GSMOON KD260-1, Repair Manual

Page 1: ...1 GO KART XYKD260 Repair Manual ...

Page 2: ...e Position of Identification Number Lubrication diagram Main Features Structure Drawing Standard Torque Rating Troubleshooting Position of Identification Number Vehicle Identification Number Engine Identification Number ...

Page 3: ... min Starting Electric Start Ignition C D I Lubrication pressure splash Transmission Automatic C V T System Spark plug DPR5EA 9 NGK Plug gap 0 6 0 8mm Fuel type RQ90 leadless Lubricate oil SAE15W 40 SF Capacities Maximum load Two seats 200Kg Fuel tank 9 5L Engine oil 1180mL Starting Time 10s Climbing 20º 25 Battery 12V 14Ah Head Light 12V 35W Tail Light 12V 21W 5W Fuse 10A Brake Track 7m at 30KM h...

Page 4: ...traint System Double quincunx safety belts Final Drive shaft drive TIRE PRESSURE kPa off road Tire Road Tire Front 25 200 Rear 30 225 WEIGHT KG KD260 1 KD260 2 KD260 3 Net Weight 355 346 365 G W 380 370 380 ...

Page 5: ... and wheel rim Front and rear 10 50 60 9 Screws of support parts Front wheel and vehicle body 10 50 60 10 Connection of brake pump parking brake and front gimbals elevation 8 20 26 11 Screws of handle adjusting line 10 30 40 12 Screws exhaust pipe and engine rear support part 8 20 26 13 Screw used on Front Vibration Damper 10 30 40 14 Screw used on Rear Vibration Damper 12 50 60 15 Connecting scre...

Page 6: ... oil If no special requirement please use the multiple functions lubricating oil In order to prevent the unusual sound and improve the durability lubricating oil also should be used in other transmission parts Connection part between Steering gear parts and handle ball Steering wheel nylon bushing Brake pedal Accelerator pedal Accelerator cable Parking brake cable Front lower swing arm Front Wheel...

Page 7: ...7 Structure Drawing Pipe of cooling liquid kettle Water tubing Temperature Control Switch Rear brake oil tube Brake cable ...

Page 8: ...8 Fuse 15A Flash apparatus Relay CDI BATTERY Ignition coil rectifier Electric parts case Quadric air intake mechanism Throttle cable Reverse cable Parking brake cable ...

Page 9: ... Yes No oil in oil tank Jam between oil tank and carburetor Oil tank hole jammed Oil filter jammed Oil cleaning net jammed Pressure oil switch not work Spark plug not work CDI parts not work Spark plug not clean Trigger not work Spark plug coil broken or short circuit Ignition coil broken or short circuit Igniter switch not work Magneto coil not work Valve gap not enough No Yes No or not enough Pr...

Page 10: ...ht method No explosion No start with explosion Take off spark plug again 火花塞是干的 火花塞湿 Too many oil in carburetor EEV of carburetor not work Value of throttle is unusual Dry Wet Reasons Check Ignition time Ignition led Battery connection badness Air filter jammed Vent hole of oil tank cover jammed CDI parts not work Trigger not work Yes No Valve gap not good Shape of valve changed Yes No Check Valve...

Page 11: ... not good Check spark plunger Check Carburetor jammed Engine is too hot or not Oil is not replaced Mix air rare Quality of oil bad No Yes Speed up or work at high speed Check oil quantity level and quality OK Too many oil Oil is not enough No Plunger or Cylinder damaged Too many carbon powers in firebox Ignition time wrong Mix air rare Ignition time wrong Quality of oil is bad Too many carbon powe...

Page 12: ... Time OK Yes CDI parts not good Magnetor not good No Mixed air is rare Take screws down Mixed air is thick Take screws up Yes No Carburetor is loosed Airproof parts not good No Yes O gasket not good Air leakage in vacuum parts Vent screw of carburetor OK Air leakage in carburetor gasket Sparks OK Reasons ...

