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Hammerhead SUPER 250 2008, Owner'S Manual And Parts Manual

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Hammerhead SUPER 250 2008 Owner'S Manual And Parts Manual Download Page 38

VALVE*TRANNY*ASSY.(I)

VALVE TRANNY ASSY.(I)

REF NO.

PART NO.

DESCRIPTION

REQ'D

NO.

1

152MI-022500

VALVE TAPPET SEAL

2

2

172MM-022300

VALVE CAM

1

3

152MI-021007

ROCKER

2

4

172MM-022001

INLET VALVE

1

5

172MM-022005

EX.VALVE

1

6

172MM-022002

OUTER VALVE SPRING

2

7

152MM-022003

INNER VALVE SPRING

2

8

152MI-022005

SPRING VALVE DISC

2

9

152MI-022001

SPRING VALVE SEAT

2

10

152MI-022006

VALVE CLIP LOCK

4

11

NTN: 16002

ROLL BEARING

2

12

GB894 1-86-15

BEARING CIRCLIP

1

13

172MM-022310

CHAIN WHEEL

1

14

172MM-022301

CAMSHAFT

1

Summary of Contents for SUPER 250 2008

Page 1: ...MINIMUM RECOMMENDED Operator age READ THIS MANUAL CARERFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION...

Page 2: ......

Page 3: ......

Page 4: ...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 instruction...

Page 5: ...azards associated with operating or maintaining a kart You must use your own good judgment You will find important safety information in a variety of forms Including These signal words mean Physical h...

Page 6: ...rotective gear Drive Off Road Only Your kart is designed and manufactured for off road use only The tires are not made for use on pavements and the kart does not have turn signals and other features r...

Page 7: ...sion can greatly reduce a driver s visibility and judgment Driving at night is dangerous and can increase the possibility for an accident Never ran your Kart indoors The exhaust from the engine contai...

Page 8: ...ormation and recommendations to help you drive your kart safely Please take a few moments to read these pages The labels should be considered permanent parts of the kart If a label comes off or become...

Page 9: ...er protective clothing You don t have any alcohol or drugs in your system Protective Clothing For your safety we strongly recommend that you always wear an D O T approved motorcycle helmet eye protect...

Page 10: ...ly Likewise drugs even if prescribed by a physician can be dangerous while operating a kart Consult your doctor to be sure it is safe to operate a vehicle after taking medication Additional Driving Ge...

Page 11: ...ers 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 highways Keep Hands and Fee...

Page 12: ...Not Perform Stunts You should always operate your kart in a safe and reasonable manner When driving always keep all four wheels on the ground Radiator Indicator Lamp During the driving you should alwa...

Page 13: ...ires tighten the nuts insert cotter Pin and put on the Rubber Cover g Raise the C B C bar as the picture shows h Install C B C bar RR put on R Washer i Install Head Rest j Check all nuts and bolts wir...

Page 14: ...COMPONENTS Gear box oil CAPACITIES Maximum load Fuel tank Engine oil Starting Climbing Battery Head Light Tail Light Fuse Water cooled 4 Stroke 250cc 72mm 60mm 244cc 10 1 VEKS4 CV30 10 5Kw 6000rpm 17...

Page 15: ...ntrol Front tire 20 7 8 Rear tire 22 10 10 Front Suspension Independent Dual A Arm Rear Suspension Full Independent Rear Suspension Oil Damped Shocks Restraint System Dual 4 point Harness Final Drive...

Page 16: ...b Brake The brake is the left foot pedal See Fig 1 Applying pressure to the pedal slows or stops the kart c Start engine Insert the key into key switch turn the key clockwise release the key when the...

Page 17: ...are in place before operating the kart i Check the Lights Check the headlights brake light and tail light are all working j Check the Steering Check that the steering wheel moves freely in both direct...

Page 18: ...Component Locations...

Page 19: ...b Move the seat to the desired position c Be sure that the seat adjustment handle snaps back into place and that seat is locked into position E Forward and Reverse Gear a Push the brake pedal down Th...

Page 20: ...controllable speed when turning to prevent the kart from rolling over The driver should keep their heels on the ramp of the main board when turning See Fig 5 Keeping their leg on the foot pedal the d...

