Carter Talon GSR 150 R2 Owner'S Manual Download

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Fig. 8

FAN COVER AND SHROUD ASSY.

COVER COMP. FAN

CLAMPER STARTER CABLE

DUCT CARBURETOR COOLING

SHROUD LOWER

SEAL SHROUD LOWER

SHROUD COMP. UPPER

CLIP HIGH TENSION CORD

SEAL SHROUD UPPER

SCREW ST4.8X16-F

BOLT M6X25

FIG.8

FAN COVER AND SHROUD ASSY.

PARTS MANUAL

SCREW ST3.5×13-F

DUST COVER

513-1043

513-2010

513-2011

513-3014

513-1078

513-3015

513-3022

513-1079

500-1062

500-1063

500-0401

513-3048

Summary of Contents for GSR 150 R2

Page 1: ...ehicle is designed and manufactured for off road use only USA only It does not conform to Federal Motor Vehicle Safety Standards and in regards to operation on public streets roads or highways is ille...

Page 2: ...maintenance improper assembly alterations abuse negligence or accident Should warranty service be required on your GSR 150 R 2 during the 180 days warranty period please contact your nearest authorize...

Page 3: ...OIL PUMP ASSY 10 DRIVEN PULLEY AND CLUTCH SUBASSY 11 TRANSMISSION ASSY 12 ELECTRIC SYSTEM 13 ELECTRIC STARTER ASSY 14 DRIVE PULLEY SUBASSY 15 CARBURETOR 16 FRAME GROUP 17 STEERING SHAFT ASSY 18 SUSPE...

Page 4: ...ies or death Be sure to follow the recommended maintenance schedule and service your kart accordingly Preventive maintenance is extremely important to the longevity of your kart Beginners should seek...

Page 5: ...n good judgment You will nd 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 words WAR...

Page 6: ...ured for o road use only The 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 get...

Page 7: ...ark vision can greatly reduce a driver s visibility and judgment So driving at night is dangerous and can increase the possibility for an accident Never run your Kart indoors The exhaust from the engi...

Page 8: ...ult if you do not follow these instructions 3031112 WARNING WARNING ALL HAIR MUST BE TIED UP AND SECURED AT OR ABOVE SHOULDER LENGTH ALL LOOSE CLOTHING MUST BE SECURED ALL NECKLACES AND SCARVES MUST B...

Page 9: ...ce of driving gear because it o ers the best protection against head injuries A helmet should t your head comfortably and securely An open face helmet o ers some protection but a full face helmet o er...

Page 10: ...t WARNING Operating this Kart after consuming alcohol or drugs can seriously affect your judgment cause you to react more slowly affect your balance and perception and could result in serious injury o...

Page 11: ...ose your balance and fall off the kart Always keep both hands on the steering wheel and both feet on the foot controls of your kart during operation WARNING O Road Use Only Your kart and its tires are...

Page 12: ...ances 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 WARNI...

Page 13: ...6 b c d e f g h j a...

Page 14: ...nt 149 6cm3 Corrected compression ratio 9 2 1 Carburator KF CB24J Output Power 7 4Kw 7500 rpm Maximum Torque 13 5500 foot lbs r min Starting Electric Ignition C D I Lubrication Force Splash Transmissi...

Page 15: ...t control 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...

Page 16: ...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 one time d Engine stop b...

Page 17: ...form engine stop button test Repair as necessary h Check all Nuts Bolts and fasteners Check wheels to see that all axle nuts and lug nuts are tightened properly Check and tighten as necessary all othe...

Page 18: ...Figure 2 15 REAR CARGO RACK FUEL TANK CAP TANK COMP FUEL TOW BALL OPERATION SEAT BELT STEERING WHEEL MIRROR HORNS Component locations...

Page 19: ...he seat ensure that kart engine is stopped Never operate this Kart when the provided seat is not securely fastened to do so could result in a strong possibility of severe personal injury or loss of li...

Page 20: ...Testing the Kart in an 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...

Page 21: ...0 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 wrench The e...

Page 22: ...the top speed e Adjust the screw and adjust the idle speed to an ideal value f Recheck and readjust the idle speed if necessary E Cleaning Instructions Keep your kart clean With a clean rag wipe o an...

Page 23: ...to left decrease as you screw to right Adjust according to the weight of the riders J Storage Instruction In the event your kart is not to be operated for a period in excess of 30 days or at the end o...

Page 24: ...s to remove 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 Rem...

