Carter Talon GSR 150 R2 Owner's Manual
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Carter Talon GSR 150 R2 Owner's Manual

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Owner's Manual
Parts Manual
READ THIS MANUAL CAREFULLY,
IT CONTAINS IMPORTANT SAFETY INFORMATION.
GSR150R2
GSR150R2
MINIMUM
RECOMMENDED
OPERATOR AGE:
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for o -road use only.
USA only:
It does not conform to Federal Motor Vehicle Safety Standards, and in regards
to operation on public streets, roads, or highways is illegal.
16
A Better Built Machine.

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  • Page 1 Owner's Manual Parts Manual A Better Built Machine. READ THIS MANUAL CAREFULLY, IT CONTAINS IMPORTANT SAFETY INFORMATION. GSR150R2 GSR150R2 MINIMUM RECOMMENDED OPERATOR AGE: FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for o -road use only. USA only: It does not conform to Federal Motor Vehicle Safety Standards, and in regards to operation on public streets, roads, or highways is illegal.
  • Page 2 GSR 150 R 2 Limited Warranty The warranty policy applies to those new units that are unloaded from its shipping container, setup, and delivered to, or by, an authorized dealer, and under normal use and service, is found to have defects in parts or workmanship under the following terms and conditions.

  • Page 3: Table Of Contents

    CONTENTS OWNER' S MANUAL Page 1. FOREWORD ------------------------------------------------------------------------------------------------------------------------- 2. A FEW WORDS ABOUT SAFETY ------------------------------------------------------------------------------------------------ 3. IMPORTANT SAFETY INFORMATION ------------------------------------------------------------------------------------------ 4. SAFETY LABELS -------------------------------------------------------------------------------------------------------------------- 5. ARE YOU READY TO DRIVE ? ---------------------------------------------------------------------------------------------------- 6. IS YOUR VEHICLE READY TO DRIVE ? ----------------------------------------------------------------------------------------- 7.

  • Page 4: Foreword

    FOREWORD Thank you for purchasing a Carter Talon GSR 150 R 2. We hope you will enjoy your new kart. Before you start to operate your kart, please read through this Owner's Manual carefully as it contains important safety and maintenance information.

  • 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 of the 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 service and pleasure.Providing you take responsibility for your own safety and understand the challenges you can meet while driving. There is much that you can do to protect yourself while operating your kart. You'll find many helpful recommendations throughout this manual.
  • 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.

  • 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 warning label replacements.

  • Page 9: Are You Ready To Drive

    ARE YOU READY TO DRIVE ? Before each drive, you need to make sure 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 ? WARNING Operating this Kart without your seat belt could cause you to be thrown from the kart, causing serious injury or death. Age Recommendation It is strongly recommended that no one under the age of 16 be permitted to operate this Go-Kart without adult supervision.

  • 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. WARNING Operating this kart on paved surfaces may seriously affect handling and control of the kart, and may cause the vehicle to go out of control.
  • Page 12 SAFE DRIVING PRECAUTIONS Control Speed Driving at excessive speed increases the chance of an accident. In choosing a proper speed, you need to consider the capability of your Kart, the terrain, visibility and other operating conditions, plus your own skills and experience. WARNING Operating this Kart at excessive speeds increases your chances of losing control of the Kart, which can result in an accident.

  • Page 14: Specifications

    SPECIFICATIONS DIMENSIONS Overall Length --------------------------------------------------------------------------- 88.2 in. (2240mm) Overall Width ---------------------------------------------------------------------------- 55.9 in. (1420mm) Overall Height --------------------------------------------------------------------------- 57.1 in. (1450mm) Wheelbase ----------------------------------------------------------------------------------- 59 in. (1500mm) Front Track ------------------------------------------------------------------------------- 45.7 in. (1160mm) Rear Track -------------------------------------------------------------------------------- 39.4 in. (1000 mm) Ground Clearance -------------------------------------------------------------------------- 6.7 in. (170mm) ENGINE Type --------------------------------------------------------------------------- Forced air-cooled.
  • Page 15 SPECIFICATIONS Brake Track --------------------------------------------------------------------------------- < 7 m@20miles/h Top speed ------------------------------------------------ 30 miles/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 -------------------------------------------- Swing Arm/Double Oil Damped Shock Restraint System -------------------------------------------------------------------- Dual 4-point Harness Final Drive Chain ------------------------------------------------------------------- (KMC) O-Ring Chain...

