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Wasp R500 Pro, Owner'S Manual, Page: 5 / 18

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Wasp R500 Pro Owner'S Manual Download Page 5

STEP FOUR 

STEP THREE 

STEP TWO 

STEP ONE 

Assembly Instructions 

Assembling rolling chassis (Steps 1 to 29) 

Stand frame on end (on a kind, level  
surface, such as an old carpet) & secure.. 
 
Press 

4 x 

3

/4’’ king pin bush

 into front axle tubes top & 

bottom, removing any flashing or paint from tubes. 

 
 

 

Grease & mount front stub 
axles left & right (steering 
arms on top facing  
forwards). 

3

/

4

” x 5” H.T hex bolt, 

3

/

4

” 

washer,

 stub axle,  

3

/

4

” washer ,  

 

3

/4” nylock nut.  

 
 
If required a 

3

/

4

” washer 

may be inserted between the bush & the inner face of the stub 
axle. Tighten until solid then back off the nylock to provide 
movement. 

 
Assemble the 2 x threaded track rods 

4 x 

M10 lock nuts & 4 x track rod ends. 

 

 

Mount rods & rod ends  to the  
top side of the steering column  
actuating arm with the 

M10 x 55 hex bolt 

through the top of the arm in the  
following order: 

M10 x 55 hex bolt

, L.H. rod end, 

2 x M10 

x 20 heavy washer

, R.H track rod, 

2 x M10 x 20 heavy wash-

er

, steering actuating arm, 

M10 nylock nut

.  

 
Mount the opposite ends of the track rods to the underside of  
the stub axle arms using 

M10 x 40 hex bolt

, stub arm, 

2 x M10 

x 20 heavy washers

, rod end & 

M10 nylock

. 

 

 
Grease & fit steering column with the 
solid nylon steering bush. 

1 x 

3

/

4

” washer & split pin. 

 

 
 

Mount the attached steering  
column bush in between the two 
rear facing brackets on the front 
axle beam, with the column  
actuating arm facing up. 

M8 x 55 soc cap & M8 washer 
& M8 nylock nut. 

 

 
Working at the opposite end of the 
steering column, fit the white split 
bush over the column shaft & fix to 
frame upright. 

M8 x 55 soc cap, 2 x M8 washers 
& nylock.  
 
 
 

To pinch the top of the bush together use, 

M8 x 40 hex bolt, 2 x M8 washers & M8 nylock. 

Do not over tighten or you may split the bush. 

 
Mount steering wheel. 

3 x M6 x 30 soc cap, 4 x M6 washers,  
2 x M6 x 25 penny washers,  
3 x nylocks. 
 
 

The

 two black wrist retainer 

straps 

should be fitted to the top 

of the steering wheel using the top 
two M6 x 30 fixings & 2 penny 
washers. 
(The straps are polyester & will 
require a mounting hole making 
near to either end of the webbing, 
any fraying may be sealed with a 
little heat.) 

STEP FIVE 

STEP SIX 

Summary of Contents for R500 Pro

Page 1: ...mance Low ground pressure knobbly tyres reduces damage to the countryside while putting down the power Race proven hydraulic disc braking for instant stopping power Low noise Honda 4 stroke engines providing the punch using as little as 1 litre per hour of unleaded REDWOOD ENGINEERING UK LTD Wasp R500 Pro Rally Kart Owners Manual Assembly Maintenance Manual Phone 0044 0 1253 713266 Fax 0044 0 1253...

Page 2: ...o Rally Kart is not designed for highway use Protective clothing approved safety helmet eye protection must be worn at all times The Kart must never be operated without supervision or in conditions that may cause danger or damage to people or property Both the driver supervisor must have read the owners manual safety precautions before operating the Kart It is a condition of purchase that Redwood ...

Page 3: ... to be less than 30mph DO NOT OPERATE THE KART WITH LONG HAIR LOOSE CLOTHING SCARVES ETC The driver must fit the kart properly within the protection of the frame must be able to operate the controls fully without hindrance The driver should be fitted properly within the seat harness the wrist retainer straps must be used whilst the kart is in operation It is good practice whilst operating off road...

Page 4: ...n 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 l...

Page 5: ...m M10 nylock nut Mount the opposite ends of the track rods to the underside of the stub axle arms using M10 x 40 hex bolt stub arm 2 x M10 x 20 heavy washers rod end M10 nylock Grease fit steering column with the solid nylon steering bush 1 x 3 4 washer split pin Mount the attached steering column bush in between the two rear facing brackets on the front axle beam with the column actuating arm fac...

