MotoTec POWERSPORTS FR5DGK, Owner'S Manual

Page 1: ...rt is designed for operators age 16 and over Adult supervision is required for riders age 16 Model GK008E FR5DGK READ THIS MANUAL CAREFULLY Provincial Municipal governments have different regulations pertaining to owning and operating an off road vehicle learn the regulations in your area ...

Page 2: ... use only if they determine that the child has the ability tooperate the Go Kart in a safe manner THIS Go Kart IS NOT A TOY AND COULD BE HAZARDOUS TO OPERATE A Go Kart handles differently from other vehicles including motorcyclesand cars A collision or rollover can occur quickly even during routine maneuvers such as turning driving on hills and over obstacles Reading the Owner s Operator s Manual ...

Page 3: ...ake procedures easier or clearer to understand We are concerned about the environment and believesin conserving and protecting all natural resources For this reason owners should recycle trade in or dispose as appropriate oil andtires This manual is based on the latest product information available atthe time of publication We have a policy of continually improving its products Due to improvements...

Page 4: ...ch are known to the state of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle ...

Page 5: ...5 IMPORTANT LABELS LOCATION 7 8 ...

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Page 7: ...bar in back of the operator is not intended to provide rollover protection Before each use make sure all tubes are securely in place and bolts are tight 11 Never operate Go Kart with long hair loose jewelry or loose cloth ing that could get caught in moving parts 12 Always go slow on unfamiliar terrain Be alert to changing terrain conditions when operating the Go Kart 13 Never take drugs or alcoho...

Page 8: ...et 5 4 Head bracket assembly 5 Chain cover 6 Rear tires 7 Side panel 8 Seat 9 Seat belt 7 6 10 Steering wheel 11 Accelerator pedal 12 Brake pedal 13 Brake fluid reservoir 14 Tie rods 15 Rear brake caliper 16 Rear axle 17 Drive chain 18 Motor 19 Motor controller 20 Battery 8 11 17 15 18 16 19 20 ...

Page 9: ...op speed When the Gear switch is place in the Low position the vehicle will go half speed Forward or Reverse Switch 3 when the Forward or Reverse Switch is place in the Forward position the vehicle will go Forward When the Gear switch is place in the Reverse position the vehicle will go Reverse Brake Pedal 5 Depressing the brake pedal will stop the Go Kart Note Always check brakes before operation...

Page 10: ...Charging port 1 To connect the power plug from the controller or charge plug Battery Charger 2 Input AC100 240AC 50 60Hz Max 1 6A Output DC57 6V 2 0A Warning the Charger is for indoor use only Risk electric shock please do not open the charger 1 2 ...

Page 11: ...rward or backward Set seat location according to the size of the operator Before operating the Go Kart after seat adjustment make sure the seat is locked in place and secure WARNING Failure to have the seat locked in position could be hazardous The seat coming loose could cause the operator to loose control Never operate the Go Kart without the seat locked in place ...

Page 12: ...ING Performing maintenance and checks while the engine is running could be hazardous You could be severely injured by moving parts or hot surfaces Never perform maintenance or check procedures while the engine is running with the exception of checking the ignition switch or throttle WHAT TO CHECK CHECK FOR Steering Smoothness No restriction of movement Brakes Correct fluid level Inspect hoses for ...

Page 13: ...iveways and streets can cause loss of control resulting in severe injury or death Go Kart tires are designed for off road use only paved surfaces adversely affect handling and control Avoid operating Go Kart on paved surfaces If you must cross a paved surface go slow and do not make sudden turns or stops WARNING Operating this Go Kart on any public road or highway could be hazardous You could coll...

Page 14: ...erating a Go Kart Wear protective clothing Long sleeve shirt 3 Gloves 4 Long pants 5 over the ankle boots 6 Operating a Go Kart exposes the operator to many hazards wearing protective clothing can helpprotect the operator from injury 5 WARNING Operating a Go Kart without a helmet eye protection and pro tective clothing can be hazardous Operating a Go Kart without a helmet increases the chance of s...

Page 15: ... the buckle is latchedproperly WARNING Riding in this go kart without the seat belt attached properly could be hazardous Riding the go kart without the seat belt worn increases the chance of injury or death in the event of an accident Never operate the go kart with out the seat belt worn and attached properly ...

Page 16: ...in severe injury or death Always Operate with both hands on the steering wheel and both feet on the floorboard while operating the Go Kart OPERATING THE GO KART STARTING 1 Connect the battery wires 2 Place the Power switch located on the Steering column in the ON position 3 Place the Forward or Reverse Switch in the Forward position WARNING Braking while turning could be hazardous Braking while tu...

Page 17: ... back the Go Kart down the hill while applying the brakes DESCENDING A HILL To operate the Go Kart going down a hill follow the instructions below 1 Stop and evaluate the hill before attempting to descend Make sure the hill is not too steep the terrainis not loose or slippery and that there are no obstacles 2 Do not go down the hill on a sharp angle this could cause the Go Kart to flip over Instea...

Page 18: ...ly by regaining traction resulting in severe injury or death Avoid skidding or sliding Drive to stay in control WARNING Applying the brakes hard on slippery surfaces could be hazardous Applying the brakes too hard on a slippery surface can cause the wheels to lock up and the Go Kart to slide out of control The Go Kart could turn over or slide into an object This could result in severe injury or de...