Page 25: ...ter than dimension B b To adjust the alignments loosen the lock nuts on both sides of the Front Tie Rods To make Dimension B smaller turn the rod to left Adjust the rod to right direction to make Dime...

Page 26: ...Horn B B G LG GR SB OFF Horn button ON O Turn button Right headlight Blue Yellow Black Pink P Brown L Orange Y B O BR 12V 35W 35W 12V 10W Front right turn Y R B Ignition Start SW R 1a L 1b 1 W B OFF O...

Page 27: ...ght 12V 21W 5W 12V 10W G Y R B BR BR G W L G W L G SB G Front left turn Left headlight Tail right turn Tail left turn G BR G BR 12V 5W Left position light Right position light 12V 5W Turn button R R G...

Page 28: ...COMPONENT LOCATIONS...

Page 29: ...CYLINDER HEAD ASSY 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...

Page 30: ...T FLANGE M6X100 CYLINDER HEAD VALVE IN SEAL VALVE STEM SEAT VALVE SPRING OUTER SPRING VALVE OUTER INNER RETAINER VALVE SPRING COTTER VALVE VALVE EX Fig 1 CYLINDER HEAD ASSY 1 2 3 4 5 6 7 8 9 10 11 12...

Page 31: ...GASKET CYLINDER WASHER SEALING 6 PIN DOWEL 10X16 BOLT FLANGE M6X12 ZN D GASKET TENSIONER LIFTER LIFTER ASSY TENSIONER GUIDE COMP CAM CHAIN BOLT FLANGE 6X20 CYLINDER ASSY 7 6 5 3 2 4 8 1 9 9 513 1013...

Page 32: ...FILTERING SRING OIL FILTING SCREEN GAUGE OIL LEVEL CLAMP AC GENERATOR CORD OIL SEAL 19 8X30X5 O RING 30 8X3 O RING 18X3 PIN DOWEL 8X14 BOLT FLANGE M6X28 BOLT FLANGE M6X95 BOLT FLANGE M6X100 BOLT FLANG...

Page 33: ...25 22 17 18 11 19 31 31 28 29 11 11 27 30 26 20 21 12 11 11 24 13 14 16 10 30 23 11 15 9 2 8 8 7 6 6 6 6 4 3 2 5 7 7 7 1 9 FIG 4 CRANKCASE ASSY 2...

Page 34: ...NER CAM CHAIN BOLT FLANGE M6X12 SEPARATOR OIL PIVOT CAM CHAIN TENSIONER OIL SEAL 15 2X12 BOLT FLANGE M6X14 PLATE KICK RETURN STOPPER BOLT FLANGE M6X35 BOLT FLANGE M6X25 Fig 4 CRANKCASE ASSY 2 1 2 3 4...

Page 35: ...FT CONROD ASSY NUT M12X1 25 WASHER 12 149HV 12 140HV NUT LOCK WASHER GEAR KICK DRIVE WASHER 12 NUT M12 KEY WOODRUFF CLIP PISTON PIN PIN PISTON PISTON PISTON RING SET 5 CRANKSHAFT CONROD PISTON ASSY PA...

Page 36: ...ING ARM VALVE ROCKER SHAFT EX ROCKER ARM CHAIN CAMSHAFT CAMSHAFT COMP 16T SHAFT COMP IN ROCK ARM PLATE COMP STOPPER PIN DOWEL 10X16 HOLDER CAMSHAFT 10 9 1 1 2 2 3 3 4 5 6 7 9 8 6 FIG 6 CAMSHAFT ASSY P...

Page 37: ...VER L GASKET L COVER SCREW TAPPING ST4 2X8 F H PLATE L COVER BOLT FLANGE M6X40 BOLT FLANGE M6X65 SPINDLE COMP KICK STARTER ASSY 7 5 5 5 5 5 4 3 3 6 1 2 6 7 FIG 7 LEFT COVER ASSY PARTSMANUAL 540 1006 5...

Page 38: ...PER STARTER CABLE DUCT CARBURETOR COOLING SHROUD LOWER SEAL SHROUD LOWER SHROUD COMP UPPER CLIP HIGH TENSION CORD SEAL SHROUD UPPER SCREW ST4 8X16 F BOLT M6X25 8 FIG 8 FAN COVER AND SHROUD ASSY PARTSM...

Page 39: ...IL PUMP ASSY 1 2 3 4 5 1 1 1 2 1 CHAIN OIL PUMP NUT FLANGE M6 SPROCKET OIL PUMP DRIVEN BOLT M6X25 OIL PUMP SUB ASSY 5 3 2 1 4 4 9 FIG 9 OIL PUMP ASSY PARTSMANUAL 513 1044 500 1064 513 2012 500 1063 51...

