Important Safety Warning

SERIES OFF-ROAD KART USER’S MANUAL

Thank you for your purchase of the 150 cc GKA-2 Go Kart

This GO- Kart is manufactured because of great demand in the market for aGO-Kart of this size and capability.

Please read the manual carefully before driving.It will help familiarize you with the basic knowledge, function, operation and maintenance of the Kart. This will be of great help to you to keep it in good condition and drive more safely.

The materials and pictures provided in the manual are the latest information available at the time of publication. There are possible differences between the contents in the manual and the actual Kart as a result of the improvements, or changes made during manufacture of the product. Operation and controls may be different then the manual. The manufacturer reserves the right to make revisions of the manual at any time, with no further information or notice.

It is illegal to copy, quote or print any part of the manual without permission from the manufacturer.

Please contact the dealer you purchased the kart from if you have any questions about the operation andmaintenance of it.

CONTENTS

  1. Brief Introduction to Off-road Go-Kart
  2. Main Specifications
  3. Vehicle Assembly
  4. Important Safety Procedures
  5. Components and operation introduction
  6. How to drive the Off-road Go- Kart properly
  7. Maintenance of the Off-road Go- Kart
  8. Schematic Diagram
  1. Brief introduction to Off-road Go- Kart
  2. Brief Introduction

  1. Headlight
  2. Rear view mirror
  3. Front role bars
  4. Control panel
  5. Steering wheel and Steering column
  6. Seat
  7. Horn
  8. Rear brake light
  9. Oil tank
  10. Rear turn indicator lamp
  11. Rear mudguard
  12. Engine assembly
  13. Rear wheel
  14. Rear shock absorber
  15. Battery
  16. Seat belt
  17. Hand brake
  18. Forward/Reverse shift Lever
  19. Front wheel
  20. Bumper
  • The unique shape of the high structural strength welded steel frame this Off-road Go- Kart is designed and manufactured for your safety, reliability and drivingfun.
  • Front independent suspension and articulated, adjustable rear shock-absorber in the rear frame are standard equipment. This is important for driving control and to help insure the longevity of the components of the whole vehicle.
  • Front wheel and rear hydraulic disk brakes are standard for control and safety.
  • This Go- kart has a high efficiency engine for power, fuel economy and low oil consumption.
  • The electrical system is simple and reliable.
  • The vehicle is equipped with a continuously variable transmission for easy and efficient driving
  • Engine and Frame identification numbers: Engine identification number: Please locateengine identification
  • Number. It is located near exhaust. It may be needed for warranty purposes. Frame identification number: frame identification number is the Vehicle Identification Number for allvehicles. Please record this number. It is used to identify the vehicle when necessary. It is on the framework under the seat.
  1. Specification

Item / Parameters
External Dimension / L x W x H (mm) / 2450x1510x1580
Axle Base (mm) / 1885
Weight / Dry Weight (kg) / 255
Load capacity / 160kg (2person)
Engine / Type / Single cylinder, 4-stroke, air cooled
Exhaust (ml) / 149.6
Form of transmission / CVT (with reverse)
Power / Highest speed (km/h) / 60
Tire / Type/air pressure front / 21x7-10
24/25 psi
Type/Air pressure rear / 22x11-10
24/25 psi
Electrical System / Battery / 12V 9Ah
Safety Fuse / 10A
Capacity / Oil Tank (L) / 6.0
  1. Vehicle Assembly
  1. Remove cardboard and metal frame.
  2. Remove steering wheel and

Install on steering column with column mounting bracket with two bolts. Install steering wheel on column with three bolts. Make sure front wheels are aligned with rear wheels when mounting steering wheel to column. Mount horn cover to steering wheel.

  1. Mount rear shocks to mounting brackets with hardware provided
  2. Mount roll cage to frame with hardware provided. Mount decorative sleeves to roll cage bars.
  3. Mount seats with hex nuts and bolts provided.
  4. Install battery in battery compartment. Connect the red wire to the positive pole of the battery and the black wire to the negative pole of the battery. Make sure all screws and nuts are tight on electrical connections.
  5. Plug in wire connectors behind driver’s seat.
  1. Operation and Safety notices

This Off-road Kart is not a toy and improper or careless operation can cause harm to the operator and others. Please abide by the following suggestions strictly to avoid the injury.

 Do not drive at excess speeds for the driving conditions. You must control the speed to retain control of the vehicle according to the road conditions.

Do not follow other vehicles to closely

Before driving each time do an inspection of cart to make sure that it is safe and ready to drive. Check all nuts, bolts and all electrical connections. Make sure to become familiar with the maintenance schedule in the manual.

Before starting the engine, make sure that you are seated and in control of the vehicle.

Do not overload the vehicle when driving. Overloading when driving can damage the cart and create an unsafe driving condition.

 This is a two passenger vehicle, never attempt to carry more than two people

Make sure all drivers and passengers can reach foot rest andarm rests armrest.

 Drivers must keep both hands on steering wheel at all time while driving to maintain control

You must abide by all state and local laws when operating the cart.

Practice driving at low speeds before trying high speed driving to get used to the operation of the cart.

 Do not let anyone who is not familiar with the operating controls of the cart drive.

This is an off-road vehicle only. The tires and suspension are made for off road driving only.

Do not drive cart while under the influence of any substance that will impair your driving ability

 Do not attempt to drive on hills or slippery surfaces until you have learned and practiced your off road driving skills

You must be 16 years are older to operate this vehicle.

WARNING Do not add fuel while the engine is running or hot

Use the same size tires on all four wheels and make sure tires are inflated to proper pressure as defined in this manual.

Adding or changing components will result in loss of warranty.