  • Page 16: Operation

    OPERATION A. Operation controls WARNING - Do not attempt to start or operate the engine until completely 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. a.
  • Page 17 OPERATION B. Pre-Drive Inspection WARNING Perform this pre-drive inspection everyday before driving vehicle. If not performed, serious damage to the vehicle or personal injury may result. a. Check for Engine Oil Level. Check for leaks, add oil if required. b. Check for Fuel Level. Add fuel as necessary and do not overfill. Check for leaks. c.

  • Page 18: Component Locations

    OPERATION Component locations MIRROR STEERING WHEEL SEAT BELT HORNS REAR CARGO RACK TOW BALL FUEL TANK CAP TANK COMP. FUEL Figure 2...
  • Page 19 OPERATION C. Passengers The vehicle allows for two riders only. Combine maximum weight of driver and the passenger should not exceed 180kg or 400lbs. D. Seat Adjustment The seat must always be securely fastened in the position which best affords the operator control of the foot pedals, steering wheel, and the remote stop button.

  • Page 20: Service Instructions

    OPERATION/SERVICE INSTRUCTIONS F. Starting And Operating Instructions a. Before starting the engine, be sure that the driver is seated properly in the Kart with the seat belt. b. Testing the Kart in an open space at the beginning to learn how to start, turn and stop. c.
  • Page 21 SERVICE INSTRUCTIONS B. Engine Lubrication You must change the oil in the crankcase after the first 5 hours of operating your new engine (See Fig. 7) and after 10 hours of use thereafter. This will insure proper lubrication of internal parts and prevent costly repairs due to excessive wear. WARNING WARNING Used Oil Must Be disposed of at a proper collection center.
  • Page 22 SERVICE INSTRUCTIONS a. Warm up the engine (5~10min). b. Tighten the air screw gently. Backout 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 SERVICE INSTRUCTIONS H. Chain Adjustment Check the chain adjustment after first two hours of use. Readjust if it has more than 1/2” flex. a. Loosen Nut #1. b. Adjust Nut #2. Turn Nut #2 clockwise in 1/2 turn increments, then turn nut #1 until tight. Follow this procedure until chain is at proper tension (See Fig.

  • Page 24: Repair

    REPAIR A. Front Wheel Replacement Do not disassemble the castle nuts when you replace the front wheels. It is only necessary to remove the 4 lug nuts to remove the wheel. (See Fig. 12) Tighten the nuts after replacing the wheels. Figure 12 B.
  • Page 25 REPAIR C. Front Wheel Alignment a. The front wheels should be “toe-in” from 1/8” to 1/4”. To check for alignment, measure distance A and B between the centerline (CL) of the wheels. The proper toe-in dimension A should be 1/8” – 1/4” greater than dimension B. b.

  • Page 26: Periodical Check And Service

    PERIODICAL CHECK AND SERVICES The maintenance intervals in the following table are based upon average driving conditions. Driving in unusually dusty areas, requires more frequent servicing. Time of service Initial service Monthly Quarterly Yearly Items (first week) Tire pressure/wear Brake performance Tightness of screws Air cleaner Carburetor...
  • Page 27 WIRING DIAGRAM...
  • Page 28 COMPONENT LOCATIONS...

  • Page 29: Cylinder Head Assy

    CYLINDER HEAD ASSY.
  • Page 30 Fig. 1 CYLINDER HEAD ASSY. HEAD CYLINDER SUBASSY 513-1000 PLUG SPARK(C7HSA NGK) 513-1077 GASKET CYLINDER HEAD 513-1001 GASKET CARBURETOR INSULATOR 513-1002 INSULATOR CARBURETOR 513-1003 PIPE COMP. IN 513-1004 BAND INSULATOR 513-1081 GASKET HEAD COVER 513-1005 O-RING 27X2 513-1006 TUBE BREATHER 513-1007 BOLT STUD M6X18 500-1000...

  • Page 31: Cylinder Assy

    CYLINDER ASSY. Fig. 2 CYLINDER ASSY. 513-1013 CYLINDER COMP. GASKET CYLINDER 513-1014 WASHER SEALING 6 500-1305 PIN DOWEL 10X16 500-1002 BOLT FLANGE M6X12-ZN. D 500-1306 GASKET TENSIONER LIFTER 513-1015 LIFTER ASSY. TENSIONER 513-1016 GUIDE COMP. CAM CHAIN 513-1017 BOLT FLANGE, 6X20 500-1307...

