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Hammerhead Off-Road GTS 150, Manual, Page: 69 / 105

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Hammerhead Off-Road GTS 150 Manual Download Page 69

WHEEL REPLACEMENT

NOTE

Do not disassemble the castle nuts when you replace the wheel and hub

assembly.

WARNING

Improperly installed wheels can adversely affect tire wear and vehicle

handling, which can result in serious injury or death. Always ensure that all

nuts are torqued to specification. Do not service axle nuts that have a cotter pin

installed. An authorized dealer can assist.

1. Position the vehicle on a level

surface.

2. Place the transmission in neutral.

Set the parking brake. Stop the

engine.

3. Loosen the wheel nuts slightly.
4. Elevate the side of the vehicle by

placing a suitable stand under the

frame.

5. Remove the wheel nuts.
6. Remove the wheel.
7. Reverse steps to install.

69

MAINTENANCE

Summary of Contents for GTS 150

Page 1: ......

Page 2: ...ncies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be a...

Page 3: ...Introduction 5 Safety 9 Features and Controls 23 Operation 31 Emission Control Systems 43 Maintenance 45 Specifications 81 Troubleshooting 87 Warranty 91 Maintenance Log 101 3...

Page 4: ...4...

Page 5: ...if not avoided COULD result in serious injury CAUTION SAFETY ALERT CAUTION indicates a hazardous situation which if not avoided COULD result in minor to moderate injury CAUTION CAUTION indicates speci...

Page 6: ...and have a valid driver s license to operate this vehicle No person under the age of 12 may ride as a passenger in this vehicle All riders must be able to sit with backs against the seat and both hand...

Page 7: ...n Number GTS Platinum on frame behind driver seat LE under right rear fender near top of shock w Engine Serial Number on engine case and air filter e Manufacturing Data Label on driver side floorboard...

Page 8: ...8...

Page 9: ...ability or change performance may present a greater risk to inexperienced or younger operators and could result in loss of control and serious injury or death Use only HAMMERHEAD approved accessories...

Page 10: ...cab area The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and or high load conditions for an extended period of time The use of certain...

Page 11: ...ar the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number...

Page 12: ...342 3764 OPERATING WITHOUT INSTRUCTION Operating this vehicle without proper instruction increases the risk of an accident The operator and the supervising adult must understand how to operate the ve...

Page 13: ...sure the seat belts are secured for both the operator and passenger before riding USING ALCOHOL OR DRUGS Operating this vehicle after consuming alcohol or drugs could adversely affect operator judgme...

Page 14: ...operate the controls which increases the risk of loss of control and accident or rollover Never carry more than one passenger in this vehicle OPERATING ON PAVEMENT This vehicle s tires are designed f...

Page 15: ...dent or rollover DO NOT do power slides donuts jumps or other driving stunts Avoid exhibition driving CROSSING HILLSIDES Driving on a sidehill is not recommended Improper procedure could cause loss of...

Page 16: ...lling backwards while climbing a hill could cause a rollover Maintain a steady speed when climbing a hill If you lose all forward speed Apply the brakes gradually until the vehicle is fully stopped Pl...

Page 17: ...fting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly OVERLOADING THE VEHICLE Overloading the vehicle or carrying towing loads may cause...

Page 18: ...n result in the vehicle and or riders falling through the ice Never operate this vehicle on a frozen body of water IMPROPER TIRES AND MAINTENANCE Operating this vehicle with improper tires or with imp...

Page 19: ...cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area Operate this vehicle only outdoors or in well ventilated areas HOT EXHAUST SYSTEMS WARNING...

Page 20: ...can result if you do not follow these instructions Read owner s manual and all labels before you operate this go kart Never operate this go kart without proper instructions Beginners require adult su...

Page 21: ...and loose clothing Wear protective eye wear and clothing Keep arms legs and feet inside kart Do not use alcohol or drugs WARNING Moving parts can crush and cut Keep hands clear Do not operate with gu...

Page 22: ...22...

Page 23: ...TROLS COMPONENT LOCATIONS q Headlights w Brush Guards e Cargo Box r Hip Bars t Steering Wheel y 12 V Aux Output u Ignition Start Switch i Headlamp Beam Selection Switch o Ignition Stop Button 23 FEATU...

Page 24: ...wheel upward or downward to the desired position 3 Hand tighten the bolt SEAT BELTS This HAMMERHEAD vehicle is equipped with seat belts for all riders Always make sure the seat belts are secured for...

Page 25: ...eleases freely 3 Pull each seat belt completely out and inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not operate prop...