Page 40: ...Fig 10 DRIVEN PULLEY AND CLUTCH SUBASSY 1 2 3 1 1 1 OUTER CLUTCH ASSY BELT DRIVE PULLEY ASSY DRIVEN 2 1 3 10 FIG 10 DRIVEN PULLEY AND CLUTCH SUBASSY PARTSMANUAL 539 1004 513 1046 513 1047...

Page 41: ...8 OIL SEAL 20X32X6 GEAR FINAL 40 TEETH GEAR FINAL 36 TEETH CIRCLIP EXTERNAL 20 SHAFT FINAL SHAFT COMP COUNTER 17 TEETH SHAFT COMP COUNTER 13 TEETH NUT COMPRESSOR FLANGE M12 WASHER 12 SHAFT DRIVE 11 FI...

Page 42: ...T FLYWHEEL COMP 8 POST FLYWHEEL COMP 6 POST FAN COMP COOLING BOLT FLANGE M6x18 1 2 3 4 12 FIG 12 ELECTRIC SYSTEM PARTSMANUAL 513 2005 513 1054 513 1055 500 1065 513 1053 513 1154 TALON ENGINES USE TWO...

Page 43: ...1 1 2 1 1 2 3 4 5 FLANGE STARTING CLUTCH SHAFT STARTER REDUCTION GEAR GEAR STARTER REDUCTION BOLT FLANGE M6X16 MOTOR ASSY STARTER 1 5 4 3 2 13 FIG 13 ELECTRIC STARTER ASSY PARTSMANUAL 513 1089 513 10...

Page 44: ...1 Fig 14 DRIVE PULLEY SUBASSY 1 1 PULLEY ASSY MOVABLE DRIVE 14 FIG 14 DRIVE PULLEY SUBASSY PARTSMANUAL 513 1060...

Page 45: ...FIG 15 CARBURETOR 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 2 1 1 1 1 1 8 6 9 7 19 5 16 29 21...

Page 46: ...5x210 TUBE JET MAIN 112 JET SLOW 35 CARBURETOR BODY Fig 15 CARBURETOR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 4 2...

Page 47: ...50 49 19 9 10 11 35 20 20 20 44 24 25 26 4 51 51 8 3 2 1 49 28 27 27 2 4 27 40 39 41 38 43 6 7 18 5 47 37 46 53 54 33 43 36 55 11 46 52 12 45 44 21 22 23 33 33 32 31 30 16 16 48 34 34 17 45 29 15 50...

Page 48: ...MIRROR MOUNT REAR VIEW MIRROR SPRING REAR MIRROR ASSY FRONT FENDER BRACKET R FOAM PADDING 1 FOAM PADDING 2 POSITION LIGHT BULB 3W 12V FRONT REFLECTOR WINKER BULB 10W 12V NUT M8 TAIL LIGHT BULB 21W 5W...

Page 49: ...FIG 17 STEERING SHAFT ASSY 12 5 6 6 7 8 9 11 13 26 25 14 15 16 17 47 46 35 24 42 41 43 40 39 26 30 29 32 31 33 34 28 27 19 18 20 21 22 23 10 4 1 2 38 37 3 36 26 44 45 30...

Page 50: ...T LOCKING FLANGE NUT M8 THROTTLE PEDAL BOLT M8x1 25x145 THROTTLE PEDAL RETURN SPRING L BOLT WASHER M8x1 25x40 NUT M8 THROTTLE PEDAL COMP PAN SCREW M5x15 FLAT WASHER 5 NYLON LOCK NUT M5 BRAKE PEDAL COM...

Page 51: ...FIG 18 SUSPENSION ARM ASSY 31 16 38 15 17 18 19 20 21 22 25 24 23 27 28 29 13 11 10 32 26 26 30 30 7 33 34 12 35 36 37 15 26 9 39 6 5 4 3 2 1 8 14 40...

Page 52: ...UT M10 TIRE FR 20x7 8 GSR RIM FR GSR LOCKING FLANGE NUT M10 CASTLE NUT M12 COTTER PIN 2x20 FR HUB COVER BOLT WASHER M10x1 25x40 FRONT BRAKE CALIPER R CUSHION ASSY FR L 325 BOLT WASHER M10x1 25x80 LOWE...

Page 53: ...13 14 15 16 10 17 20 19 21 8 9 9 18 11 12 1 4 2 3 4 2 3 22 23 3 6 5 4 2 GAS TANK SEAT BELT...