Page 19: ...r if doing so could damage the river bank or shore line Brakes need to be inspected cleaned and replaced more often if Go Kart is used in muddy wet or sandy conditions Inspect the Go Kart brakes regularly have a service center clean or replace as needed WARNING Operating this Go Kart through fast or deep water could be hazardous Deep or fast moving water could cause the Go Kart to loose trac tion ...

Page 20: ...arm area to thaw out Once brakes are thawed check again for proper operation if they still do not work take the Go Kart to a authorized service center Do not attempt to operate the Go Kart with brakes that do not work correctly Preventive maintenance in cold weather operating is important After operating in cold weather with snow slush water or ice dry off the Go Kart including brake and throttle ...

Page 21: ...r suitability of all the accessories available When purchasing an accessory use caution the handling of the Go Kart could become affected Some accessories may make the Go Kart unsafe to operate If you have a question about a modification or accessory contact your dealer WARNING Modifications or adding accessories could be hazardous Modifications to the Go Kart including adding accessories could ad...

Page 22: ...n while the engine is running could be hazardous Performing maintenance and inspections while the engine is running could result in getting body parts or clothing caught in moving parts or could result in touching hot items which could result in severe injury Shut off engine when perform ing maintenance and inspec tion checks with the exception checking the ignition switch and throttle CAUTION Fai...

Page 23: ...before each ride Clean and lubri cate as necessa ry Brakes I I Brake hose I I Brake fluid Inspect brake fluid level before each ride if low check brake pads for wear and brake lines and compone nts for leaks Replace brake fluid every 2 years Tires I Steering I I Front suspension I Rear suspension I I Chassis nuts and bolts T I T Recommended to be performed by an authorized service center or servic...

Page 24: ... for leaks or cracks If there are no leaks inspect the brake pads for excessive wear If brake pads are worn take to a service center for replacement To add brake fluid remove the lid 3 Use only DOT3 or DOT4 brake fluid WARNING Failing to inspect brakes before each use could be hazardous Inspect brakes before each use according to the Pre ride check list make sure to follow the maintenance schedule...

Page 25: ... to ensure maximum life of the chain and sprockets Instructions for cleaning and chain lubrication 1 Clean chain with a chain cleaner or a cleaning lubricant such as WD40 2 Lubricate chain with chain lube 5 12mm 2 Check tension of drive chain 2 chain tension slack should be 0 2 0 5in 5 13mm Chain tension slack Adjustment 1 Loosen nuts 3 on bottom of engine mounting plate 2 Adjust chain tension by ...

Page 26: ...pment and expertise to change tires without causing damage Punctures to tires can usually be repaired by using plug type patches Plug type patches cannot repair tires that have been cut If the tire has been cut or has a puncture in a location or size that cannot be repaired replace the tire Be prepared for flat tires always carry a plug type patch kit and air pump with you Minimum tread 4mm 16 in ...

Page 27: ...nents 2 Place the power switch to the off position Charge the battery once a month at least 3 Fill tires with correct air pressure 4 If possible store Go Kart in a shed or garage with a cover to protect from dust dirt and humidity If the Go Kart must be stored outdoors cover com pletely with a good waterproof cover Returning to service 1 Wash Go Kart thoroughly Note Keep water away frombattery and...

Page 28: ...e soft rag or brush Do not use any cleaning materials that could scratch the Go Kart Note Be careful not to allow water to enter battery and motor controller brake cables or switches TRANSPORTING 1 Place the power switch to the off position Take off the power plug from battery case 3 Transport the Go Kart in the upright position tied down securely Battery Controller ...

Page 29: ...4 the foot brake is not put in the end 1 re connected securely 2 Check the battery recharge or whether failure 3 re wiring 4 put the foot brake in the end Brake is unnormal 1 without resistance 2 brake pad wear 3 uninterruptible power brakes 1 adjust the brake rod 2 the replacement of brake pads 3 check wiring replace the brake off switch The motor does not turn or weakness 1 motor damage 2 the co...

Page 30: ... 69 104 in lbs 8 12 nm 8mm bolts and nuts 13 18 ft lbs 18 25 nm 10 mm bolts and nuts 22 29 ft lbs 30 40 nm 12 mm bolts and nuts 36 43 ft lbs 50 60 nm 4 mm screws 22 30 22 30 in lbs 2 5 3 4 nm 5mm screws 30 43 in lbs 3 5 5 nm 6 mm hex bolts 87 121 in lbs 10 14 nm 8 mm hex bolts 17 22 ft lbs 24 30 nm 10 mm hex bolts 25 32 ft lbs 35 45 nm ...

Page 31: ...V 2A Braking Rear Brake Hydraulic disk Tires Front Tire Size AT13 5 6 Rear Tire Size AT13 5 6 Tire pressure 14psi 96 5kpa Dimensions and Weights Length 54 7in 1390mm Height 38 3 in 975mm Width 32 in 815mm Wheelbase 36 2in 920mm Gd Clearance 2 2in 55mm Vehicle Wt 198 lbs 90kg Weight Cap 150 lbs 68kg Transmission Type Planetary Reducer Drive System Type Chain Drive Dual Wheel Gear Ratio 6 1 Suspensi...

Page 32: ... when calling for parts service center help or when registering your Go Kart Locate the number and list the number below for yourreference The 17 digit Vehicle Identification Number VIN is stamped on the left rear bumper support frame on the go kart Vehicle Identification Number VIN ...