Page 13: ...r damaged Yes Cut Air Valve not good Vacuum line jammed or damaged No Cut Air Valve OK Ignition time OK Yes CDI parts not good Magnetor not good No Adjustment not good Value socket damaged Yes No Oil line or oil filter jammed Vent hole is jammed OK Unusual Not enough oil in oil tank minus Pressure line switch not work Handspike gap OK Check oil automatic screw function Clean carburetor socket No Y...

Page 14: ...ne works at high speed Ignition coil wrong connection Spark plug bad connection No high speed or easy to stop reverse gear OK Check reverse operation system Length of reverse cable is not suitable reverse position wrong Connection of battery not good Oil line not good No Yes Any unusual sound of engine gear case Differential gear damaged reverse gear damaged Connector sheath of reverse gear damage...

Page 15: ... Check battery whether out of usage Battery not good Normal Connection of line is not good Normal Stator not good Yellow line is broken Unusual Resistance value of coil Yes Blue yellow or Green line is broken No Voltage between Blue yellow and Green li Yes Booster not good connection peg not good No Whether any looseness of booster and connection peg Magneto not good Reasons ...

Page 16: ...en Any looseness or default of booster connection peg No Yes connection peg not good booster not good Use a new spark plunger then check i No or less sparks Sparks OK No Any looseness between lid of spark and between high voltage lines Lid of spark is loosen Yes previous Spark Plunger broken Connection of CDI parts OK Yes No Connecter is not good Check statement and features of connecter of CDI an...

Page 17: ...000Km remark Oil System I I I Carburetion System I I I Carburetor I I I I Core of air filter often R Spark plug I R I Lubricating oil in engine First time1000Km then per 2000 Km Clean net of lubricating oil Per year R C C C Gap of valve I I I I Battery I I I Brake system I I I I OK No Yes No Related parts OK Ignition switch not good Magneto coil not good Trigger not good Ignition coil not good cab...

Page 18: ...dometer reading surpasses the maximum features listed in the table the maintenance should be done repeatedly according to the table Brake System Adjustment Check pedal free travel 20 30 mm If it is beyond of this distance please take down up adjustment screw When air enters the brake cylinder piston or the brake oil pipe resulting in brake failure it is necessary to discharge the air in the brake ...

Page 19: ...formation Spec of Tire Pressure Value off road Pressure Value Road Front AT21X8 10 28kPa 200kPa Rear AT22X11 10 35kPa 225kPa Check mental hexad flange screws of front wheel and axle tight them as per required torque Cushion System Brake oil pump Attention When exhaust you must guarantee that there is enough brake fluids in brake pump oil cup Adjustment bolt of brake Attention Please make sure that...

Page 20: ...ssion System Transmission case leakage and capacity Stop the engine and take down oil position screw If oil level reach at standard position it is OK otherwise pour in oil OIL TYPE 85W 140 or 15W 35S Put on oil position screw after checking airproof gasket Replacement of lubricating oil Take down oil position screw Take down vent bolt and put oil out Put on vent bolt with revolving Pour oil accord...

Page 21: ... or steel wire brush Spark Plug Distance should be 0 6 mm to 0 8 mm Ignition Timing Take off ignition screw Check ignition LED to confirm ignition time When idle speed is 1500 100rpm it matches F well Function of Ignition Advance Angle Driving wheel Driven wheel Check gap whether any dirt and Carbon Chechecks any broken Checks gasket Important When install spark plunger please tight it by plug soc...

Page 22: ...ent of air filter core Open six clips and take off air filter cover Take off filter core Change filter core if it is dirty or damaged Standard period of change filter core per 4000 KM If road condition is not good you should change filter core early Lubricating System Standard Position Note idle speed adjustment shall be made when the engine is warmed up And Carburetor adjustment following inspect...

Page 23: ...id and let oil out Take up filter lid with revolving Pour in lubricating oil Full capacity 0 8 Liter Type 85W 140 Start engine to make sure no leakage problem Stop engine and check oil quantity Attention During check oil quantity you should guarantee the vehicle is in the horizontal position Let the engine works 2 3 minutes then stops the engine After 2 3 minutes then check oil quantity Oil vernie...