Page 21: ...Check the oil level before each use of the kart or after each 10 hours of operation Add oil when necessary to keep the level between the bottom of the dipstick and the 0 mark Do not mix various grade...

Page 22: ...the idle speed if necessary Figure 9 D Cleaning Instructions Keep your kart clean With a clean rag wipe off all dirt and oil from around the controls Wipe off any spilled fuel and oil Keep the engine...

Page 23: ...ving the air spark plug and pouring a small amount of oil into the plug hole then re fit the plug c Do not save or store gasoline over winter Using old gasoline which has deteriorated from storage wil...

Page 24: ...a The front wheels should toe in from 1 8 to 1 4 inch To check for alignment measure distance A and B between the centerline CL of the wheels The proper toe in dimension A should be 1 8 to 1 4 inch gr...

Page 25: ......

Page 26: ...The maintenance intervals in the following table are based upon average driving conditions Driving in unusually dusty areas require more frequent servicing...

Page 27: ......

Page 28: ...007 SPRING SEAT FLANGE BOLT 1 5 152MI 023006 SPRING 1 6 152MI 023004 TENSIONER SEAL 1 7 172MM 023007 WATER INFLOW RUBBER TUBE 1 8 172MM 023009 WATER TUBE SHEATH 1 9 QC T621 1999 B24 WIRE CLAMP 2 10 15...

Page 29: ...Cylinder Cover Assy...

Page 30: ...x1 25 1 13 152MI 021013 BOLT M8x25 1 14 152MI 021008 VISION HOLE CAP 1 15 152MI 021016 WASHER 8 3 16 152MI 021012 EAR WASHER 1 17 152MI 021014 WASHER 12 2 18 152MI 021009 VISION HOLE CAP SEAL 1 19 152...

Page 31: ...CYLINDER COVER ASSY 2...

Page 32: ...TEMPERATURE RETAINER COVER 1 12 172MM 022400 SPARK PLUG 1 13 152MI 021017 FLANGE BOLT M6x25 2 14 172MM 022800 EX OUTLET SEAL 1 15 152MI 022600 WATER TEMPERATURE SENSOR 1 16 GB T6191 1986 INNER HEX FLA...

Page 33: ...Crankcase Assy...

Page 34: ...FLANG BOLT M6x60 5 12 152MI 011018 FLANG BOLT M6x70 3 13 152MI A 011006 FLANG BOLT M6x105 1 14 152MI 011010 HANGER OUTER BUSH 2 15 152MI 011008 O RING 15 8x2 4 4 16 152MI 011009 HANGER INNER BUSH 2 17...

Page 35: ......

Page 36: ...M 013001 DIPSTICK 1 12 172MM 013019 EXHAUST THREE JOINT 1 13 152MI 021008 VISION HOLE CAP 1 14 172MM 013031 FLANGE BOLT M6x80 1 15 172MM 013028 O RING 30x3 55 1 16 152MI 021009 VISION HOLE CAP SEAL 1...

Page 37: ...E FIRST PISTON RING 1 2 172MM 040009 THE SECOND PISTON RING 1 172MM 042000 OIL RING ASSY 1 3 172MM 040005 PISTON 1 4 172MM 040007 PISTON PIN 1 5 152MI 040011 OIL TUBE JOINT 1 6 152MI 040010 OIL TUBE J...

Page 38: ...KER 2 4 172MM 022001 INLET VALVE 1 5 172MM 022005 EX VALVE 1 6 172MM 022002 OUTER VALVE SPRING 2 7 152MM 022003 INNER VALVE SPRING 2 8 152MI 022005 SPRING VALVE DISC 2 9 152MI 022001 SPRING VALVE SEAT...

Page 39: ...2 VALVE TRANNY ASSY 2 REF NO PART NO DESCRIPTION REQ D NO 1 172MM 022200 TIME CHAIN 1 2 172MM 023200 TENSIONER 1 3 172MM 023001 CHAIN GUIDE PLATE 1 4 GB96 85 6 D Zn BIG WASHER 1 5 GB T5781 2000 HEX FL...

Page 40: ...ION REQ D NO 1 172MM B 012001 LEFT SIDE COVER 1 2 172MM B 012002 WINDSHIELD 1 3 GB T 818 2000 M6X12 BOLT 3 4 172MM B 012005 BOLT M6X28 7 5 152MI 013008 BOLT M6X35 2 6 152MI 021005 DOWEL PIN 10X14 2 7...

