90) days from the date of purchase for the frame, and one (1) year from date of purchase on select engines. -
Page 3: Table Of Contents
Electrical ................33 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST... -
Page 4: Forward
This vehicle is designed for for some reason, you did not receive these items please drivers and riders 13 years and older. contact American Sportworks or visit our website at www. amsportworks.com. For more information on American Sportworks and its WARNINGS AND CAUTIONS products visit our website at www.amsportworks.com. -
Page 5: Section 2 Operation
STOP SWITCH the process for the other Engine Stop Switch. With the engine running, turn the ignition key to the “OFF” position to shut down the engine. = RUN = STOP fig. F1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1... - Page 6 Use regular unleaded 87 octane gasoline with up to a 10% ethanol blend. b. This engine supplied with this Fun-Kart is NOT designed for Flex Fuel operation. 15362R1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST...
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Page 7: Kart Features And Locations
Kart Features and Locations Spoiler Manual Choke Whip Flag Stem Steering Wheel Park Brake Latch Fuel Tank Backup Recoil Start Air Filter Fuel Valve Fuel Tank Fuel Valve Air Filter Engine Stopswitch Backup Recoil Start 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1... -
Page 8: Replacement Parts
Take this manual and all supplements to the dealer when ordering parts in person. If replacement parts are not available from a dealer, they may be ordered directly from American Sportworks by contacting ASW at 1-800-643-7332 or online at www.amsportworks.com. -
Page 9: Air Cleaner
(see fig. G1) Remove cotter pin and castle nut. Wheel should be easily removed. After replacing the wheels, tighten castle nut and replace cotter pin with a new one. Replace rubber cover fig. G1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1... -
Page 10: Storage Instructions
To protect the paint, plastics and upholstery, it is a good idea to keep the unit covered when not in use. CAUTION Prevailing torque type locknuts must be replaced with new after the old locknuts are removed. 15362R1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST... -
Page 11: Cylinder
5210 ELECTRICAL SCHEMATIC ENGINE STOP SWITCH (MOUNTED ON ENGINE) STARTER ENGINE STOP SWITCH ENGINE MAGNETO 12V SWITCHED POWER (NOT USED) KEY SWITCH ENGINE GENERATOR WIRE COLOR CHART Black Green White Yellow BATTERY VOLTAGE REGULATOR 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1... -
Page 12: Frame Warning Labels
SECTION 4 illustrated parts lists 5210 SECTION 1 FRAME GROUP WARNING LABELS 15362R1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST... -
Page 13: Frame Group
14087 WASHER, CONCAVE CLAMP DAC 20a 15565 SCREW, M6 X 1.0 X 16 BUTTON HEAD SOCKET SS 14696 BOLT, M8 X 1.25 X 50 FHCS DAC 20b 15567 WASHER, M6 FENDER 14088 NUT, M8 X 1.25 LOCKING FLANGE ZN 15479 SPOILER, 5210 14466 NUT,1.75 THREAD DECORATIVE PLSTC FLG MNT 15480 HARNESS, MAIN WIRING - 5210 15474 BAR, OH FRONT - 5210 15113 COVER, BOLT CAP 15475 ENDCAP, BAR - 1.125” BLACK PLASTIC 15546 SEAL, BAR CONNECTION - 1.125” 14464 FLAG, SAFETY 15114 WASHER, BAR CONNECTION M8 X 24 X 1.25 (This item is intentionally left blank.) 14086 BOLT, M8 X 1.25 X 55 FHCS DAC 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1... - Page 14 15271 SWITCH, ENGINE STOP ROCKER 15485 BOLT, M12 X 1.25 X 25 FHCS DAC 15482 IGNITION SWITCH W/KEY - 5210 14451 BOLT, M10 X 1.25 X 25 FHCS DAC 14588 KEY SET (not shown) 15371 HEADREST - 5210 BLACK 15369 ASM, SEAT W/SLIDES - DRIVER 5210 15370 ASM, SEAT W/ NO SLIDES - PASS 5210 14440 BOLT, M8 X 1.25 X 40 HHCS DAC 15483 BOLT, M8 X 1.25 X 40 “T” STYLE DAC 14088 NUT, M8 X 1.25 LOCKING FLANGE DAC 14243 NUT, M10 X 1.25 LOCKING FLANGE DAC 14289 SPACER, M10 STEPPED SEAT BELT DAC 14451 BOLT, M10 X 1.25 X 25 FHCS DAC 8778 SEATBELT, RETRACTABLE W/ SLEEVE 14324 NUT, M12 X 1.25 LOCKING FLANGE DAC 15362R1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST...
