Assembly Instructions
Tips & Helpful Notes.
Key to terminology.
E.g :
M8 x 55 hex bolt.
M
= metric.
8
= 8mm diameter thread / shank.
55
= 55mm the length of the bolt measured from the underside of
the bolt head to the end of the thread.
E.g :
M6 washer
= Normal flat washer with a 6mm hole in the middle.
Hex bolt
= A hexagonal head with a plain shank then thread.
Hex set
= A bolt threaded all the way to the head.
Socket cap
=
Allan key driven bolt.
Cup square
=
Coach bolt head domed with a square locator
Roof bolt
=
Shallow domed head with a screwdriver crossed head.
Nylock nut
=
Standard nut with a plastic insert to hold the nut tight.
Locking nut
=
Thinner than a standard nut without any plastic insert.
Penny washer
= A large diameter washer (aprox. 25mm).
Points to note before assembly:
Please read carefully the instructions through first before attempting to work on the kart.
Take each step in the assembly of the kart slowly with precision. Work in a clean, clutter free
environment. Use suitable containers for loose parts such as fixings.
Do not throw any of the packaging away until your kart has been completely assembled & is
operating correctly.
For safety reasons, where at all possible, bolts should face downwards. All bolts should be locked
in position with their nylock insert or a thread locking compound such as Locktite should be used.
(Drilling & split pinning may be used if required.)
Left & right
hand
of the frame is described as the driver’s left & right as they would be sat in the
kart.
Each assembly instruction is numbered in step by step order, with the fixings required for each
instruction written in
bold
for ease of identification & also so that fixings may be readily selected
before assembly begins.
A standard flat washer is normally placed on a fixing just before the nylock nut, sometimes two
washers can be used together, & on plastic or slotted holes a washer should be used on either side
of the component
Grease all moving parts on the frame.