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Kinroad 1100GK-2 Owner'S Manual Download Page 27

26

REPAIR

C. Clutch replacement
Do not remove the whole engine from vehicle when you replace the clutch, but you’ll
need to remove rear suspension, driven shaft, clutch cable, muffler, wires and
rubber cushion that is in the middle of transmission and frame.

1. Remove bolt M14 (

See Fig. 22

)

Figure 22

2. Remove two bolts (M12) on the starter (

See Fig. 23

), Remove the starter (

See Fig. 24

)

Figure 23

Figure 24

Summary of Contents for 1100GK-2

Page 1: ...0 Owner s manual EEC READTHISMANUALCAREFULLY ITCONTAINSIMPORTANTSAFETYINFORMATION MINIMUM RECOMMENDED OPERATOR AGE 650 800 1100GK 2 ...

Page 2: ...650GK 2 during the 90 days warranty period please contact your nearest authorized dealer for repairs What is not covered under thiswarranty This warranty does not cover any seller vehicle that has been subjected to a This warranty does not cover any seller vehicle in any way so to adversely affect its safety or reliability b Renting c Disassembly adjusting or repairing of the vehicle in any way so...

Page 3: ...RTANTSAFETY INFORMATION 5 4 SAFETY LABELS 7 5 AREYOUREADY TO DRIVE 8 6 IS YOURVEHICLEREADY TO DRIVE 11 7 SAFE DRIVING PRECAUTIONS 12 8 SPECIFICATIONS 14 9 OPERATIONS 15 10 SERVICEINSTRUCTIONS 20 11 REPAIR 25 12 PERIODICAL CHECK AND SERVICE 36 13 WIRING DIAGRAM 37 ...

Page 4: ...result in serious injuries Be sure to follow the recommended maintenance schedule and service your kart accordingly Preventative maintenance is extremely important to the longevity of your Go Kart We believes in conservation and protection of earth s natural resources To that end we encourage every vehicle owner to recycle trade in or properly dispose of as appropriate used motor oil coolant and o...

Page 5: ...Go Kart You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels On the Go Kart Safety Messages Preceded by a safety alert symbol and one of two signal words WARNING or CAUTION Thesesignal words mean Physical harm may result from failure to adhere to the instructions that are described within the WARNING labels Safety Headings suc...

Page 6: ...this Go Kart s size and weight Because many accidents involve inexperienced or untrained drives we urge all drivers to take a training course approved by the Go Kart Safety Institute Check with your dealer for more information on training courses BeAlert for Off Road Hazards The terrain can present a variety of challenges when you drive off road Continually read the terrain for unexpected turns dr...

Page 7: ... Go Kart Failure to adhere to this warning will cause physical harm to your body Skidding or Sliding The terrain surface can be a major factor affecting turns Skidding a turn is more likely to occur on slippery surfaces such as snow ice mud and loose gravel If you skid on ice you may lose all directional control To avoid skidding on slippery terrain keep you speed low and drive carefully ...

Page 8: ...nformation and recommendations to help you drive your Go Kart safely please take a few moments to read these pages The labels are considered permanent parts of the Go Kart If a label comes off or becomes hard to read contact your dealer for warning labels replacements ...

Page 9: ... motorcycle helmet eye protection 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 following suggestions will help you choose the proper driving gear Helmets and Eyes Protection Your helmet is your most important piece of driving gear because it offers the ...

Page 10: ... skills Do not drive in rough terrain until you get accustomed to the Go Kart s controls and feel comfortable with its size and weight Age Recommendation It is strongly recommended that no one under the age of 16 be permitted this Go Kart without adult supervision Operating Go Kart without proper instruction could increase your risk of an accident which could leadto serious injury or death Attempt...

Page 11: ...ges or other problems you can not see Pre drive Inspection Check the following items before you get on the Go Kart Engine Oil Check the level and add oil if needed Check for leaks Coolant Check the coolant and add coolant if need Check for the leaks Fuel Check the level and add fuel if needed Also make sure the fuel fill cap is securely fastened Check for leaks Tires Use a gauge to check the air p...

Page 12: ...e play and adjust if needed Press the throttle to make sure it moves smoothly without sticking and snaps back automatically when it is released Clutch cable Check the free play of clutch cable and adjust if needed Press the clutch cable to make sure it moves smoothly without sticking and snaps back automatically when it is released Brakes Press the brake pedal several times check for proper brake ...

