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Ace Sports Maxxam 150 2R, Owner'S Manual, Page: 5 / 78

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Ace Sports Maxxam 150 2R Owner'S Manual Download Page 5

GENERAL INFORMATION

PERIODIC MAINTENANCEAND TUNE-UP PROCEDURES

ENGINE

LUBRICATION SYSTEM INSPECTIONAND SERVICING

FUEL SUPPLY SYSTEM INSPECTION AND SERVICING

TRANSMISSION CONPONENTS

ELECTRICAL STARTING SYSTEM

REDUCTION MECHANISM

CONTROLLING MECHANISM

BELT DRIVEN CVT MECHANISM INSPECTIONAND SERVICING

CLUTCH

DRIVEN BELT PULLEY

REAR TRANSMISSION MECHANISM INSPECTIONAND SERVICING

ELECTRICAL SYSTEM

PRIMARY COIL

IGNITION SYSTEM INSPECTIONAND SERVICING

CHASSIS

WIRING DIAGRAM

INDEX

1

5

9

24

28

33

34

37

39

40

44

46

49

54

56

60

64

70

71

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3.

4.

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6.

7.

8.

9.

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18.

19.

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SERVICE MANUAL

INDEX

Page

Summary of Contents for Maxxam 150 2R

Page 1: ...150 2R Owner s Manual Parts Manual Service Manual ACE Maxxam 002 03 2007...

Page 2: ......

Page 3: ...and service your kart accordingly Preventive maintenance is extremely important to the longevity of your kart If you are a beginner please seek instructions from your dealer or qualified instructor be...

Page 4: ...SSEMBLY 8 FAN COVER AND SHROUD ASSEMBLY 9 OIL PUMP ASSEMBLY 10 DRIVEN PULLEY AND CLUTCH SUBASSEMBLY 11 TRANSMISSION ASSEMBLY 12 ELECTRIC SYSTEM 13 ELECTRIC STARTER ASSEMBLY 14 DRIVE PULLEY SUBASSEMBLY...

Page 5: ...TEM REDUCTION MECHANISM CONTROLLING MECHANISM BELT DRIVEN CVT MECHANISM INSPECTIONAND SERVICING CLUTCH DRIVEN BELT PULLEY REAR TRANSMISSION MECHANISM INSPECTION AND SERVICING ELECTRICAL SYSTEM PRIMARY...

Page 6: ...e remainder of the kart s warranty Void if 1 Frame is broken or bent due to abuse 2 Underside scraped abusively 3 Wheels are bent or broken due to impact 4 Spindles are bent due to impact 5 Paint is w...

Page 7: ...any way A C E Sports reserves the right to change product specifications designs and standard equipment without notice and without incurring obligation These vehicles are not designed or manufactured...

Page 8: ...arts only a proper helmet eye protection and protective clothing _____7 Never operate the Vehicle on unsafe terrain or at excessive speeds _____8 Never do wheelies jumps or other stunts _____9 Never a...

Page 9: ...r own good judgment You will find important safety information in a variety of forms including Safety Labels _ On the kart Safety Messages _ Preceded by a safety alert symbol and one of two signal wor...

Page 10: ...ff road use only Its tires are not made for pavement and the kart does not have turn signals and other features required for use on public roads If you need to cross a paved or public road shut the ka...

Page 11: ...iptions Do Not Operate this Kart at Night Lower visibility at night can greatly reduce a driver s judgment Driving at night is dangerous and will increase the possibility of an accident Never Run Your...

Page 12: ...AND SECURED AT OR ABOVE SHOULDER LENGTH ALL LOOSE CLOTHING MUST BE SECURED ALL NECKLACES AND SCARVES MUST BE SECURED NO LONG HAIR READ OWNER S MANUAL AND ALL LABELS BEFORE YOU OPERATE THIS GO KART NE...

Page 13: ...ection boots gloves long pants and long sleeved shirt or jacket whenever you drive Although complete protection is not possible wearing proper gear can reduce the chance of injury when you drive The f...

Page 14: ...thout adult supervision No Alcohol or Drugs Alcohol drugs and karts don t mix Even a small amount of alcohol can impair your ability while operating a kart Consult your doctor to be sure it is safe to...