 Do not start and run motor unless in a well ventilated environment where exhaust gases can escape. .

 Please keep hands and body away from vehicle during and just after operation.

 Always wear a helmet, goggles and protective clothing when driving or riding in cart. .

Please fasten seat belt at all times when in the cart. Keep hands and feet in the cart while operating the vehicle.

When storing the vehicle for any length of time remove the fuel from fuel tank. Store in a cool dry location. Please store the manual properly for future use.

Have an experienced mechanic do any repairs or maintenance. Make sure to disconnect the battery when doing repairs or maintenance.

  1. Components and Operation introduction

5.1 Location of components

See picture 1.1

5.2 Operation of components

You must come to a complete stop before shifting gears from forward or reverse.

Control Panel (ignition key and blanket switch

  1. Ignition key
  2. Cutout
  3. Headlamp
  4. Turn signal switch
  5. Horn switch

Ignition Key

Put shift lever in the neutral position. Turn the ignition key clockwise and step on the brake pedal to start the vehicle.

Kill switch

If you want to stop the engine, you can press the red kill switch

Turning lamp switch

Light Switch

Horn Switch

Seat

You can adjust the location of seat by moving the hand lever under the cushion. After moving the seat re-engage seat lever so the seat will remain in position.

Hand brake

The hand brake of this kart is between the two seats. Pull upward to engage the hand brake.

5.1Check before driving

It is necessary for you to spend a few minutes inspecting your Go-kart before driving the first time,to help keep your cart in good running condition for a long time

Shipping oil is in the unit. The cart should only be driven a short time before changing engine oil.

You must use the following engine oils

-Crank case: SAE15W/40SE, 0.9L;

-Gear case: 85W/90,0.18L;

  1. Use only 90 octane or above for fuel. Make sure fuel tank is not leaking from shipping damage
  2. Brake

Check the operations of the brakes to make sure they do not need to be adjusted before driving. Check fluid level in brake fluid reservoir

  1. Tires

Check all bolts on the wheels to make sure they are secure. Make sure tire pressure is set at 24/25 psi for all four tires

  1. Accelerator

Please check the accelerator to see if it can move freely and comes back to start position

  1. Ignition key and kill switch
  2. After initial start up check to make sure kill switch is working
  3. Screws, nuts and fasteners

Please check all nuts , bolts and fasteners to make sure they are tight (loctite)

  1. Check exhaust and underneath cart to make sure there are no foreign objects that could interfere with the operation of the cart
  2. .

5.2Starting the engine

Make sure the vehicle is in neutral and your foot is on the brake pedal before trying to start. Do not try to start for more than 5 or 6 seconds at a time

Press gas pedal lightly and repeat the above steps if you fail to start it the first time

5.3Break-in

The new vehicle must

Go through a breaking in period of 500 to 1000 km. Drive at various speeds for the break in period. Never drive at one speed for an extended period of time. Do not drive or run the engine at full speed until the break in period is over.

Stopping

When coming to a complete stop engage the hand parking brake before removing your foot from the brake pedal.

  1. Maintenance of off-road kart
  2. Routine Maintenance

The following is the routine maintenance table. You may have to do certain things more often depending on your driving habits. The more you drive the more maintenance is needed

Routine maintenance Table

Notes: I – inspection, clean, adjust and lubricate or replace when necessary, C – clean, R – replace, L – Lubricate

Item / Weekly
Maintenance / Monthly Maintenance / Annual Maintenance
Fuel system / I / I
Accelerator / I / I
Air filter / C / I
Spark Plug / I
Engine Idle speed / I / I
Drive chain / I,L / I,L
Braking pads / I / I
Brake system / I / I
Screws, nuts,bolts and fasteners / I / I
Tires / I / I
Steering / I
suspension system / I / I
Engine oil / I / I / R

6.2Spark Plug

Remove spark plug and inspect plu. If the electrodes are burnt or dirty replace plug. The gap between electrodes shouldbe .61-.71mm

When re-installing spark plug make sure it is screwed all the when in and snug

6.3Air cleaner

Routine cleaning is necessary.The more often you drive the often the air filter needs to be cleaned.

6.3.1Cleaning of air cleaner

Take off the plastic cover.

 You can clean the filter in a non-flammable solvent. Then soak the filter in clean engine oil for 5 minutes. Let it drain of all the excess oil and re-install.

6.4Brake System

Disc brakes are used in the vehicle. Make sure there is not too much free play in the brake pedal, inspect all couplings for leakage and make sure the fluid level in the brake reservoir is correct.

Routine inspection is necessary for the brake pads to make sure that it does not get less then 3mm thick. The pads need to be replaced once they reach the 3mm thickness.

6.5Accelerator

Inspect the return spring for accelerator and the throttle cable on a regular basis and replace if not working properly.

6.6Tires

The cart is equipped with low pressure tires, tire pressure should be checked before each use and maintained at the proper psi. (24/25 psi) Tires need to be replaced when the tread depth is less than 2mm in depth

6.7Battery

You must connect the red wire to positive(+) pole and the black wire to the negative(-) pole when installing the battery. Generally speaking, the battery should be replaced every 2-3 years.

6.8Fuse There is a fuse in the electrical box on top of the motor. To check or change the fuse just remove the electrical box cover and inspect the fuse. If it is blown change it. If you have a frequent problem you need to check for a short in the electrical system

6.9Carburetor

The idle speed adjusting screw on the carburetor is used to adjust theidle speed. Tighten the screw to decrease idle,loosen to increase idle speed.

6.10Steering system.

Routine inspection of the steering assembly is necessary. There should be 3-6mm of toe-in on the cart. This can be adjusted with the tie rods..