Page 13: ...to react Never drive past the limit of visibility Maintain a safe distance between your Go Kart and other on road vehicles Always exercise caution and use extra care on rough slippery and loose terrain Removing handfrom Steering wheelor feet from foot controls during operation can reduce your ability to control the Go Kart or could cause you to lose your balance and fall off the Go Kart Always kee...

Page 14: ...use loss of traction or vehicle control which could result in an accident including an overturn Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the Go Kart on such terrain Always be especially cautious on these kinds of terrain Attempting wheelies and other stunts increases the chance of an accident including an ove...

Page 15: ...nce 310mm SPECIFICATIONS Brake Track 7m 20miles h Top speed 50 miles h or limited as customers require CHASSIS Front Rearbrake Hydraulicdisc rightfoot control Front tire 25 8 12 Reartire 25 10 12 Front Suspension Independent DualA Arm RearSuspension Independent Dual A Arm Final Drive shaft driven TIRE PRESSURE Front 70kpa 0 7kg c 10psi Rear 70kpa 0 7kg c 10psi ...

Page 16: ...wheels and slows or stops the kart c Clutch The left foot pedal controls the clutch cable See Fig 2 With the pedal down you can shift the shift lever Figure 1 Each time prior to starting the engine check the throttle assembly to ensure that when pedal is pushed all the way forward the assembly is working smoothly and returns to idle when released Do not operate if pedal or engine throttle linkage ...

Page 17: ...clockwise to the on position release the key and the throttle when the engine starts Each time prior to starting the engine check the throttle assembly to ensure that when pedal is pushed all the way forward the assembly is working smoothly and returns to idle when released Do not operate if pedal or engine throttle linkage fail to return to idle If unable to correct the problem through lubricatio...

Page 18: ...y or replace the clutch if necessary 6 Check Tires Check tires condition and pressure The pressure on both Front and Rear tire is 12psi 7 Check Throttle Check for smooth operation Ensure the throttle snaps back to idle 8 Check Engine Stop key Perform engine stop key test Repair as necessary 9 Check all Nuts Bolts and fasteners Check wheels to see that all axle nuts and lug nuts are tightened prope...

Page 19: ... back into place and that seat is locked into position See Fig 4 E ParkingAdjustment Park brake OFF Park brake On Figure 6 a Pull the park brake lever up so that the unit can engage park brake b To release the unit press button on front end of parking lever then push the parking lever to the bottom c Adjustthe parking cable if necessary Before attempting to adjustthe seat ensure that engine of the...

Page 20: ...ow speed slowly 3 Avoid braking strongly 4 Do not exceed the vehicle speed on the below schedule H Starting And Operating Instructions a Before starting the engine be sure that the driver is seated properly in the Go Kart and tighten the seatbelt b Testing the Go Kart in a open place at the beginning to learn how to start turn and stop c Operate the Go Kartslowly until you are familiar with it d T...

Page 21: ...10 hours of use thereafter That will insure proper lubrication of internal parts and prevent costly repairs due to excessive wear Figure 10 Figure 11 Figure 12 Figure 13 a With the engine warm put the vehicle on the level ground b Shut down the engine put a collecting oil plate under the engine oil outlet Loosen the oil outletplug in the warm engine Let the engine oil outfully seeFig 10 c Tighten ...

Page 22: ...ground b Shut down the engine put a collecting oil plate under the transmission oil outlet Loosen the oil outlet plug in the warm engine Let the transmission oil out fully see Fig 15 c Remove the iron dust plug this plug has a magnet on it Iron dustcaused by moving parts will stick to the plug Clean the iron dustfrom this dust plug d Tighten the transmission oil outlet plug and the iron dustplug e...

Page 23: ...unterclockwise and open the cap see Fig 17 8 Pour fresh coolant of the specified type into the reserve coolant tank till the coolant reaches 2 5 to 3 5 of the reserve coolant tank volume 9 Close the reserve coolant case cap turn it clockwise and tighten it Top up the reserve coolant If the coolant in the reserve tank is less than 2 5 it needs to be topped up 1 Turn the reserve coolant case cap cou...