Page 15: ...k the wheels to see that the axle nuts are tight Use a wrench to make sure all accessible nuts bolts and fasteners are tight Underbody Exhaust System Check for and remove any dirt vegetation or other...

Page 16: ...smoothly without sticking and snaps back automatically when it is released Brakes Press the rear brake pedal several times check for proper brake pedal freeplay Make sure there is no brake fluid leaka...

Page 17: ...hey are not paved Drivers of street vehicles may have difficulty seeing and avoiding you which could lead to a collision In many states it is illegal to operate karts on public streets roads and highw...

Page 18: ...chances of losing control of the kart which can result in an accident Always drive at a speed that is proper for your kart the terrain visibility and other operating conditions and your experience WAR...

Page 19: ...149 6cm3 Corrected Compression Ratio 9 2 1 Carburetor KF CB24J Output Power 7 4Kw 7500rpm Maximum Torque 13 5500 foot lbs r min Starting Electric Ignition C D I Lubrication Force Splash Transmission A...

Page 20: ...l Front Tire 20 x 7 8 Rear Tire 22 x 10 10 Front Suspension Independent Dual A Arm Rear Suspension Swing Arm Double Oil Damped Shock Restraint System Dual 4 point Harness Final Drive Chain KMC O Ring...

Page 21: ...he key when the engine starts The engine will warm up within 5 minutes and the engine choke will close automatically and operate at the normal RPM Warning Don t crank starter more than 5 seconds at on...

Page 22: ...rive chain Check drive chain s condition and tension Lubricate if necessary f Check throttle Check for smooth operation Assure throttle snaps back to idle g Check engine stop button Perform engine sto...

Page 23: ...Figure 2 32 5 7 5 5 5 2 5 8 7 1 3 7 1 203 8 72 OPERATION 6 7 7 67 5 1 0 5525 Component locations MIRROR 18...

Page 24: ...allows for two riders only Combined maximum weight of driver and the passenger should not exceed 180kg or 400lbs D Seat Adjustment The seat must always be securely fastened in the position which best...

Page 25: ...n open space at the beginning to learn how to start turn and stop c Operate the kart slowly until you are familiar with it d The turning radius of this kart is small and agile so the centrifugal force...

Page 26: ...r each 10 hours of operation Add oil to bring up to proper level Do not mix various grades of oil C Spark Plug a Remove the spark plug and inspect it each time you change the oil Use a spark plug wren...

Page 27: ...eed e Adjust the screw and adjust the idle speed to an ideal valve f Recheck and readjust the idle speed if necessary E Cleaning Instructions Keep your kart clean With a clean rag wipe off dirt and oi...

Page 28: ...se as you screw to the left and will decrease as you screw to the right Adjust accordingly to the weight of the riders J Storage Instruction In the event that your kart is not to be operated for a per...

Page 29: ...the wheel See Fig 12 Tighten the nuts after replacing the wheels Figure 12 B Rear Wheel Replacement Do not disassemble the castle nuts when you replace the rear wheels and hub assembly Remove the cot...

Page 30: ...8 1 4 greater than dimension B b To adjust the alignments loosen the lock nuts on both sides of Front Tie Rods To make Dimension B smaller turn the rod to the left Adjust the rod to the right directio...

Page 31: ...y Quarterly Yearly Items Tire pressure wear Brake performance Tightness of screws Air cleaner C Carburetor Spark plug Drive chain Brake oil I I Replace gearbox oil Chassis I Fuel switch fuel tank Batt...

Page 32: ...ttery YTX9 BS main relay brake SW right headlight 12V 35W emergency stop LAMP SW lgnition start SW cigar lighter 12V 72W left headlight 12V 35W colour sign table CDI REG grounding generator bystarter...

Page 33: ...ONT SUSPENSION Attach tie rod end to strut by inserting ball joint stud into steering arm of strut Place flat washer then lock washer on stud Secure with castle nut using 17mm wrench socket Lock with...

Page 34: ...with the holes in the frame behind the seat Tighten with 10mm wrench socket Once in position tighten the rack supports with a 10mm wrench socket and 12mm wrench socket 5 A B CARGO RACK Place floor ja...

Page 35: ...on each side and finger tighten with lock nut Align the top of the shoulder bars up with the holes in the main bar Insert a bolt and washer and finger tighten Place top cross bar between the main bars...