Page 41: ...TER PUMP HOUSING 1 4 172MM 080002 WATER PUMP HOUSING SEAL 1 5 172MM 080001 WATER PUMP SHAFT 1 6 152MI 013009 FLANGE BOLT M6x40 2 7 152MI 02017 FLANGE BOLT M6x25 2 8 GBT8931 86 19 CIRCLIP 1 9 152MI 080...

Page 42: ...CARBURETOR COMP CARBURETOR COMP REF NO PART NO DESCRIPTION REQ D NO 1 172MM 100000 CARBURETOR COMP 1...

Page 43: ...152MI 070001 OIL PUMP SPROCKET 1 6 152MI 073000 OIL PUMP CHAIN 1 7 152MI 071004 INNER OIL PUMP ROTOR 1 8 152MI 071005 OUTER OIL PUMP ROTOR 1 9 152MI 070002 OIL PUMP DIVISION PLATE A 1 10 152MI 072000...

Page 44: ...LOCK 7 172MM A 052006 RETURN SPRING 8 172MM A 052003 SIDE DISC 9 T896 1986 9 CIRCLIP 10 172MMZ052310 ROLL BEARING 22X29X 18 11 T893 1 1986 28 CIRCLIP 12 1060902 BEARING 13 172MM A 052300 DRIVEN WHEEL...

Page 45: ...O PART NO DESCRIPTION REQ D NO 1 172MM 090001 DOUBLE GEAR AXLE 1 2 172MM 092000 DRIVEN GEAR 1 3 172MM 091000 DOUBLE GEAR 1 4 172MM 090007 FIX PLATE 1 5 172MM 093000 START MOTOR 1 6 152MI 080013 FLANGE...

Page 46: ...2 10 172MM B 062009 GEAR SHIFTING BUSH 1 11 172MM B 062001 SECONDARY SHAFT 1 12 172MM B 062007 WASHER 24X33X2 2 13 GB T894 1 86 24 CIRCLIP 1 14 K24X28X10 NEDDLE BEARING 1 15 172MM B 062003 DRIVEN GEA...

Page 47: ...M 051006 WASHER 14 5X30X2 3 172MM A 051005 DRIVE WHEEL 4 172MM A 051003 DRIVE WHEEL BUSH 5 172MM A 051100 MOVABLE DRIVE WHEEL 6 172MM A 051200 CENTRIFUGAL ROLLER 7 172MM A 051004 SIDE BLOCK 8 172MM A...

Page 48: ...2 172MM 033000 IGNITION COIL 1 3 172MM 013008 WIRE PLATE 1 4 172MM 031000 FLYWHEEL 1 5 172MM 032000 STATOR 1 6 GB T701 2000 INNER HEX FLANGE BOLT M8x18 3 7 172MM 040001 NUTM 16x1 1 8 172MM 040002 WASH...

Page 49: ...6303 1 9 GB T 276 1994 6305 2RS BEARING 6305 2RS 1 10 172MM B 011107 BEARING M8X48 3 11 172MM B 011111 BEARING M8X30 5 12 1P52M l A 011007 BEARING M8X55 2 13 CF188 332004 O RING 19X2 5 1 14 CF188 3320...

Page 50: ...SPEED 1 14 172MM B 063000 OUTPUT DRIVE SHAFT ASSY 1 15 172MM B 063001 OUTPUT DRIVE SHAFT 1 16 172MM B 063005 OUTPUT DRIVEN GEAFT 1 17 172MM B 063002 ADJUSTING GASKET IF NEED 18 172MM B 063003 DRIVE CO...

Page 51: ...SHIFT 1 7 CF188 065201 GASKET 1 8 CF188 065203 DRIVEN FAN GEAR 1 9 CF188 065204 GASKET 13 5x22x1 1 10 CF188 065202 FAN GEAR SHAFT 1 11 CF188 065204 SPRING 1 12 CF188 065206 GASKET 6 6x20x2 2 13 152M1...

Page 52: ...FRAME GROUP...