Page 24: ...ng oil from the Oiling hole Cooling System Water Level Guarantee the vehicle is in the horizontal position Inspect kettle liquid surface whether between upper limit and lower limit On the kettle has two across above is the upper limit and under is the lower limit If the radiator liquid is insufficient must pour the kettle liquid to upper limit The coolant liquid should fit the engine Water Leakage...

Page 25: ...Remember position of O gasket and use a new one in installation Take down vent screws of floater room clean carburetor before disassembly Do not take off auto double starter valve Troubleshooting Can not start engine No power and engine stops when accelerate max No fuel in oil tank septum of vacuum piston is destroyed No oil flow into Pressure entrance is jammed Too much oil in cylinder Oil switch...

Page 26: ...t working Vacuum lines or connecter are jammed Oil is too many Accelerator is heavy Air filter is jammed Installation of carburetor is not good Wrong installation of support part in EEV Switch of carburetor destroys cam drum wheel Disassembly of Carburetor Take off oil line Take off pressure three way line Take down Oil drain bolt and drain oil out from Carburetor Take off carburetor line Take off...

Page 27: ...e value is deviated 10 omegas you must use a new electricity enrichment valve Disassembly Take down screws of support pats and take down support part Take down electricity enrichment valve Inspection of Valve Check any damage on electricity enrichment valve and pin of EEV If any please use a new EEV Installation Do installation in oppositive turn in disassembly E E V Connecter Screws of support pa...

Page 28: ...ssure value 400 600mmHg With pressure no air in vent line and without pressure air in vent line valve is ok Replacement Take down two screws and take off cut air valve Take off O gasket Use a new O gasket and fix valve on carburetor with screws Vaccum Room Disassembly Take down two screws and take off vacuum room cover Cut air valve Bolt Cut air valve O gasket Cover of Vacuum Room Screw ...

Page 29: ...pport bottom of vacuum plunger make sure that it is open and put septum to chimp position of carburetor completely Put on spring Match septum hole with cover and fix cover Floater Room Take off four screws and floater room Inspection of Pin Valve Check station of valve socket Plunger Spring Important Please protect septum of vacuum plunger Vacuum Plunger Septum Nozzle Pin Spring Support pats Impor...

Page 30: ...oppositive turn in disassembly Do adjustment as following Accelerator line adjustment Idle adjustment Oil Tank Disassembly Main Ejector Sub Ejector Main Ejector Socket Vent bolt Important To protect ejector and screws Note down zip number when take down screws If drives vent screws strongly it would be destroyed Attention Extractive oil should be fresh one Attention Please install vent screws acco...

Page 31: ...e should be no oil leakage Otherwise you should clean pressure line 2 Dismantles the pressure line from the carburetor With pressure oil leakage and without pressure no oil leakage then the switch is normal 3 Switch negative pressure value Above 130kpa 4 Cooling System Replacement of cooling liquid in Radiator Oil Line Pressured line Oil switch Important NO SPARK Important Before take off radiator...

Page 32: ...id 5 checks enough water in sluice bottle Function Inspection Radiator Lid Put lid on is inspector and it is good that keep on SIX seconds under standard pressure Standard pressure of Radiator lid valve 73 5 103Kpa Radiator Inspection Connect Inspector and radiator add air and it is good that keep on SIX seconds under standard pressure Standard pressure 73 5 103 Kpa Important Before take off radia...

Page 33: ...parts and make sure rear Wheel takes off Take down screws and take off rear wheel Take down screws and take off rear brake Take down rear bone left and right break connection between rear bone and engine Take off gimbals left and right Take apart water line and out cooling liquid Rear Wheel Screw Support Part Attention When 80 C the fan can automatically open if failed it needs the prompt inspecti...

Page 34: ...uretion Take off auto restarted plug Take off transmission line Take off earth line Take off line between engine and battery Take down screws of bumper Take down screws between air filter support part and Vehicle body Erath Line Power Line Bumper Water Line Air Filter Screw Muffle Screw ...

Page 35: ...ews of muffle and take it part from engine Take down clips of carburetion take carburetion exhaust line and air filter Installation Installation is in oppositive turn and please makes sure that screws are fixed according to standard strength Rear Suspend Screw Front Suspend ATTENTION The engine is heavy so multi people coordination is import to disassemble in order to avoid offends somebody or the...