Page 6: ...M5 washers 6 x M5 nylocks Keep the screw heads on the carrier side nuts washers on the sprocket side N B The sprocket must sit true on the machined register Location shoulder Leave fixings finger tight STEP NINE a Assemble rear axle as follows 1 Slide down lst wheel hub studs first 2 1st axle bearing with plates on loosen grub screw protruding grub screw boss first 3 Sprocket assembly sprocket sid...

Page 7: ...lt to remove the bearings Mount the rear wheels to the hubs with the tapered end of the nuts against the wheel the valves facing outwards Insert the 6mm key into the sprocket carrier adjusting the fit as before It is good practice to clamp to the axle firmly first then tighten the six sprocket fixings The whole assembly may now be un clamped the alignment adjusted the key checked then re clamped I...

Page 8: ... bracket This ensures free movement of the brake operating arm on that side that the M6 screw locknut do not foul the kart bracket Spacers are not normally required on Wasp F series karts Fit the M8 x 20 soc cap screws 2x washers lightly tighten ensuring the disc is roughly centred between the pads At this stage determine if the pads are parallel square to the disc A small degree of non alignment ...

Page 9: ... torque converter The torque converter has a pulley on the engine a pulley on the idle shaft These pulleys are asymmetrical have an almost flat pulley working face on the side nearest the engine This can be lined up in the same way as sprockets checking for parallel that they are in line The straight edge will form a small angle with the pulley This must be equal on both sides of the pulley face t...

Page 10: ... the risers are mounted to the chassis sliders the idle shaft assembly can be introduced into the bearings Step Four When aligned the idle shaft bearing bosses need to be secured to the idle shaft This is done by using a drill bit just smaller than the grub screw hole in the bearing drilling through the hole into the shaft by 1 2mm Be sure the shaft is centralized in the bearings make sure the ris...

Page 11: ...g 1x black heavy gauge washer 2 or 2x 3 8 x 11 4 mudguard washers 1x 5 16 spring washer 1x 5 16UNF x 11 2 hex bolt Torque down to 20ft Lbs Max Be sure the washers do not bend out through over tightening Warning The standard Honda engine has an imperial output shaft UNF threads Not metric in the output shaft its four planet holes The UNF thread form is fin er than on metric bolts Fit tension align ...

Page 12: ...o allow easy removal re fitting Mount the inspection panel using 6x self tapping screws 6x 5mm shake proof washers Step Twenty Mount the small inspection panel R H S of the engine using 4x 3mm equally spaced holes Fit the inspection panel using 4x self tapping screws 4x shake proof washers Warning Never run the engine with the guard or inspection sides removed Wasp R500 Pro Rally Kart Having now f...

Page 13: ...rough the long cable adjuster through the twin screw brass nipple through the pe dal loop back through the nipple Adjust up the play in the cable with the throttle closed Minor adjustment may be made with the cable adjuster Tighten the two nipple screws adjuster lock nuts Step Twenty Five Using r clips supplied the dual peddles can be fitted quickly and easily to suit the size of the driver Always...

Page 14: ...ute the wire to allow for movement of the steering wheel 4 The long wire goes from the switch tag to the existing stop on the engine 5 At the engine pull apart the bullet connection Black wire at the front of the engine joining in the long wire into the bullet then close the bullet securely insulate the connection This stop switch can now be used in conjunction with the existing engine switch Chec...

Page 15: ...ess webbing should be tie wrapped neatly securely to itself under no circumstances allowed to dangle loose Thread the two bungy lengths through the top of the bottom netting skirt and through the bottom edge of the roll bar net Secure each end around on itself wrapping around the roll bar upright Wasp R500 Pro Rally Kart On completion of your kart it is highly recommended that the driver kart supe...

Page 16: ...te the kart seek expert advice CABLES Check all cables run freely with excess play taken out either by using the adjusters or by moving the cable nipples Check the return springs are working effectively and are free from obstruction Lubricate if necessary Replace frayed or damaged cables where necessary STEERING Check for effective and free operation Investigate any heavy steering clean and lubric...

Page 17: ...o remove this build up Petrol is not suitable When the parts are clean and degreased they can be inspected for wear and damage and replaced as necessary When assembling the unit all the moving faces Not the pulley belt faces or the belt should be lightly lubricated with the recommended greaseless dust retardant lubricant The chain should be cleaned and then re lubricated with a low fling chain spr...

Page 18: ...nd or the kart be put in the situation where there is any possibility of the kart rolling over The top speed of the kart should be appropriately governed to the terrain age and ability of the driver This is recommended to be less than 30MPH Suitable protective clothing such as Padded fire retardant overalls sturdy foot wear gloves and an approved helmet with eye protection Must be worn at all time...

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