Page 54: ...UM TUBE COMP SEAT COMP R GSR SEAT COMP L GSR 1 1 1 1 2 1 2 1 1 1 1 4 4 4 4 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10 11 12 12a 12b 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Fig 19 GAS TANK SEAT BELT 535 3...

Page 55: ...FIG 20 REAR SWING ARM ASSY UPPER 40 15 28 29 37 30 26 31 32 33 34 36 35 26 39 27 25 1 2 3 4 5 6 7 8 12 13 9 38 16 22 19 20 20 21 17 23 24 9 11 10 18 41 42 43 14...

Page 56: ...ROD SPACER BOLT WASHER M8x1 25x16 BOLT WASHER M10x1 25x195 ENGINE MOUNT COLLAR REVERSE LEVER COVER NYLON LOCKING NUT M8 BOLT WASHER M8x1 25x20 CABLE SPRING LEVER BRACKET BOLT M8x30 LEVER REVERSE PARK...

Page 57: ...FIG 21 ENGING MUFFLER AIR CLEANER OIL COOLER 22 23 21 20 9 25 1 2 6 7 6 5 3 4 24 4 1 29 11 8 12 13 16 18 17 19 10 9 26 27 28 15 32 33 30 34 24 31 32...

Page 58: ...OT CLAMP BOOT SIDE CASE MUFFLER JOINT NUT M6 EX PIPE GASKET AIR CLEANER CASE COMP TAPPING M5x16 SCREW ELEMENT AIR CLEANER AIR CLEANER COVER CHAIN PROTECTOR RR RUBBER CUSHION AIR CLEANER DUCT AIR CLEAN...

Page 59: ...FIG 22 REAR SWING ARM 15 3 9 8 6 11 7 4 13 12 12 14 17 2 1 3 2 1 16 10 18 19 21 22 23 24 22 23 24 20 8 6 5 8 6 25...

Page 60: ...AP M8x1 25x12 REAR FENDER BRACKET R SWING ARM BUSH SWING ARM COLLAR RR BRAKE PAD SET CALIPER ASSY RR CHAIN DISC GUARD BATTERY COVER BATTERY BAND BATTERY LOWER CUSHION BATTERY YTX12 BS RR SWING ARM COM...

Page 61: ...FIG 23 REAR HOUSING 13 8 7 6 2 1 4 3 3 3 5 17 16 15 14 23 22 21 20 18 24 19 3 9 10 11 12 27 30 29 28 11 26 31 10 8 25 32 33...

Page 62: ...AXLE HUB TIRE RR 22x10 10 GSR DLX RIM RR 20X7X8 GSR DLX CAP LUG NUT M10 REAR WHEEL ASSY R SPACER RR WHEEL 16 CASTLE NUT M16 COTTER PIN 4X30 COVER RR HUB REAR WHEEL ASSY L CHAIN MASTER LINK BOLT WASHE...

Page 63: ...FIG 24 WIRE HARNESS ELECTRICAL G H I M Q N E F A 19 10 14 13 12 11 21 15 16 17 18 11 23 26 22 28 31 30 25 27 29 29 35 24 34 33 32 32 20 9 8 7 1 2 3 4 1 2 3 4 5 6...

Page 64: ...D HEAD BOLT M4X10 NYLON LOCKING NUT M4 RESISTOR COMP 10W 10 COIL COMP IGNITION TURN SWITCH BLINKER CONTROL RELAY ENGINE STOP BUTTON TURN SIGNAL REPLAY BOLT M6X20 WIRE HARNESS FRONT IGNITION START SWIT...

Page 65: ...FIG 25 REVERSE ASSY 7 20 14 9 8 4 11 21 12 13 22 18 23 10 19 5 6 15 16 17 3 2 1...

Page 66: ...E GEAR COUNTER GEAR SHAFT COMP GEAR SHIFT YOKE GEAR SHIFTING YOKE SPRING CIRCLIP 12 DRIVE GEAR BUSHING NEEDLE BEARING 22x30x14 BUSHING DRIVE GEAR GEAR SEAT BEARING 6003 DDU RUBBER OIL SEAL GEAR CASE R...

Page 67: ...RED FOR OFF ROAD USE ONLY DO NOT OPERATE ON PUBLIC STREETS ROADS OR HIGHWAYS 3031105 NO RIDING WARNING Moving parts can crush and cut Keep hands clear Do not operate with guard removed PARKING PARKING...

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