BV Powersports Go-kart 300-1, Owner'S Manual

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Page 5: ...SAFETY INFORMATION 3 4 SAFETY LABELS 5 5 ARE YOU READY TO DRIVE 6 6 IS YOUR VEHICLE READY TO DRIVE 7 7 SAFE DRIVING PRECAUTIONS 8 8 P D I 10 9 SPECIFICATIONS 11 10 OPERATION 13 11 SERVICE INSTRUCTIONS...

Page 6: ...sure to follow the recommended maintenance schedule and service your kart accordingly Preventive maintenance is extremely important to the longevity of your kart Beginners should seek instruction from...

Page 7: ...You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels On the kart Safety Messages preceeded by a safety alert symbol and one of...

Page 8: ...s gloves and other protective gear Drive Off Road Only Your kart is designed and manufactured for off road use only The tires are not made for use on pavements and the kart does not have turn signals...

Page 9: ...the dark visinon can greatly reduce a driver s visibility and judgment So driving at night is dangerous and can increase the possibility for an accident Never run your kart indoors The exhaust from t...

Page 10: ...tions or your experi3wence NEVER ATTEMPTWHEELIES JUMPS OR OTHER STUNTS 303115 WARNING 3031107 Loss of control collision or getting caught in moving parts can result in serious injuries Not to be opera...

Page 11: ...t eye protection boots gloves long pants and long sleeved shirt or jacket whenever you drive Aothough completeprotection isnot possible wearing propergear canreduce thechance of injury should you have...

Page 12: ...to operate a vehicle after taking medication Before each drive it is important to inspect your kart and make sure any problems you find are corrected Apre drive inspection is a must not only for safet...

Page 13: ...h feet on the foot controls It is important to maintain your belance and to control the kart Removing hands or feet away from the controls can reduce your ability to react and control the kart Operati...

Page 14: ...rating on excessively rough slippery or loose terrain could cause loss of traction or vehicle control which could res in an accident including an overturn Do not operate on excessively rough slippery...

Page 15: ...ll Front Tires and tighten the nuts F Install Rear Tires tighten the nuts insert cotter Pin and put on the Rubber Cover G Raise the C B C bar as the picture shows H Install C B C bar RR put on R Washe...

Page 16: ...rected compression ratio 10 1 Carburetor VEKS4 CV30 Output Power 13KW 6500RPM Maximum Torque 22N m 5000RPM Starting Electri Ignition C D I Lubrication Force Splash Transmission Automatic C V T system...

Page 17: ...ear 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 Full Independet Rear Suspension Oil Damped Shock Restraint S...

Page 18: ...to correct the problem through lubrication adjustment or replacement of worn parts contact your dealer for assistance b Brake The brake is the left foot pedal See Fig 1 Applying pressure to the pedal...

Page 19: ...ts and fasteners Check the C B C Bar Ensure all C B C bars are in place before operating the kart Check the Lights Check the headlights brake light and tail light are all working Check the Steering Ch...

Page 20: ...STEERING WHEEL HORN NUITS TANK COMP FUEL REAR CAPGO PACK Figure 2 SEAT BELT MIRROR FLAG POLE BRACKER FUEL TANK CAP OPERATION Component Iocations 15...

Page 21: ...ush the brake pedal down The brake pedal must be pushed in to change the gear settings b Push the lever forward to the D position for the kart to move forward c Each time you need to apply the brake t...

Page 22: ...st be seated properly in the kart with the seat belt on b Practice in the kart in an open space at the beginning to learn how to start turn and stop the vehicle c Drive slowly until you are familiar w...

Page 23: ...ug needs inspection c It is advisable to replace the spark plug at least once a year to ensure easy starting and good engine performance Never make unnecessary adjustments The factory recommended sett...

Page 24: ...ufacturer see Fig 10 Use a round nut wrench as you adjust the shock the tension of xhock spring will increase as you screw to the left decrease as you screw to the right Adjust according to the weight...

Page 25: ...g hole then re fit the plug c Do not save or store gasoline over winter Using old gasoline which has deteriorted from storage will make the engine difficult to start and affect engine performance 20 S...

Page 26: ...nt a The front wheels should be toe infrom 1 8 to 1 4 inch Tocheck for alignment measure distance A and B between the centerline CL of the wheels The proper toe in dimension A should be 1 8 to 1 4 inc...