Page 36: ...t into the fender sleeve on the frame Insert provided bolt into the mounting hole and tighten the fender to the frame with 8mm and 10mm wrench Install the rear fenders to the swing arm by placing the...

Page 37: ...n press cap firmly closing all ports securely Position battery into battery holder on swing arm 13 A B C D E F G H I J BATTERY Remove the nut and lock washer from each bolt in tail light Mount tail li...

Page 38: ...239 County Road 4435 Brundidge AL 36081 www acesportsonline com P 1 888 562 9ACE F 1 888 562 8ACE...

Page 39: ...PARTS MANUAL LAGBTRFU145000789 4 2 0 3 1 0 1 13 26 16 12 6 5 7 6 18 16 15 14 9 8 43 31 32 33 34 19 COMPONENT LOCATIONS...

Page 40: ...FIG 1 CYLINDER HEAD ASSEMBLY 10 13 13 15 23 22 21 20 19 23 22 21 20 19 18 24 8 2 1 9 7 14 14 5 6 4 12 16 4 4 11 17 11 3 26 27 29 28 25 30 30...

Page 41: ...513 1011 513 1012 600 0030 613 0010 613 0011 613 0012 613 0013 557 1000 Cylinder Head Comp Spark Plug C7HSA NGK Cylinder Head Gasket Carburetor Gasket Insulator Carburetor Insulator Intake Pipe Comp I...

Page 42: ...9 PART NO Cylinder Body Comp Cylinder Gasket Washer Sealing M06 Dowel Pin M10x16 Flange Bolt M06x12 ZN D Tensioner Lifter Gasket Tensioner Lifter Assy Cam Chain Guide Comp Flange Bolt M06x20 513 1013...

Page 43: ...021 513 1083 513 1022 513 1074 513 1023 500 1308 500 1309 500 1310 500 1304 500 1311 500 1057 500 1313 500 1314 R Crankcase Cover Comp Crankcase Cover Gasket Cap Tappet Adjusting Hole Oil Filtering Sc...

Page 44: ...25 22 17 18 11 6 19 28 19 11 11 27 26 20 21 12 11 11 24 13 14 16 10 28 23 11 15 9 2 8 8 7 6 6 6 6 4 3 2 5 7 7 7 1 9 28 FIG 4 CRANKCASE ASSEMBLY 2...

Page 45: ...0 1009 513 1084 513 1070 513 1033 500 1057 R Crankcase Assy Engine Hanger Rubber Bushing Crankcase Gasket L Crankcase Assy Bushing RR Cushion Under Rubber Flange Lock Nut M08 Washer M08 Stud Bolt M08x...

Page 46: ...PISTON ASSEMBLY PART NO Crankshaft Conrod Assy Flange Nut Compression M12 Washer 12 149 HV 12 140HV Lock Nut M22 Washer M22 Kick Drive Gear Washer M12 Flange Nut Compression M12 Woodruff Key Piston P...

Page 47: ...G 6 CAMSHAFT ASSEMBLY PART NO 500 1006 500 1007 513 2004 513 1027 513 1039 513 1073 513 1072 513 2008 500 1002 513 1067 Tappet Adjusting Nut Tappet Adjusting Screw Valve Rocker Arm Exhaust Rocker Arm...

Page 48: ...7 5 5 5 5 5 3 3 6 1 2 6 8 8 3 9 7 540 1006 513 1040 500 1060 513 2009 600 0063 500 1061 613 0015 500 1308 613 0030 L Cover L Cover Gasket Screw ST 4 2x8 F H L Cover Plate Flange Bolt M06x40 Flange Bol...

Page 49: ...78 513 3015 513 3022 513 1079 500 1062 500 1302 613 0016 600 0032 613 0017 613 0018 613 0019 613 0020 Fan Cover Comp Starter Cable Clamper Cooling Duct Lower Shroud Lower Shroud Seal Upper Shroud Comp...

Page 50: ...2 3 4 5 1 1 1 2 1 REF QTY DESCRIPTION 5 3 2 1 4 4 FIG 9 OIL PUMP ASSEMBLY PART NO 513 1044 500 1064 513 2012 500 1302 513 1045 Oil Pump Chain Flange Lock Nut M06 Oil Pump Driven Sprocket Flange Bolt...

