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MODEL 3204 REPLACEMENT PARTS IDENTIFICATION

Item

Part No.

Description

Item

Part No.

Description

60

HH1256T

NUT, 5/16-18 NYLOCK

61

HH62518

NUT, 5/8-18 THIN NYLOCK

62

01226

NUT, 5/16-18 JAM

63

01225

BOLT, 5/16-18 X 5/8" HEX

64

01133

SPACER 0.78 ID DRIVE

65

04166

PITMAN ARM, BLACK

66

01528

RETAINING RING, 1" HEAVY DUTY

67

H91470W

RETAINING RING, 1/4"

68

00980

THROTTLE / BRAKE ROD, BLACK

69

27000100

ROLL PIN, 1/4 X .875

70

001474P

SCREW, SHEET METAL

71

02946

HXHD BOLT FLTRD 1/4-20x1-1/2

72

H93200W

SCREW, 1/4-28 X 0.250 SET

73

04449

BOLT, 3/8-16 X 2 _”

75

00927

SEAT FRAME, BLACK

76

H92740W

SEAT RAIL, 1 PAIR

77

26000900

SEATBELT, RETRACTABLE

78

02972B

SHOCK ABSORBER BLACK

79

00951

SLEEVE, 13-1/8" BLACK PLASTIC

80

00919

SLEEVE, 2-3/8" BLACK PLASTIC

81

00983

SLEEVE, 4-5/8" BLACK PLASTIC

82

001467P

SPACER, BLACK PLASTIC

83

00513

SPACER, SPINDLE

84

04159

SPINDLE, LEFT, BLACK

85

04160

SPINDLE, RIGHT, BLACK

86

H55030W

SPRING, 1/2 X 3.00 COMPRESSION

87

H92541W

SPROCKET, 10 TOOTH

88

23001100

SPROCKET, 60 TOOTH

89

02956

STEERING SHAFT, RED

89

04161

STEERING SHAFT, BLACK

90

H92561W

STEERING WHEEL, 13"

91

04162

SWING ARM, BLACK

92

04265

THROTTLE CABLE, 40"

93

02063

TIE ROD, SHORT

94

26000209

TIE ROD, LONG

95

02451

TIRE, FRONT, TURF

96

02564

TIRE, REAR, 20" SUPER TURF

97

Q43200W

TORQUE CONVERTER, DRIVEN

98

Q43201W

TORQUE CONVERTER, DRIVER

100

001616P

WASHER, 3/8" SPECIAL FLAT

101

001618P

WASHER, 5/16" FLAT

102

H53132W

WASHER, 5/16" INTERNAL TOOTH

104

H56251W

WASHER, 5/8" NARROW FLAT

105

H92690W

WIRE CLIP

106

00925

WIRE, 16GA X 107" KILL SWITCH

107

01079

SEAT CUSHION, WESTERN

108 

05678                      EYE BOLT

110

H32505W

SCREW, SELF TAPPING 1/4"

111

02625

SLEEVE AXLE, 4"

112

01474

SPACER, 3/8”

113

01069

STEERING WHEEL CAP

02604

4-CYCLE ENGINE OIL

                04081                      OWNERS MANUAL

1

01263

A-ARM, LEFT, BLACK

2

01264

A-ARM, RIGHT, BLACK

3

01132

AXLE SHAFT

4

H93110W

BEARING RETAINER

5

H92010W

BEARING, 1" I.D.

7

Q43203W

BELT, DRIVE

8

000710P

1/4" LOCK WASHER

9

H32503W

BOLT, 1/4-20 X 1.75 HEX

10

H33137W

BOLT, 3/8-16 X 1.00 CARRIAGE

11

H61610W

BOLT, 3/8-16 X 1.00 HEX

12

00922

BOLT, 3/8-16 X 1.50 HEX

13

22000300

BOLT, 3/8-16 X 1.75 HEX

15

22000900

BOLT, 3/8-16 X 2.00 HEX

16

H95188W

BOLT, 5/16-18 X 0.75 CARRIAGE

18

H93290W

BOLT, 5/16-18 X 1.50 CARRIAGE

19

2200030

BOLT, 5/16-18 X 1.50 HEX

20

H33135W

BOLT, 5/16-18 X 1.75 HEX

21

04002

BOLT, 5/16-18 X 2.00 HEX

22

H33136W

BOLT, 5/16-24 X 0.50 HEX

23

H36254W

BOLT, 5/8-18 X 3.75 HEX

24

22001700

BOLT, 5/8-18 X 7.00 HEX

25

04476

BRACKET, BRAKE BAND RETAINER

26

5311015

BRACKET, FOOT PEDAL, LEFT

27

5311016

BRACKET, FOOT PEDAL, RIGHT

28

04421

BRAKE BAND

29

04446

BRAKE CABLE 18 7/8”

30

04420

BRAKE DRUM, 6” DIAMETER

31

04087

BRUSH GUARD, FRONT;BLACK

32

04088

BRUSH GUARD, CROSS BLACK

33

04093

BRUSH GUARD, MAIN, BLACK

34

31004600

CABLE ATTACHMENT, BLACK

35

M12501W

CABLE TIE, 11" BLACK

36

04091

BRUSH GUARD, REAR, BLACK

37

M13501W

CABLE TIE, 23"

38

M01001W

CABLE TIE, 4" BLACK

39

00994

CHAIN, DRIVE, #40, 70 LINKS

40

04079

CHASSIS, FULL, BLACK

41

03191

CLUTCH MOUNT, ASSY, ZINC

42

H91480W

COLLAR, 7/16" BORE X 7/8" O.D.