Page 27: ...REPAIR LOCK NUT FR WHEEL TIE ROD RIGHT ROATE LEFT ROATE Fiqure 13 FR WHEEL TIEROD RIGHT ROATE LEFT ROATE 22...

Page 28: ...23 PERIODICAL CHECK AND SERVICES...

Page 29: ...WIRING DIAGRAM 24...

Page 30: ...WIRING DIAGRAM 25...

Page 31: ...TrailMaster GO KART 300 XRX PARTS MANUAL Version 2 9 19 2011...

Page 32: ...5 1 1 9 157 3 11 307 TRANSMISSION HUB POSITIONING BOLT 1 1 10 157 3 11 834 WASHER AL 14X22X1 3 1 1 11 157 3 10 829 TRANSMISSION HUB POSITIONING SPRING 1 1 12 GB T308 10 STEEL BALL S 10 319 1 1 13 GB...

Page 33: ...ART NO DESCRIPTION QTY 2 1 169 12 104 FRONT ABSORBER BUSHING SET 1 2 2 169 03 211 RIGHT CRANKCASE 1 2 3 169 09 414 FILTER OIL TUBE 1 2 4 169 09 412 FILTER ELEMENT 1 2 5 169 09 413 FILTER SPRING 1 2 6...

Page 34: ...RING 1 3 5 169 01 323 OIL RING ASSY 1 3 6 169 01 312 PISTON PIN 1 3 7 169 01 313 PISTON PIN CIRCLIP 2 3 8 169 05 410 WATER PUMP COMP 1 3 9 157 3 11 508 PIN 10X14 2 3 10 169 11 215 DOUBLE SCREW LONG BO...

Page 35: ...4 4 8 169 02 112 INTAKE ARM SHAFT 1 4 9 169 02 113 EXHAUST ARM SHAFT 1 4 10 169 02 120 ARM COMP 2 4 11 169 02 210B CAM SHAFT 1 4 12 169 11 120 CAM SHAFT CLAMP 1 4 13 169 11 121 CLAMP OUTSIDE SPACER 1...

Page 36: ...EAL 2 4 25 169 12 507 O RING 9X2 1 4 26 GB T 276 6005 BALL BEARING 1 4 27 GB T 276 6202 RS BALL BEARING 1 4 28 GB T 5789 M6 12 BOLT M6X12 1 4 29 GB T 16674 1 M6 12 BOLT M6X12 2 4 30 GB T16674 1 M6 20...

Page 37: ...710 CHAIN GUIDING PLATE 1 5 5 169 02 610 TENSIONING PLATE 1 5 6 169 02 506 TENSIONING PLATE SCREW 1 5 7 169 02 410 TENSIONING DEVICE COMP 1 5 8 169 02 221 INTAKE VALVE COVER 1 5 9 169 02 222 EXHAUST...

Page 38: ...CYLINDER HEAD COPPER SPACER 8X18X2 4 5 24 169 12 514 O RING 14 5X1 8 1 5 25 169 12 526 O RING 57 5X2 3 2 5 26 169 12 527 O RING 94X3 3 1 5 27 169 12 516 O RING 15 5X2 5 2 5 28 169 12 306 TENSIONING DE...

Page 39: ...6 3 169 03 412 PEEP DOOR SCREW PLUG 1 6 4 169 05 511 PUMP DRIVE SHAFT 1 6 5 169 05 512 PUMP GEAR 1 6 6 169 06 260 ELECTRIC START INTERMEDIATE GEAR COMP 1 6 7 IN 169 06 310 FREE WHEELING CLUTCH INNER R...

Page 40: ...311 ENGINE OIL PUMP PAPER SPACER 1 6 24 GB T 70 1 M5 12 SCREW M5 12 2 6 25 GB T 70 1 M5 25 SCREW M5 25 3 6 26 GB T 70 1 M8 18 SCREW M8 18 3 6 27 GB T70 2 M6 25 SCREW M6 25 2 6 28 GB T16674 1 M6 16 BO...

Page 41: ...Y 7 1 169 10 110 DRIVE COMP 1 7 2 169 10 310 V BELT 1 7 3 169 10 210 CLUTCH DRIVEN PULLEY COMP 1 7 4 152 03 323 HAND STARTING PART 1 7 5 157 3 11 838 WASHER 15 1 7 6 169 11 312 FLANGE BOLT M14X1 2 7 7...