Page 53: ...0 156 WINKER LIGHTASSY R FR L RR 20 9 700 004 BANJO BOLT M10x24 21 6 000 089 BRAKE HOSE ASSY L 34 22 6 000 090 BRAKE HOSE ASSY R 43 23 6 000 230 BRAKE HOSE ASSY RR 80 24 6 000 232 THROTTLE CABLE COMP...

Page 54: ...00 116 FOAM PADDING 2 45 9 000 004 A POSITION LIGHT BULB 3W 12V AMBER 46 6 000 114 FRONT REFLECTOR 47 9 090 006 WINKER BULB 10 W 12 V 48 9 220 008 LOCKING FLANGE NUT M8 49 9 106 012 BOLT M6X12 50 2 10...

Page 55: ...STEERING SHAFT ASSY...

Page 56: ...18 8 010 157 250 TIE ROD 19 6 000 062 ROD END 20 9 300 010 FLAT WASHER 21 9 400 010 LOCK WASHER 10 22 9 800 010 CASTLE NUT M10 23 9 500 215 COTTER PIN 24 7 020 066 STEERING KNUCKLE DUST COVER 25 8 02...

Page 57: ...FRONT SUSPENSION ARM ASSY...

Page 58: ...14 6 000 14 IB FR WHEELASSY R 20x7 8 15 7 020 016 FR BRAKE CALIPER PAD SET 16 6 000 028 FRONT BRAKE CALIPER L 17 8 010 054 BRAKE DISC 18 9 040 002 DUST SEAL 47x25 7 19 9 030 002 Z BEARING 6204 Z 20 9...

Page 59: ...FULL SHIFTING ASSY...

Page 60: ...x30 19 6 100 001 PIVOT ARMSHIFT 20 6 100 236 SHORT CLEVIS ROD 21 9 200 010 L LEFT TURN NUT M10 22 9 220 008 LOCKING FLANGE NUT M8x1 25 23 9 110 040 BOLT WASHER M10x40 24 6 000 233 LONG CLEVIS ROD 25 9...

Page 61: ......

Page 62: ...9 P FUEL TANK COMP PURPLE 12 4 000 029 BL FUEL TANK COMP B S BLACK 12 4 000 029 G FUEL TANK COMP B S GREEN 13 9 108 025 BOLT WASHER M8x1 25x25 14 8 010 034 TANK COMP COLLAR 15 7 020 005 RUBBER MOUNT 1...

Page 63: ...AIR CLEANER RADIATOR BATTERY MUFFLER ASSY...

Page 64: ...10 028 BATTERY COVER 21 6 000 085 BATTERY YTX12 BS 22 7 021 023 BATTERY BAND 23 7 020 020 BATTERY LOWER 24 7 090 049 MUFFLER COMP EX 25 9 040 027 MUFFLER JOINT NUT M6 26 7 090 050 EX PIPE GASKET 27 9...

Page 65: ...REAR SUSPENSION ASSY...

Page 66: ...EN HEAD BOLT M8x1 25x16 24 6 000 244 CV SHAFT JOINT 25 6 000 245 CUSHION ASSY RR L 480 26 6 000 247 SWING ARM COMP R 27 6 000 246 SWING ARM COMP L 28 9 040 011 DUST SEAL 29 6 000 148B REAR WHEEL ASSY...

Page 67: ...AR FENDER BRACKET L 2 BOLT MOUNT 47 7 190 010 PROTECTOR DISC 48 7 190 011 SENSOR BRACKET 49 6 000 268 SENSOR 50 7 050 001 MAGNET 51 9 60 308 SCREW M3X8 52 6 000 244 C CIRCLIP 53 7 190 014 LARGE CLAMP...

Page 68: ......

Page 69: ...N START SWITCH 16 6 000 153 RELAY COMP AUDIBLE PILOT WINKER 17 6 000 251 TEMPERATURE BUZZER 18 6 000 252 HORN RECTIFIER 19 6 100 253 SOCKET COMP 20 9 600 655 PAN SCREW M6x55 21 6 100 254 WIRE HARNESS...

Page 70: ...ING BRAKE 1 2 9 090 008 LABEL REVERSE LEVER 1 3 9 090 023 LABEL GEAR CASE 1 4 9 090 010 LABEL NO LONG HAIR 1 5 9 090 011 LABEL WARNING 1 6 9 090 012 LABEL NO CLIMBING 1 7 9 090 013 LABEL WARNING 1 8 9...

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