  • Page 32: Crankcase Assy

    CRANKCASE ASSY. (1) Fig. 3 CRANKCASE ASSY.(1) COVER R CRANKCASE COMP. 513-2015 CRANKCASE COVER, GASKET 513-1019 CAP TAPPET ADJUSTING HOLE 500-1015 SCREEN OIL FILTERING 513-1020 SRING OIL FILTING SCREEN 557-1003 GAUGE OIL LEVEL 513-1021 CLAMP AC GENERATOR CORD 513-1083 OIL SEAL 19.8X30X5 513-1022 O-RING 30.8X3 513-1074...
  • Page 33 FIG.4 CRANKCASE ASSY. (2)
  • Page 34 PARTS MANUAL Fig. 4 CRANKCASE ASSY. (2) CRANKCASE ASSY. R 513-2013 BUSH ENGINE HANGER RUBBER 513-1021 GASKET CRANKCASE 513-1025 CANKCASE ASSY. L 513-2007 BUSH RR CUSHION UNDER RUBBER 513-1026 NUT FLANGE M8 500-1004 WASHER 500-1052 BOLT STUD M8X187.5 500-1053 BOLT STUD M8X195.5 500-1030 BEARING RADIAL BALL E6002 522-1301...

  • Page 35: Crankshaft Con'rod &Piston Assy

    PARTS MANUAL CRANKSHAFT CONROD & PISTON ASSY. CRANKSHAFT CONROD & PISTON ASSY. CRANKSHAFT & CONROD ASSY. 513-1034 NUT M12X1.25 500-1039 WASHER 12-149HV 12-140HV 500-1038 NUT LOCK 500-1023 WASHER 500-1024 GEAR KICK DRIVE 513-1086 WASHER 500-1032 NUT M12 500-1059 KEY WOODRUFF 513-1068 CLIP PISTON PIN 513-1035...

  • Page 36: Camshaft Assy

    FIG.6 PARTS MANUAL CAMSHAFT ASSY. Fig. 6 CAMSHAFT ASSY. TAPPET ADJUSTING NUT 500-1006 SCREW TAPPET ADJUSTING 500-1007 ARM VALVE ROCKER 513-2004 SHAFT EX ROCKER ARM 513-1027 CHAIN CAMSHAFT 513-1039 CAMSHAFT COMP. 16T 513-1073 SHAFT COMP. IN ROCK ARM 513-1072 PLATE COMP. STOPPER 513-2008 PIN DOWEL 10X16 500-1002...

  • Page 37: Left Cover Assy

    FIG.7 PARTS MANUAL LEFT COVER ASSY. Fig. 7 LEFT COVER ASSY. COVER L 540-1006 GASKET L COVER 513-1040 SCREW TAPPING ST4.2X8-F-H 500-1060 PLATE L COVER 513-2009 BOLT FLANGE M6X40 500-1312 BOLT FLANGE M6X65 500-1061 SPINDLE COMP. KICK STARTER ASSY. 513-1042...

  • Page 38: Fan Cover And Shroud Assy

    FIG.8 PARTS MANUAL FAN COVER AND SHROUD ASSY. Fig. 8 FAN COVER AND SHROUD ASSY. COVER COMP. FAN 513-1043 CLAMPER STARTER CABLE 513-2010 DUCT CARBURETOR COOLING 513-2011 SHROUD LOWER 513-3014 SEAL SHROUD LOWER 513-1078 SHROUD COMP. UPPER 513-3015 CLIP HIGH TENSION CORD 513-3022 SEAL SHROUD UPPER 513-1079...

  • Page 39: Oil Pump Assy

    FIG.9 PARTS MANUAL OIL PUMP ASSY. Fig. 9 OIL PUMP ASSY. CHAIN OIL PUMP 513-1044 NUT FLANGE M6 500-1064 SPROCKET OIL PUMP DRIVEN 513-2012 BOLT M6X25 500-1063 OIL PUMP SUB ASSY. 513-1045...

  • Page 40: Driven Pulley And Clutch Subassy

    FIG.10 PARTS MANUAL DRIVEN PULLEY AND CLUTCH SUBASSY. Fig. 10 DRIVEN PULLEY AND CLUTCH SUBASSY. OUTER CLUTCH ASSY. 539-1004 BELT DRIVE 513-1046 PULLEY ASSY. DRIVEN 513-1047...

  • Page 41: Transmission Assy

    FIG.11 PARTS MANUAL TRANSMISSION ASSY. Fig. 11 TRANSMISSION ASSY. COVER TRANSMISSION 513-1048 GASKET TRANSMISSION COVER 513-1049 BEARING RADIAL BALL E6203 513-2200 BEARING RADIAL BALL E6202 513-2201 BEARING RADIAL BALL E6204 513-2202 BOLT SPECIAL M8X12 500-1025 WASHER 500-1010 OIL SEAL 20X32X6 513-1050 GEAR FINAL - 40 TEETH 513-1087...