Page 42: ...WASHER ST 15 19 1 1 8 10 169 4 10 420 SHIFTING SHAFT COMP 1 8 11 157 3 10 820 DECLUTCH SHIFT SHAFT 1 8 12 157 3 10 821 DECLUTCH SHIFT 1 8 13 157 3 03 612 SHORT SHAFT 2 8 14 169 4 10 450 OUTPUT GEAR S...

Page 43: ...YLE 1 9 2 157 3 11 508 PIN 10 14 2 9 3 169 12 302 LEFT CRANKCASE COVER SPACER 1 9 4 169 11 119B L CRANK CASE COVER PLATE 2 9 5 GB T 845 TAPPING SCREW ST3 5 8 3 9 6 169 03 315 FRONT COVER COMP 1 9 7 GB...

Page 44: ...ETOR REF NO PART NO DESCRIPTION QT Y 10 1 169 08 100 CARBURETOR COMP 1 10 2 169 08 210 INTAKE PIPE COMP 1 10 3 169 08 260 INTAKE PIPE INSULATION SPACER 1 10 4 169 12 523 O RING 35X2 2 10 5 GB T 16674...

Page 45: ...FIG 11 ELECTRIC PARTS ELECTRIC PARTS REF NO PART NO DESCRIPTION QTY 11 1 169 06 110 STARTOR COMP 1 11 2 169 07 410 IGNITOR 1 11 3 169 07 310 IGNITION COIL 1 11 4 169 07 510 RECTIFIER COMP REGULATE 1...

Page 46: ...OSS BAR B R S 1 13 2 8 070 034 250 C B C BAR CAGE B R S 2 13 3 8 080 033 C B C CROSS BAR RR B R S 1 13 4 8 070 035 C B C BAR L R SIDE B R S 2 13 5 2 010 045 FRAME COMP B R S 1 13 6 7 010 049 R WASHER...

Page 47: ...UBE SEAT 35 6 13 28 7 010 016 TUBE SEAT 32 2 13 29 9 090 003 HEADLIGHT BULB 35W 35W 12V 2 13 30 7 110 034 FENDER FR 2 13 31 6 100 067 FRONT FENDER BRACKET L 1 13 32 9 100 640 BOLT M6 40 2 13 33 9 210...

Page 48: ...2 SCREW M6 12 8 13 55 7 120 010 RUBBER PIECE 1 13 56 9 100 640 BOLT M6 40 1 13 57 9 131 192 DECORATION PLATE I 1 13 58 9 130 192 DECORATION PLATE II 1 13 59 9 312 192 PROTECTING PLATE 1 13 60 2 041 07...

Page 49: ...IPTION QTY 14 1 7 010 041 STEERING BOLT COVER 1 14 2 9 100 612 SCREW M6 12 3 14 3 8 030 024 SPINDLE WHEEL 1 14 4 7 020 038 STEERING WHEEL 1 14 5 6 000 122 STEERING SHAFT 1 14 6 6 017 001 NEEDLE NK2016...

Page 50: ...E PEDAL BOLT M8 1 25 145 1 14 28 8 040 001 THROTTLE PEDAL RETURN SPING L 1 14 29 9 108 040 BOLT WASHER M8 1 25 40 2 14 30 9 200 008 NUT M8 2 14 31 4 000 016 THROTTLE PEDAL COMP 1 14 32 9 600 515 PAN S...

Page 51: ...ENSION ASSY REF NO PART NO DESCRIPTION QTY 15 1 2 000 028 SS STRUT AND SPINDLE SUPPORT R WITH BRACKET BLACK 1 15 2 9 108 105 BOLT WASHER M8 1 25 105 2 15 3 8 010 015 UPPER SUSPENSION ARM COLLAR 2 15 4...

Page 52: ...Z 2 15 20 9 710 031 CAP LUG NUT M10 1 25 31 8 15 21 8 010 085 WHEEL HUB 2 15 22 9 030 010 Z BEARIG 6202 Z 2 15 23 8 010 118 CAP LUG NUT M10 8 15 24 7 020 050 TIRE FR 20 7 8 2 15 25 6 000 142B RIM FR...