Page 36: ...36 6 Front Wheels and Steering System ...

Page 37: ...37 Disassenmbly Support front part of vehicle and make front wheel take off Take apart four screws of front wheel Left wheel for example Front wheel rim screws ...

Page 38: ...s and take apart front vibration Damper Take down two screws between support parts and vehicle body Take down two screws between down support part and vehicle body Take apart down support part and front bone assembly Take down screws between up down support part and front bone Front Wheel Rim Brake Disc Important It is connected by bearing You should use special tools Screws Front Vibration Damper...

Page 39: ...l Take apart steering assembly Take down screws between steering bearing and gimbal Take off gimbals Take down screws between steering bearing and vehicle body Take apart steering assembly Front Bone U D Support Part Fix part of S S Steering assembly Bolt Gimbal Fixing parts of S W Bolt Gimbal Screw Steering assembly Important It is connected by wimble please knock assembly carefully ...

Page 40: ...40 Take down six screws and gather respective assembly Installation Do it as opposite procedure compared with DISASSEMBLY 7 Seat System Disassembly Steering Wheel Screw Steering Wheel Screw ...

Page 41: ...ly safety bolt on seat right Disassembly safety bolt on seat back Disassembly safety bolt on vehicle body Take off seat Handle counter clock wise rotation may carry on to the seat adjustment back or front Bolt Bolt Man Handle ...

Page 42: ...42 Disassembly setting screws of safety belt on left side of seat Take off safety belt It is same to take off left seat and safety belt 8 Rear Drive Line System Screw Man handle Slide Rail ...

Page 43: ...t behind the entire vehicle and make the trailing wheel to take off Dismantles 4 front wheels fixing g screws Left side Wheel Take down the cotter pin of the front wheel hub locking screws Front wheel screw Rea wheel rim screw ...

Page 44: ...ke pump Dismantle four setting screws of rear bone Take down rear bone rear wheel rim and brake disc assembly Take down rear bone off rear wheel rim Dismantle four setting screws and take off brake disc Take off SPEED SENSER ASS Parking Brake Rear brake pump Screw Screw Rear Bone Brake Disc Rear Wheel Rim Screw Important IT IS CONNECTED WITH AXLTREE YOU SHOULD USE PROFESIONAL TOOL Parts of speedom...

Page 45: ...ke of tranquilization part Disassembly setting screws of rear vibration damper L R Take off left and right rear vibration damper Disassembly setting screws and take off rear support part Left is same with Right Installation Do it as opposite procedure compared with DISASSEMBLY Universal Joint Screw Rubber sheath Fixed part Rear Support Part Screw Tranquilization part Rear Vibration Damper Screw Sc...

Page 46: ... data and standard features Magneto installment and disassemble As to other problems please view more information in CHARTER 1 Battery Do periodic inspection electrolyte the capacity make sure line is between the scale division line if lower than the scale division please supplement the distilled water When charging the battery you must dismantle the battery from the vehicle but do not take off th...

Page 47: ...r not good The magnetic stator not good Coupling connection is not good Battery not good Battery line cable connection falls off Electric current not steady going on Fuse in short Line cable connection not good Line cable in short Charge system not good Ignition trigger not good Ignition system not good or in short Coupling connection is not good or short Charge system Leakage examination Put igni...

Page 48: ... the flying wheel whether some of them has the distortion or the damage If any you must carry on the replacement Maintains of Igniter Maintains of Spark Plug Various cables must carry on the connection by the same color one The different color line cable must be same with one kind of color The colored throat is closed to the connect part When doing the connection you must pay attention to the colo...

Page 49: ...rigger is not good Magneto Stator is not good Main features of Igniter Dismantles the accumulator cell fixed belt Dismantles the electric appliance lid ITEM Checking Position Standard Value Igniter switch Black White Green Electric current bleed when switch is off Magnetor coil Black Red Green 50 350Ω 20 Trigger Green White Blue Yellow 50 170Ω 20 Igniter coil Main coil Black Yellow Green 3 6 4 6kΩ...