Page 24: ... at least once a year to insure easy starting and good engine performance New and used coolant can be hazardous Children and pets may be harmed by new or used coolant Continuous or brief contact with coolant may be dangerous for your health Keep new and used coolant away from the children and pets To minimiz e your exposure to new and used coolant wear a long sleeve shirt and moisture proof gloves...

Page 25: ...ff and dirt and oil from around controls Wipe off any spilled fuel and oil Keep the engine clean of foreign object and be sure to check that air intake fan is free of debris for proper cooling H Kart Lubrication Lubricate vehicle every 90 days of use Apply several drops of oil in specific points I Storage Instruction In the event your kart is not to be operated for periods in excess of 30 days or ...

Page 26: ...stle nuts whenyou replacethe front wheels See Fig 20 Tighten the nuts after replacing the wheels Figure 20 B Rear Wheel Replacement Do not disassemble thecenter castle nuts whenyou replacethe front wheels See Fig 21 Tighten the nuts after replacing the wheels Figure 21 ...

Page 27: ...heclutch but you ll need to remove rear suspension driven shaft clutch cable muffler wires and rubber cushionthat is in themiddle of transmissionand frame 1 Remove bolt M14 See Fig 22 Figure 22 2 Remove two bolts M12 on the starter See Fig 23 Remove the starter See Fig 24 Figure 23 Figure 24 ...

Page 28: ...move two nuts M14 on two side of transmission SeeFig 25 26 Figure 25 Figure 26 5 Remove two bolts M8 on the low mud plate of transmission See Fig 27 28 Figure 27 Figure 28 6 Remove the mud plate See Fig 21 Figure 29 ...

Page 29: ...28 REPAIR 7 Remove the transmission See Fig 30 31 Figure 30 Figure 31 8 Remove upper mud plate SeeFig 32 Figure 32 ...

Page 30: ...ft into the hole See Fig 33 Remove six bolts on the pressing plate of clutch SeeFig 34 Figure 33 Figure 34 10 Remove the pressure plate See Fig 35 Remove the friction disc of clutch See Fig 36 37 Figure 35 Figure 36 Figure 37 ...

Page 31: ...9 Figure 38 Figure 39 11 Fix pressure plate of clutch Two bolts with Y G mark must be inserted into two anchor hole SeeFig 40 Tighten six bolts with torque 30 N m SeeFig 41 Figure 40 Figure 41 12 Fix upper mud plate See Fig 42 43 Figure 42 Figure 43 13 Fix parts according to reverse operation to the disassembly ...

Page 32: ... crankshaft Mark A on the sprocket of crankshaft must be in the middle of double white links of timing chain 2 Fix the guide plate 3 Fix the tensional plate 4 Fix the sprocket Mark on the sprocket must be in straight line to the single white link on the timing chain ...

Page 33: ...ound the crank shaft See Fig 44 direct the line on the pulley of crankshaft straight to the 0 degree line on the cover of engine See Fig 46 Figure 44 Figure 45 Figure 46 2 Remove the rocker cover of head by removing two bolts See Fig 47 Figure 47 ...

Page 34: ...1 as to obtain the hole direction shown by Fig 4 Insert the screwdriver into the hole turn the drive of oil pump shaft untill parallel to the crankshaft SeeFig 48 49 Figure 48 Figure 49 5 Align the mark 2 on the shaft of distributor to the mark 1 on the aluminum housing See Fig 50 Figure 50 ...

Page 35: ...utor slowly to the hole See Fig 51 Confirm the direction of distributor is as per the figure See Fig 52 53 Tighten the nut of distributor housing Figure 51 Figure 52 Figure 53 7 Fix the cover of the distributor See Fig 44 Figure 42 ...

Page 36: ...the front wheels should be 1 18 inches 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 18 inches greater than dimension B c To adjust the alignments loose the lock nuts on both sides of Front Tie Rods To make Dimension B smaller turn the rod to the left Turn the rod to the right to make Dimension B larger After adjus...

Page 37: ...oints I I R 6 Exhaust I I 7 Transmission oil I R Ignition 8 Coil I 9 Distributor for ignition I 10 Air cleaner C I 11 Throttle cable and choke I A L I R A 12 Fuel tank cover Breathe hose and joint I I R 13 Idle I 14 Breathe hose I 15 Fuel hose and joints I I I R Control system 16 Wire and plugs I 17 The free display of clutch pedal I I R 18 Brake fluid hose joints I 19 The free display of brake pe...

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