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9.

The vehicle should never be started without first checking to see that the throttle is in idle position. Do
not start engine without verifying proper function of the throttle.

10. Never attempt to start this vehicle without having the operator sitting in the proper

position to ensure control of the kart.

11.

The operator’s ability to operate this off-road vehicle safely is largely dependent upon the operator’s
ability to exercise proper judgment.  An operator also must not be too small or too large for controlled
operation. The operator must be at least 16 years of age and have understanding, mental capacity and
physical capability to safely operate this vehicle.  This vehicle should only be operated after mature,
supervised instruction and sufficient practice in non-congested areas.

12. This vehicle is designed for one operator and one passenger

.  A passenger on any vehicle

must be sufficient age, understanding, mental capacity, and physical capability to act to protect
himself/herself, and wear a D.O.T approved helmet at all times.

  This kart is not recommended

cumulative weights exceeding 250 pounds.

13.

The engine should be stopped when the vehicle is not in use.

14. Loose clothing, long hair, or articles worn by any riders must be fully contained, or

covered to prevent them from possibly being caught in rotating parts of the vehicle or
the surrounding environment while riding.  Failure to obey could endanger the personal
safety of the Riders
.

15. Do not place hands, feet, or any other part of the body or any clothing near the engine,

muffler, wheels, chain, and other rotating parts of the vehicle while riding or running
the engine

Caution must be used in performing required maintenance on or near an operating engine.

Special caution should be taken after the engine has been running, since the engine and other drive
components may be extremely hot.

16. 

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. The
Operator must use mature judgement, skill, and experience to choose a speed suitable for the terrain
and riding conditions.

17. The Governor settings for this vehicle’s engine must not be tampered with, altered or

changed

The governor is set by the engine manufacturer and limits the maximum speed of the engine

(and vehicle) and protects the engine from damage.  Excessive speeds are potentially dangerous to
the rider and the engine.

18. Each time before using this vehicle, the fuel supply should be checked.  The fuel tank should

never be filled while the engine is running or while the engine is hot.  Do not fill tank in closed
area such as a garage, while smoking, or in the vicinity of an open flame.  Do not overfill the
tank. Always allow at least 1/4 inch of space at the top of the tank for expansion.  Never top
off tank. Replace cap tightly to prevent spillage of fuel and potential fire hazard.  After filling
tank, move the vehicle at least 15 feet away from spot of filling before starting.

19.

If the vehicle should start making unusual noise or vibrating abnormally, the engine should be stopped
and the spark plug wire disconnected. The vehicle should then be checked for damage. Excessive
noise or vibration is generally a warning of loose or worn parts.

20.

When making repairs or adjustments to the vehicle which do not involve adjustments to the engine,
the spark plug wire must be disconnected and kept away from the spark plug to prevent accidental
starting.  When working on or around or when restarting engine, use extreme caution to avoid contact
with the muffler, cylinder head, or any other potentially hot area on or around the engine.

21.

Always perform a Pre-Ride Inspection before starting the engine.  See Pre-Ride Inspection in the
manual.

22.

The custom brush guard assembled on this vehicle is for deflecting loose vegetation and must not be
removed.

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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