Page 51: ...DRIVEN PULLEY AND CLUTCH SUBASSEMBLY 1 2 3 1 1 1 REF QTY DESCRIPTION 2 1 3 FIG 10 DRIVEN PULLEY AND CLUTCH SUBASSEMBLY PART NO 539 1004 513 1046 513 1047 Outer Clutch Assy Drive Belt Driven Pulley As...

Page 52: ...7 513 2831 500 1011 513 1051 513 2832 513 3023 513 1088 500 1032 513 1052 Transmission Cover Transmission Cover Gasket Radial Ball Bearing E6203 Radial Ball Bearing E6202 Radial Ball Bearing E6204 Fla...

Page 53: ...1 1 1 4 REF QTY DESCRIPTION 1 2 3 4 FIG 12 ELECTRIC SYSTEM PART NO 513 2005 513 1053 513 1054 513 1154 513 1055 500 1065 Stator Comp 8 pose Stator Comp 6 pose Flywheel Comp 8 pose Flywheel Comp 6 pose...

Page 54: ...6 REF QTY DESCRIPTION 1 5 4 3 2 FIG 13 ELECTRIC STARTER ASSEMBLY PART NO 6 513 1056 513 1090 513 1058 500 5302 513 1059 613 0021 Flange Starting Clutch Starter Reduction Gear Shaft Reduction Gear Fla...

Page 55: ...1 Fig 14 DRIVE PULLEY SUBASSEMBLY 1 y s s A y e l l u P e v i r D e l b a e v o M 1 REF QTY DESCRIPTION FIG14 DRIVE PULLEY SUBASSEMBLY PART NO 513 1060 14...

Page 56: ...18 12 30 3 22 28 24 4 26 22 26 20 10 14 20 13 17 25 27 25 23 11 15 31 1 2 1 1 1 1 1 8 6 9 7 19 5 16 29 21 FIG 15 CARBURETOR...

Page 57: ...8 500 1172 500 1179 500 1169 500 1168 500 1066 500 1099 500 1098 513 1099 513 1100 513 1101 513 1102 513 1103 Gasket Set A Jet Set Float Set Float Chamber Set Screw Set A Screw Set B Valve Plate Set A...

Page 58: ...25 26 35 30 32 33 15 31 21 22 23 20 16 18 19 42 37 36 34 FIG 16 FRAME GROUP 1 2 2 41 40 30 38 27 5 VIN No LAGBTRFU145000789 28 6 6 7 12 11 10 6 7 4 9 7 7 7 7 7 13 13 14 14 44 44 6 6 6 6 39 43 43 43 3...

Page 59: ...w C B C Cross Bar FR Red C B C Bar Blue C B C Bar Yellow C B C Bar Red C B C Cross Bar RR Blue C B C Cross Bar RR Yellow C B C Cross Bar RR Red C B C Bar L R Side Blue C B C Bar L R Side Yellow C B C...

Page 60: ...12 5 6 8 9 11 13 25 14 15 16 17 7 26 35 37 36 30 29 32 31 24 33 34 28 27 19 18 20 21 22 23 10 4 1 2 46 45 40 42 39 43 44 41 40 38 3 32 48 40 23 FIG 17 STEERING SHAFT ASSEMBLY...

Page 61: ...1079 652 0014 500 1078 Steering Cap Bolt M06x20 Washer M06 Steering Wheel Rack and Pinion Assy Steering Shaft Bushing Brake Pedal Pad Needle Bearing 2617 Bolt M08x35 Lock Washer M08 Steering Shaft Ste...

Page 62: ...31 16 38 15 17 18 19 20 21 22 25 24 23 27 28 29 13 11 10 32 40 26 30 30 33 34 12 35 36 37 15 26 9 7 6 5 4 3 2 1 8 14 39 7 40 40 26 40 FIG 18 SUSPENSION ARM ASSEMBLY...

Page 63: ...0102 636 0004 400 1107 R Strut Spindle Flange Bolt M08x105 Upper Suspension Arm Collar Upper Suspension Arm Bush Upper Suspension Arm Flange Lock Nut M08 Castle Nut M12 Ball Head Dust Seal Ball Head...