Page 53: ...3 40001 300GK REVERSE CABLE FIXED PLATE 1 16 4 40002 300GK SHIFTER DISK 1 16 5 578910020125 BOLT M10x1 25x20 4 16 6 58310300k000 FRONT ENGINE MOUNT BRACKET 1 16 7 618712000125 NUT M12x1 25 3 16 8 5832...

Page 54: ...CAA CHAIN ADJUSTER ASSY 1 16 19 618710000125 LOCKING FLANGE NUT M10x1 25 2 16 20 578510045125 BOLT M10x1 25 1 16 21 8 010 076 COLLAR ENGINE MOUNT BOLT PLATE 1 16 22 618708000125 LOCKING FLANGE NUT M 8...

Page 55: ...2 6 000 144 TAIL LIGHT 2 17 3 9 210 006 LOCK NYLON NUT M6 4 17 4 2 100 046 250 REAR CARGO RACK B R S 1 17 5 6 000 111 REAR SIDE REFLECTOR 4 17 6 8 010 171 LUG NUT 2 17 7 7 020 032 TUBE COVER 2 17 8 6...

Page 56: ...17 24 6 000 264 SEAT COMP L 1 17 25 9 700 001 SPECIAL BOLT M7 16 28 1 17 26 9 700 002 BELT WASHER 12 1 17 27 9 700 003 NUT BELT M7 A6 1 17 28 9 900 840 BOLT STRAP M8 1 25 40 2 17 29 9 910 841 BOLT M8...

Page 57: ...OR BATTERY MUFFLER ASSY REF NO PART NO DESCRIPTION QTY 18 9 49000 300G AIR CLEANER ASSY 1 18 10 7 090 042 TUBE COMP WATER 1 1 18 11 7 190 043 TUBE COMP WATER 2 1 18 12 7 090 044 TUBE CLAMP 10 18 13 7...

Page 58: ...051 TUBE CLAMP 2 18 31 9 200 006 NUT M6 2 18 32 6 100 249 300G FAN COMP 2 18 33 7 090 052 BOLT M6 10 6 18 34 10000 300G 300cc ENGINE 1 18 35 7 090 053 TUBE COMP WATER 5 1 18 36 7 090 054 TUBE COMP WAT...

Page 59: ...SUSPENSION ASSY REF NO PART NO DESCRIPTION QTY 19 1 7 020 039 RR HUB COVER 2 19 2 9 500 430 COTTER PIN 4 30 2 19 3 9 800 018 CASTLE NUT M18 2 19 4 8 010 118 LUG NUT CAP M10 8 19 5 6 000 143B RIM RR 2...

Page 60: ...244 C CV SHAFT JOINT 2 19 25 6 000 245 CUSHION ASSY RR L 480 2 19 26 6 000 247 SWING ARM COMP R 1 19 27 6 000 246 SWING ARM COMP L 1 19 28 9 040 011 DUST SEAL 62 44 10 2 19 29 6 000 148B REAR WHEEL AS...

Page 61: ...USH2 1 19 52 7 190 017 CIRCLIP2 1 19 53 7 190 018 TIRE NIPPLE 2 19 54 7 190 019 REAR AXLE CIRCLIP 2 19 55 7 120 081 SCREN M3 6 2 19 56 7 145 076 BOLT M6 16 2 19 57 8 020 410 BRACKET 1 19 58 9 220 006...

Page 62: ...N QTY 20 1 9 100 630 BOLT M6 30 2 20 2 9 200 006 NUT M6 2 20 3 6 000 250 REGULATE RECTIFIER COMP 1 20 4 9 600 615 PAN SCREW M6 15 4 20 5 9 300 006 WASHER 6 4 20 6 9 210 005 LOCKING NYLON NUT M5 2 20 7...

Page 63: ...ER 1 20 18 6 000 252 HORN RECTIFIER 1 20 19 6 100 253 SOCKET COMP 1 20 20 9 600 655 PAN SCREW M6 55 2 20 21 6 100 254 WIRE HARNESS 2 20 22 7 010 029 ELECTRIC ASSY COVER 1 20 23 80018 300K C D I UNIT C...

Page 64: ...KE 1 21 2 9 090 008 LABEL REVERSE LEVER 1 21 3 9 090 023 LABEL GEAR CASE 1 21 4 9 090 010 LABEL NO LONG HAIR 1 21 5 9 090 011 LABEL WARNING 1 21 6 9 090 012 LABEL NO CLIMBING 1 21 7 9 090 013 LABEL WA...