Page 26: ...ion when released LIGHT SWITCH The ignition switch key must be in the ON RUN position to operate the headlights Press the TOP of the rocker switch toward the dash to turn the headlights on Press the B...

Page 27: ...the dash HORN NON LE MODELS The vehicle is equipped with a horn To use press in on horn button GEAR SELECTOR F Forward N Neutral R Reverse The gear selectorq is located between the seats To change ge...

Page 28: ...1 Apply the brakes 2 When the vehicle is fully stopped pull the parking brake lever REARWARD as far as possible to set the parking brake 3 Stop the engine 4 To release the parking brake apply the brak...

Page 29: ...dd washers underneath limiter bolt head until desired max speed is reached FUEL CAP The fuel tank filler capq is located in the rear of the vehicle behind the seats When refueling always use unleaded...

Page 30: ...30...

Page 31: ...operate at full throttle or high speeds during the first three hours of use Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute...

Page 32: ...to make sure it s in safe operating condition ITEM REMARKS REF Brake system pedal travel Ensure proper operation page 28 page 64 Brake fluid Ensure proper level page 65 Front suspension Inspect lubri...

Page 33: ...vehicle on pavement or on any public street road or highway including dirt and gravel roads 7 Drive in a manner appropriate for your skills and operating conditions Never operate at excessive speeds N...

Page 34: ...e choke 5 Do not press the throttle pedal while starting the engine 6 If operating an LE model make sure the Engine Stop Switch is in the ON position 7 Turn the ignition key past the ON RUN position t...

Page 35: ...labels before operating this vehicle 2 Visit the Recreational Off Highway Vehicle Association web site rohva org and take the free on line training course Hands on training is also available through...

Page 36: ...ring wheel abruptly Operate at speeds appropriate for your skills the conditions and the terrain DO NOTattempt to do power slides donuts jumps or other driving stunts DRIVING WITH A PASSENGER 1 Comple...

Page 37: ...hicle handling may change with a passenger on board Always travel at a speed appropriate for your skills your passenger s skills and operating conditions Avoid unexpected or aggressive maneuvers that...

Page 38: ...ch can cause skids 3 Correct a skid by turning the steering wheel in the direction of the skid Never apply the brakes during a skid DRIVING UPHILL Whenever traveling uphill follow these precautions 1...

Page 39: ...s and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide 4 If the vehicle begins to slide downhill immediately turn downhill to stop the slide or stop the...

Page 40: ...ted in water that exceeds the floor level service is required before starting the engine Your HAMMERHEAD dealer can provide this service If it s impossible to bring the vehicle in before starting the...

Page 41: ...ocks and low hanging branches 3 Drive slowly and use extra caution when driving on unfamiliar terrain Obstacles are not always clearly visible 4 Do not drive over large obstacles such as large rocks a...

Page 42: ...42...

Page 43: ...iance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements CRANKCASE EMISSION CONTROL SYSTEM This engine is equipped with a closed crankcase system Blow by gases are...

Page 44: ...44...

Page 45: ...just and replace parts as necessary When inspection reveals the need for replacement parts genuine HAMMERHEAD parts are available from your HAMMERHEAD dealer Equivalent parts may be used for emissions...

Page 46: ...is reached first Record maintenance and service in the Maintenance Log ITEM MAINTENANCE INTERVAL WHICHEVER COMES FIRST REMARKS HRS CLNDR MILES KM Steering Daily Check each day before driving the vehic...

Page 47: ...ange at one month Drive chain break in 5 Monthly Adjust and lubricate Fuel System 25 Monthly Inspect check lines and fittings for leaks and abrasion Battery 25 Monthly 250 400 Check terminals clean te...

Page 48: ...necessary torque to specification XU Engine mounts 100 12 M 1000 1600 Inspect Exhaust muffler pipe 100 12 M 1000 1600 Inspect D Ignition timing 100 12 M 1000 1600 Inspect XU Wiring 100 12 M 1000 1600...

Page 49: ...FERENCE Engine Oil 10w40 Conventional Engine Oil page 50 Brake Fluid DOT 4 Brake Fluid page 65 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Fluid page 53 Drive Chain Chain Lube o...

Page 50: ...the oil level within the safe range on the dipstick Do not overfill TIP A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the c...

Page 51: ...nal oil filter is located behind the driver s seat in front of the battery tray The screw on the oil filter should be replaced when oil is changed With the oil drained from the crankcase unscrew the o...