  • Page 42: Electric System

    FIG.12 PARTS MANUAL ELECTRIC SYSTEM Fig. 12 ELECTRIC SYSTEM STATOR COMP. - 8 POST 513-2005 STATOR COMP - 6 POST 513-1053 FLYWHEEL COMP. - 8 POST 513-1054 FLYWHEEL COMP. - 6 POST 513-1154 FAN COMP COOLING 513-1055 BOLT FLANGE M6x18 500-1065 TALON ENGINES USE TWO DIFFERENT STATORS &...

  • Page 43: Electric Starter Assy

    FIG.13 PARTS MANUAL ELECTRIC STARTER ASSY. Fig. 13 ELECTRIC STARTER ASSY. FLANGE STARTING CLUTCH 513-1089 SHAFT STARTER REDUCTION GEAR 513-1090 GEAR STARTER REDUCTION 513-1058 BOLT FLANGE M6X16 500-5302 MOTOR ASSY. STARTER 513-1059...

  • Page 44: Drive Pulley Subassy

    FIG.14 PARTS MANUAL DRIVE PULLEY SUBASSY. Fig. 14 DRIVE PULLEY SUBASSY. PULLEY ASSY MOVABLE DRIVE 513-1060...

  • Page 45: Carburetor

    FIG.15 CARBURETOR...
  • Page 46 PARTS MANUAL Fig. 15 CARBURETOR GASKET SET A 513-1061 NEEDLE SET. JET 513-1062 FLOAT SET 513-1091 CHAMBER SET. FLOAT 513-1092 SCREW SET A 500-1012 SCREW SET B 500-1013 PLATE SET. VALVE 513-1063 BYSTARTER ASSY., AUTO 513-1064 VALVE SET. AIR CUT 513-1065 SPRING.

  • Page 47: Frame Group

    FIG.16 FRAME GROUP 13 14...
  • Page 48 PARTS MANUAL FRAME GROUP C.B.C. CROSS BAR, FR (B.R.S.) 512-1103 blue, 512-1603 carbon, 512-1503 silver 1, 1a, 1b 512-1100 blue, 512-1600 carbon, 512-1500 silver C.B.C. BAR CAGE (B.R.S.) 2, 2a, 2b 512-1100 blue, 512-1600 carbon, 512-1500 silver C.B.C. CROSS BAR, RR (B.R.S.) 3, 3a, 3b 512-1114 blue, 512-1514 carbon, 512-1614 silver C.B.C.

  • Page 49: Steering Shaft Assy

    FIG.17 STEERING SHAFT ASSY.
  • Page 50 PARTS MANUAL STEERING SHAFT ASSY. 536-3026 STEERING BOLT COVER 500-1084 BOLT STRAP M6x12 540-3012 SPINDLE BRACKET STEERING WHEEL 536-3072 536-3028 STEERING SHAFT 522-3012 BEARING NK20/16 SPECIAL WASHER Φ20 500-3001 CIRCLIP Φ20 500-1067 BOLT M8x25 500-1068 LOCKING WASHER Φ8 500-1069 536-3004 STEERING KNUCKLE 536-3029 STEERING GEAR...

  • Page 51: Suspension Arm Assy

    FIG.18 SUSPENSION ARM ASSY.
  • Page 52 Fig. 18 PARTS MANUAL Fig. 18 SUSPENSION ARM ASSY. STRUT AND SPINDLE SUPPORT, R 536-1003 BOLT-WASHER M8x1.25x105 500-1081 UPPER SUSPENSION ARM COLLAR 536-3013 UPPER SUSPENSION ARM BUSH 536-3014 536-3015 blk, 536-2841 slv, 536-2861 cbn UPPER SUSPENSION ARM 5, 5a, 5b 500-1043 LOCKING FLANGE NUT.

  • Page 53: Gas Tank/Seat/Belt

    GAS TANK/SEAT/BELT 21 8...
  • Page 54 Fig. 19 GAS TANK/SEAT/BELT 535-3007 SAFETY BELT COMP. BELT WASHER Φ12 500-1044 500-3033 SPECIAL BOLT M7/16”X28 NUT BELT M7/16” 500-1045 BOLT STRAP M8X1.25X40 500-1173 WASHER Φ8 500-1069 534-2801 SEAT RALL SET 500-1174 VACUUM TUBE 537-3012 FUEL TUBE CLIP LOCK FLANGE NUT. M8 500-1043 540-3011 FUEL TANK CAP COMP.