Page 64: ...24 22 7 a 5 6 8 9 10 23 23 25 27 6 29 28 13 14 15 16 6 17 20 19 18 11 12 30 1 2 3 4 26 14 21 21 7 1 FIG 19 REAR CARGO RACK SEAT BELT...

Page 65: ...0067 500 1181 634 0004 Tail Light Bulb 21w 5w 12v Tail Light K30 50 long wire 95 Lock Nut M06 Rear Cargo Rack Blue Rear Cargo Rack Yellow Rear Cargo Rack Red Flange Bolt M08x16 color Flange Lock Nut M...

Page 66: ...26 27 28 24 14 13 12 2 6 10 7 8 4 16 11 16 17 29 19 21 20 22 3 5 32 5 18 12 1 23 30 31 33 25 9 34 36 37 38 39 40 41 42 35 15 43 FIG 20 ENGINE MUFFLER AIR CLEANER...

Page 67: ...23 613 0024 500 1040 613 0026 613 0009 613 0034 Reverse Assy Internal Collar Reverse Castle Nut M16 Bolt M10x20 Bolt M08x16 Reverse Bracket Flange Bolt M08x40 Reverse Connector Panel Slotted Bolt M08...

Page 68: ...13 30 6 25 24 27 16 37 36 28 19 23 9 6 7 19 20 19 7 6 18 16 15 14 22 11 10 6 5 4 2 1 25 6 31 32 33 19 19 6 52 26 40 21 12 51 34 6 42 45 50 43 44 45 21 39 49 48 47 43 38 41 53 FIG 21 REAR SWING ARM...

Page 69: ...aliper Assy Strap Bolt M08x160 Rear Swing Arm Comp Flange Bolt M06x20 Lock Nut M06 Flange Bolt M06x16 Rr L Fender Bracket Flange Bolt M08x40 Battery Cover Battery YTX9 BS Bolt chain Adjuster Rear Disc...

Page 70: ...23 22 21 20 18 17 16 15 14 13 12 11 10 9 3 8 7 6 25 5 4 3 3 2 1 19 24 FIG 22 REAR HOUSING...

Page 71: ...516 3001 619 0001 500 3014 618 0201 528 3002 500 1037 500 1040 520 3004 618 0101 531 1002 Flange Bolt M08x25 RR Brake Disc Flange Lock Nut M08 Rear Axle Drive Chain Rear Housing Sprocket Flange Bolt M...

Page 72: ...F A 1 3 7 9 8 10 14 13 12 11 15 16 17 18 11 O 4 5 18 21 6 19 20 2 0 10 20 30 40 50 60 70 12V PO WER SUPPLY OFF ENGINE STOP BUTTON IGNITIO N START SW ICH BEAM SELECTING SW ITC H FIG 23 WIRE HARNESS EL...

Page 73: ...500 5302 500 1031 609 2830 509 1007 509 1008 500 1114 609 0010 509 3028 509 3022 600 0055 600 0056 609 0014 Wire Harness Lock Nut M05 Switch Panel Cover Pan Screw M05X12 Power Outlet Wire Harness tie...

Page 74: ...12 20 20 18 18 11 10 2 9 8 7 6 5 16 4 1 18 17 19 3 13 14 15 FIG 24 REVERSE ASSY...

Page 75: ...ollar Rubber Oil Seal Needle Bearing Drive Sprocket Internal Collar Gear Shifting Yoke Spring Circlip 12 Gear Shifing Yoke Pan Screw M6x20 Hex Nut M08 Lock Washer M08 Bolt M8X40 Bolt M8X25 Reverse Ass...

Page 76: ...ded Wrench 13x15 Open Ended Wrench 12x14 Open Ended Wrench 8x10 Slip Joint Pliers Spark Plug Wrench Tube Wrench ROD Screw Drive Handle Stem 608 0001 608 0002 608 0003 608 0004 608 0005 608 0006 608 00...

Page 77: ...NEVER OPERATE THIS GO KART WITHOUT PROPER INSTRUCTIONS Beginners require adult supervision NEVER OPERATE THIS GO KART ON PUBLIC ROADS It is intended for off road use only ALWAYS WEAR AN APPROVED MOTOR...

Page 78: ...A C E SPORTS LLC 239 County Road 4435 Brundidge AL 36010 Phone 1 888 562 9 ACE Fax 1 888 562 8 ACE www acesportsonline com...

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