Page 52: ...ed to bring the level to the upper mark on the dipstick 17 Dispose of used oil properly NOTICE This vehicle comes with an external oil cooler for the engine Make sure to use authentic replacements fro...

Page 53: ...Maintain the fluid level at the bottom of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plugq 3 Check the fluid level 4 Add the recommended fluid as needed 5 Reinstall...

Page 54: ...and drive chain failure Don t use a high pressure washer or gasoline to clean the drive chain Adjusting or operating the vehicle with improper rear drive chain slack can result in severe damage to the...

Page 55: ...hand tighten the adjustment bolt until significant brake drag is detected Then back the adjustment bolt out 1 4 turn or until the wheel freely spins 6 Hold the adjustment bolt in place and tighten th...

Page 56: ...is NOTset lever is DOWN 3 Pull the brake cable back to inspect freeplay between the cable end and the caliper bracket Freeplay should be 1 16 1 8 1 5 3 mm 4 To adjust freeplay loosen the jam nutq Tur...

Page 57: ...s driven at higher speeds Immediately check the spark plug for correct color SPARK PLUG CONDITION NORMAL SPARK PLUG The normal insulator tip is gray tan or light brown There will be few combustion dep...

Page 58: ...lightly with graphite grease if possible to ensure easy removal next time the spark plug needs inspection 4 Reverse the procedure for spark plug installation Torque to specification VALVE ADJUSTMENT...

Page 59: ...cam lobes are pointed down 3 Insert correct thickness feeler gauge between end of exhaust valve stem and adjuster screw 4 Loosen locknut and turn adjuster screw until there is a slight drag on feeler...

Page 60: ...d person for service and repair assistance This CVTsystem is intended for use on HAMMERHEAD products only Do not install it in any other product Always make sure the CVT housing is securely in place d...

Page 61: ...the air filter To remove loosen the two 2 boltsq securing the box to the frame as well as the attached intake clamp 2 Pull air filter box away from the machine 3 Loosen the five 5 screws on the outsi...

Page 62: ...ng operation THROTTLE FREEPLAY If the throttle pedal has excessive play due to cable stretch or misalignment it will cause a delay in throttle response especially at low engine speed The throttle may...

Page 63: ...de it far enough to expose the end of the in line cable adjusterw 3 Loosen the adjuster lock nute 4 Move the cable adjuster until desired freeplay is achieved at the throttle pedal While adjusting lig...

Page 64: ...s of braking which could cause an accident resulting in severe injury or death Never operate the vehicle with a spongy feeling brake pedal BRAKE INSPECTION 1 Check the brake system for fluid leaks 2 C...

Page 65: ...ervoir through the front of the vehicle near the left headlamp 1 Position the vehicle on a level surface 2 Place the transmission in neutral Set the parking brake 3 View the brake fluid level in the r...

Page 66: ...e them in this position 3 Place a chalk mark on the center lineq of the front tires as close to the hub axle center line as possible Make sure both marks are the same distance from the floor 4 Measure...

Page 67: ...ecrease when turned right Adjust according to weight of the rider TIRES WARNING Operating your vehicle with worn tires will increase the possibility of skidding loss of control and an accident which c...

Page 68: ...ons All service must be performed by your authorized dealer or other qualified service facility WHEEL NUT TORQUE SPECIFICATIONS Check the wheel nut torques occasionally and when they ve been loosened...

Page 69: ...e that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed An authorized dealer can assist 1 Position the vehicle on a level surface 2 Place the transmissio...

Page 70: ...r engine damage can result if the machine is not thoroughly inspected Take the vehicle in for service before starting the engine Your HAMMERHEAD dealer or authorized person can assist If it s impossib...

Page 71: ...the engine If necessary repeat the drying procedure 10 Take the vehicle in for service as soon as possible whether you succeed in starting it or not Your HAMMERHEAD dealer can provide the required ser...

Page 72: ...duce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehic...

Page 73: ...e vehicle Be careful not to tip a conventional battery sideways which could spill electrolyte BATTERY INSTALLATION Using a new battery that has not been fully charged can damage the battery and result...

Page 74: ...e factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sea...

Page 75: ...mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 vo...

Page 76: ...and safest way to clean your HAMMERHEAD vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last...

Page 77: ...Proper maintenance will protect chrome wheels from corrosion preserve wheel life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas...

Page 78: ...on deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes in a well ventilated area to allow the stabilizer to disperse through the entire fuel delivery sys...