43

02907

COVER MOUNT BRACKET

44

01080

DECAL, WESTERN LTD

45

02908

DRIVE COVER, BLACK

46

Q43160W

ENGINE, 6 H.P. TECUMSEH

47

01094

FLAG, SAFETY

48

M72038W

FOAM, 2" X 72" BLACK

51

H92250W

KEY, 1/4 X 1/4 X 2.00

52

01134

KEY, 3/16 X 3/16 X 3.25

53

Q33100W

KILL SWITCH

55

001203P

NUT, 1/4-20 NYLOCK

56

HH10014

NUT, 1-14 THIN NYLOCK

57

001205P

NUT, 3/8-16 NYLOCK

59           HH37524

           NUT, 3/8-24 THIN NYLOCK

Summary of Contents for 3204

Page 1: ...gine and other portions of the vehicle Pay close attention to all caution and warning labels 7 31 03 04081 Rev D Read Tecumseh Engine Owner s Manual and Important Rules for Safe Operation before Opera...

Page 2: ...ht to ensure that the vehicle is in safe operating condition The engine must be kept free of all dirt and other accumulations paying particular attention to throttle linkage area 6 Prevailing Torque t...

Page 3: ...6 Wet slippery rough or steep terrain is potentially dangerous and may result in injury if proper caution is not observed Slow speeds are required to safely operate this vehicle under those conditions...

Page 4: ...as a service manual 28 Assembly maintenance and or repair of this Go Kart should only be performed by persons of sufficient mechanical skill experience and judgment such as outdoor equipment dealers...

Page 5: ...due to impact 4 Paint is worn off of rear bumper indicating an extra rider 5 Axles are bent out of ordinary position either horizontally or vertically 6 Non Factory altering of engine or it s compone...

Page 6: ...z or 11 4 pints 6 Liters of SAE 30 weight oil For additional information refer to Tecumseh engine manual for servicing the engine 5 Fill fuel tank with regular gasoline leaded or unleaded Do not use p...

Page 7: ...witch Perform this stop switch test While the engine is running move the steering column remote stop switch to the OFF position If this does not stop the engine move the engine remote switch to the OF...

Page 8: ...urning at slow constant speeds Defer increased speeds until you are confident of your proficiency and are intimately familiar with the terrain Steer in the direction of the turn and lean your body to...

Page 9: ...fter the first two hours of operating your new engine and after each 25 hours of use thereafter That will insure proper lubrication in internal parts and prevent costly repairs due to excessive wear R...

Page 10: ...hown in Figure B When your Go Kart gets an inward camber on the front tires from shock wear as shown in Figure C and steering becomes difficult the shocks will need to be readjusted Adjust the front s...

Page 11: ...6 Turn the SHOCK ADJUSTMENT HOLE clockwise around the SHOCK to increase shock absorption 7 Experiment with the adjustment until the desired effect is attained SHOCK ABSORBER ADJUSTMENT STEERING WHEEL...

Page 12: ...d 76 76 77 Female End Item 11 18 57 60 77 76 Description BOLT 3 8 16 X 1 HEX BOLT 5 16 18 X 1 1 2 CARRIAGE NUT 3 8 16 NYLOCK NUT 5 16 18 NYLOCK SEAT BELT RETRACTABLE SEAT RAIL SEAT BELT ATTACHMENT HAR...

Page 13: ...ce nut 60 on end of carriage bolts 18 and tighten all 4 nuts front and rear STEP 2 Note Make sure the seat belts are extending to the outside of the seat frame To move the slide on the rail with the a...

Page 14: ...WASHERS 101 AND four 5 16 NYLOCK NUTS 60 Item 60 101 Description Nut 5 16 18 Nylock Washer 5 16 Flat SEAT ATTACHMENT HARDWARE Qty 4 4 Threaded Studs on seat bottom Seat Bracket Holes Slide SEAT CUSHI...

Page 15: ...ds of the shoulder belt The BELT must rotate SHOULDER BELT ATTACHMENT Attach both driver and passenger shoulder belts using BOLTS 20 WASHERS 101 and NUTS 60 Finished Assembly BRUSH GUARD CROSS ATTACHM...

Page 16: ...ross Brush Guards as shown on this page and the previous page BEFORE tightening bolts 2 Attach flag as shown on this page FLAG ATTACHMENT 4 Wrap CABLE TIE 37 around FLAG BRACKET and REAR BRUSH GUARD 5...

Page 17: ...wn 2 Finish splitting FOAM 48 Foam is partially split 3 Attach FOAM to the BRUSH GUARDS using CABLE TIES 35 48 35 Caution Take care to not cut yourself when cutting and splitting foam with a sharp ins...

Page 18: ...xpose adhesive surface NOTE DO NOT REMOVE DECAL BACKING COMPLETELY This will cause decal to curl and stick to itself 2 Align the decal with floor pan Gently press adhesive to floor pan to start applic...

Page 19: ...W SCREW SELF TAPPING 1 4 111 02625 SLEEVE AXLE 4 112 01474 SPACER 3 8 113 01069 STEERING WHEEL CAP 02604 4 CYCLE ENGINE OIL 04081 OWNERS MANUAL 1 01263 A ARM LEFT BLACK 2 01264 A ARM RIGHT BLACK 3 011...

Page 20: ...20 MODEL 3204...

Page 21: ...de and do not ride a slope that is greater than 15 degrees A 15 degree slope is a hill that increases in height at approximately 2 5 feet in 10 feet A 10 degree slope is a hill that increases in heigh...

Page 22: ...the following precautions OPERATE THIS KART OFF ROAD ONLY ADULT SUPERVISION FOR OPERATORS UNDER 16 YEARS OLD WEAR A D O T APPROVED HELMET PROTECTIVE EYE WEAR AND CLOTHING SECURE LONG HAIR AND LOOSE C...

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