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Page 15: Front Suspension
BOLT, M10 X 1.25 X 40 FHCS ZN 15542 PIN, M2.5 X 25 COTTER 14619 SHOCK, FRONT - RED 14629-2 SPINDLE AND STRUT SUPPORT, L - BLK 14620 BOLT, M8 X 1.25 X 105 14241 WASHER, M10 SPLIT LOCK ZN 14621 LOWER SUSPENSION ARM COLLAR, 85MM 15542 PIN, M2.5 X 25 COTTER 14622-2 LOWER SUSPENSION ARM ASSY - BLACK (This item is intentionally left blank.) 14623-2 SPINDLE AND STRUT SUPPORT, R - BLK 14923 CAP, NUT COVER RUB - BLK 14624 BEARING 6003Z 14857 SEAL, BALL JOINT 15367 ASM, TIRE/WH RH 16X6-8 14088 NUT, M8 X 1.25 LOCKING FLANGE ZN 15368 ASM, TIRE/WH LH 16X6-8 (not shown) 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1... - Page 16 ASM, HYDRAULIC BRAKE 14641 DUST COVER 14656 BOOT, BRAKE 14657 SHAFT, BRAKE MASTER CYLINDER 14236 NUT, M6 X 1.00 NYLOC FLANGE ZN 14642-2 STEERING GEAR BRACKET (R.S.B.) - BLACK 14658 ASM, BRAKE CALIPER (includes brake pads) 14643 SPRING, THROTTLE PEDAL 14455 BOLT, M8 X 1.25 X 14 SHCS PL 14119 BUSHING, SLEEVE 12 X 21 X 12 14744 MASTER CYLINDER, BRAKE (RESERVOIR AND CAP INCLUDED) 14645-2 PEDAL, THROTTLE BLACK 14130 HOSE, HYD BRAKE - 75” 14526 CAP, THROTTLE PEDAL - 31X/41X/61X 14495 WASHER, M8 SPLIT LOCK 14646 CAP, BRAKE MASTER CYLINDER 15362R1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST...
- Page 17 15444 ENGINE, LCT 208CC 49 STATE 15388 ENGINE, LCT 208CC 50 STATE 15489 ASM, REAR SWINGARM - 5210 14662 BOLT, M10 X 1.25 X 174 HHCS 15491 FILTER, AIR - PAPER ELEMENT (SEE SPECS) 14666 SPANNER 15057 SPARK PLUG, TORCH F6RTC 14426 BOLT, M6 X 1.00 X 14 FHCS DAC 15059 PLUG, OIL DRAIN - LCT 136CC / 208CC 15054 COVER, DRIVE - PLASTIC 15058 DIPSTICK, OIL - LCT 136CC / 208CC 8227 NUT, 1/4-20 CLIP NUT 15055 CAP, FUEL - LCT 136CC / 208CC 49 STATE 14778 SCREW, M4 X 1.75 X 12 PH 15495 CAP, FUEL - LCT 208CC 50 STATE 14341 BOLT, M6 X 1.00 X 20 FHCS 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1...
- Page 18 JACKSHAFT NOTE: * For vehicles assembled prior to March, 2013 ** For vehicles assembled after March, 2013 Provide your American SportWorks Customer Service Representative with the VIN to determine the vehicle’s assembly date. Ref# Part# Description Ref# Part# Description 15542 PIN, M2.5 X 25 COTTER 15061 GUARD, REAR CHAIN (black plastic) 14727 NUT, M14 X 1.25 CASTLE...
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Page 19: Rear Axle
15488 AXLE - 5210 14249 NUT, M16 X 1.5 CASTLE 14724 WASHER, 29.5 X 17MM X 3.0 ZN 15365 ASM, TIRE/WH RH - 18X9.5-8 14675 CHAIN (#420 1/2” pitch) 15366 ASM, TIRE/WH LH - 18X9.5-8 14676 KEY, 5 X 5 X 75 15487 TIRE, 18 X 9.5 - 8 FAR EAST “V” TREAD (not shown) 14434 BOLT, M8 X 1.25 X 16 FHCS ZN 14668 FLANGE BEARING - 150CC 14593 BEARING 6005Z 14669 MASTER LINK 14670 DISK, REAR BRAKE - 150CC 14671 SPACER, SPROCKET 14769 SCREW, SET M8 X 1.25 X 14 SHCS PL 14672 SPROCKET, 60 TOOTH 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1... - Page 20 4404 Engle Ridge Drive Fort Wayne IN 46804 62194 Commercial Street Roseland, LA 70456 Toll Free 800-643-7332 Fax 800-399-1399 www.amsportworks.com...
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