  • Page 55: Rear Swing Arm Assy. Upper

    FIG.20 REAR SWING ARM ASSY. UPPER 30 26...
  • Page 56 PARTS MANUAL Fig. 20 REAR SWING ARM ASSY. UPPER 500-3006 LOCKING FLANGE NUT 500-3007 ENGINE MOUNT LINK WASHER 500-3008 ENGINE MOUNT LINK CUSHION 500-3009 ENGINE MOUNT LINK SPACER 500-3010 ENGINE MOUNT LINK COLLAR FLAT WASHER Φ12 500-3011 500-3012 ENGINE MOUNT BOLT PLATE 500-3013 LOCKING FLANGE NUT 500-3014...

  • Page 57: Enging/Muffler/Air Cleaner/Oil Cooler

    FIG.21 ENGING/MUFFLER/AIR CLEANER/OIL COOLER...
  • Page 58 PARTS MANUAL ENGINE/MUFFLER/AIR CLEANER/OIL COOLER REVERSE ASSY. 513-3028 INTERNAL COLLAR REVERSE 539-3026 500-3022 LOCKING FLANGE NUT 500-1009 BOLT-WASHER M6x12 539-1001 REVERSE BRACKET LOCKING FLANGE NUT 500-1043 BOLT STRAP M8x1.25x40 500-1316 AIR CLEANER CLAMP 513-3001 AIR CLEANER ASSY. 513-3020 CARBURETOR 513-3003 ENGINE.

  • Page 59: Rear Swing Arm

    FIG.22 REAR SWING ARM...
  • Page 60 FIG.22 PARTS MANUAL REAR SWING ARM BOLT-WASHER M10x1.25x40 500-1091 LOCKING FLANGE NUT 500-3014 REAR SHOCK 535-3005 BOLT STRAP M8x1.25x100 500-3029 REAR FENDER BRACKET, L 537-3008 LOCKING NYLON NUT 500-1031 BOLT-WASHER M8x1.25x45 500-3030 500-2105 BOLT-WASHER M6x16 DISC. RR COVER 540-1004 BOLT STRAP M8x1.25x12 500-3026 537-3006...

  • Page 61: Rear Housing

    FIG.23 REAR HOUSING...
  • Page 62 PARTS MANUAL FIG. 23 REAR HOUSING 500-1096 BOLT-WASHER M8x1.25x22 552-3014 BRAKE DISC. RR 500-1043 LOCKING FLANGE NUT M8 527-2813 REAR AXLE - GSR 539-3006 CHAIN O-RING DRIVE REAR SPROCKET 539-3007 BOLT-WASHER M8x1.25x27 500-1027 DUST SEAL 50X34-7 539-3008 539-3009 AXLE BRG HOUSING COMP. RR 522-3002 BEARING 6206...

  • Page 63: Wire Harness/Electrical

    FIG.24 WIRE HARNESS/ELECTRICAL...
  • Page 64 FIG.24 PARTS MANUAL FIG. 24 WIRE HARNESS/ELECTRICAL 540-2804 BOLT COVER 500-1101 PAN SCREW M6X15 WASHER Φ6 500-3018 500-3019 LOCKING NYLON NUT M6 509-3035 SWITCH PANEL COVER 509-2806 SPEEDOMETER 509-3023 HORN SWITCH 509-3028 POWER OUTLET COVER 509-3024 POWER OUTLET 500-1102 BOLT M6X20 500-1031 LOCKING NYLON NUT M6 509-3017...

  • Page 65: Reverse Assy

    FIG.25 REVERSE ASSY.
  • Page 66 FIG. 25 PARTS MANUAL REVERSE ASSY. 500-1068 500-1106 BOLT M6x25 539-3026 INTERNAL COLLAR REVERSE 539-3025 KEEPER 523-3000 DRIVE SPROCKET 522-3010 NEEDLE BEARING 26x35x20 539-3024 BEARING FLANGE PLATE 539-3023 GEAR CASE. L 539-3022 GEAR CASE FLANGE PLATE 539-3021 DRIVE GEAR 539-3027 COUNTER GEAR SHAFT COMP 539-3020 GEAR SHIFT YOKE...

  • Page 67: Warning Stickers

    FIG.26 PARTS MANUAL WARNING STICKERS PARKING PARKING BRAKE REVERSE LEVER WARNING 3031107 Loss of control, collision,or getting caught in moving parts can result in serious injuries. Not to be operated by person under 16 years old Wear a D.O.T. approved motorcycle helmet Secure long hair and loose clothing Wear protective eye wear and clothing Keep arms, legs and feet inside kart...
  • Page 69 Carter Brothers Mfg. Co., Inc. 1871 US Hwy 231 Brundidge, AL 36010 334.735.2301 - 800.523.5278 www.carterbro.com...

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