Page 79: ...k fuel lines and injectors should be completely drained of gasoline 7 Reinstall the spark plug cap to the spark plug BATTERY MAINTENANCE Remove the battery and recharge it as outlined in the Battery C...

Page 80: ...the front control arm bolt pockets 1 Place the transmission in neutral Set the parking brake 2 Stop the engine 3 Remove the key to prevent loss during transporting 4 Secure the fuel cap and seats Ens...

Page 81: ...AE 10W 40 Spark Plug Type CR7HSA NGK Drivetrain Drive Clutch Automatic CVT Drive Type 2 Wheel Drive Transmission Transaxle F N R Driveline Chain Chassis Front Suspension Dual A Arm Rear Suspension Swi...

Page 82: ...Capacity 50 lbs Towing Capacity N A Vehicle Capacity 400 lbs Fuse 15A Battery 12V 9 Amp Hours Weight Dry Weight 515 lbs ENGINE TUNE UP SPECIFICATION Idle Mixture Non Adjustable Intake Valve Clearance...

Page 83: ...CR7HSA NGK Drivetrain Drive Clutch Automatic CVT Drive Type 2 Wheel Drive Transmission Transaxle F N R Driveline Chain Chassis Front Suspension Dual A Arm Rear Suspension Swing Arm Steering Rack Pini...

Page 84: ...wing Capacity N A Vehicle Capacity 400 lbs Fuse 15A Battery 12V 9 Amp Hours Weight Dry Weight 515 lbs ENGINE TUNE UP SPECIFICATION Idle Mixture Non Adjustable Intake Valve Clearance 0 004 0 1 mm Exhau...

Page 85: ...35 35 35 Needle 2 shims 2 shims 2 shims 2 shims 1 shim 1 shim 1 shim 1 shim 4000 6000 1200 1800 Main Jet 111 111 111 111 110 110 110 110 Pilot Jet 35 35 35 35 35 35 35 35 Needle 1 shim 1 shim 1 shim 1...

Page 86: ...86...

Page 87: ...ing occurs Clutch malfunction A HAMMERHEAD dealer or other authorized person can assist Poor engine performance Check for fouled plug or foreign material in gas tank fuel filter and fuel lines A HAMME...

Page 88: ...ailure Your authorized dealer can assist ENGINE BACKFIRES POSSIBLE CAUSE SOLUTION Weak spark from spark plug Inspect clean and or replace spark plug Incorrect spark plug gap or heat range Set gap to s...

Page 89: ...fuel Clogged air filter Inspect and clean or replace Throttle control malfunction An authorized dealer can assist Other mechanical failure An authorized dealer can assist POSSIBLE LEAN FUEL CAUSE SOLU...

Page 90: ...wires An authorized dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge...

Page 91: ...ainst defects in material or workmanship on all consumable components general wear items or any parts exposed to friction surfaces stresses environmental conditions and or contamination for which they...

Page 92: ...ty also does not cover acts of God accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle component or part that has been altered structurally...

Page 93: ...L HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT O...

Page 94: ...aler s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another country be sure t...

Page 95: ...ed outside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other t...

Page 96: ...his EPA emissions warranty period is extended for at least as long as the standard factory warranty that HAMMERHEAD provides on the vehicle as a whole The EPA emissions warranty period does not furthe...

Page 97: ...IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILIT...

Page 98: ...rket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law To receive information about how to make a warranty c...

Page 99: ...Ste 400 Flower Mound TX 75028 Or Fax to 214 513 1738 Or go online to www hammerheadoffroad com under dealer s only section HAMMERHEAD OFF ROAD WARRANTY REGISTRATION CARD Must be sent in with a copy of...

Page 100: ...100...

Page 101: ...MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 101 MAINTENANCE LOG...

Page 102: ...102...

Page 103: ...ation 54 Drive Chain Slack Adjustment 54 Driver s Seat Adjustment 24 Driving Downhill 39 Driving Downhill Improperly 16 Driving in Reverse 40 Driving on a Sidehill Sidehilling 39 Driving on Slippery S...

Page 104: ...New Operator Driving Procedures 35 Noise Emission Control System 43 Normal Plug 57 Notice 95 O Off Road Warranty Registration Form 99 Oil Change 51 Oil Check 50 Oil Recommendations 50 Operating at Exc...

Page 105: ...nspection 65 Stop Engine Button Non LE Models 27 Stopping the Engine 34 Storage Area Covers 79 Storage Tips 78 T Tail Light Lamp Replacement 70 Throttle Freeplay 62 Throttle Freeplay Adjustment 63 Thr...

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