TrailMaster MINI XRX Assembly Manual Download | Manualshive

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Summary of Contents for MINI XRX

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Page 2: ...6 wrenches or socket 4 Remove metal crating and unpack all parts 5 Place parts out on the floor and take inventory making sure of proper quan tities At this time if missing or damaged parts call or email us 6 Remove bolts and nuts at lower front A arms GOKARTMASTERS COM GOKARTMASTERS COM GOKARTMASTERS COM GOKARTMASTERS COM GOKARTMASTERS COM GOKARTMASTERS COM ...

Page 3: ...n Sheet Fill battery according to Instruc tion Sheet Let sit 10Lay out all hardware on a clean work bench Take inventory per hardware list 11Locate one of the long cage bars GOKARTMASTERS COM GOKARTMASTERS COM GOKARTMASTERS COM GOKARTMASTERS COM 12Place bar on front pin above head light GOKARTMASTERS COM ...

Page 4: ...Locate 2 long bolts 4 nuts 8 chrome cup washers GOKARTMASTERS COM GOKARTMASTERS COM 16It may be necessary to align the hole in the bar with a screwdriver 17Install a second cup washer and the nut NOTE DO NOT TIGHTEN AT THIS TIME GOKARTMASTERS COM GOKARTMASTERS COM 18Install bolt washers and nut at rear of bar GOKARTMASTERS COM ...

Page 5: ...RS COM GOKARTMASTERS COM 19Repeat steps 16 19 for the other top bar 20Locate the passenger side bar GOKARTMASTERS COM GOKARTMASTERS COM 21Locate 4 large bolts 6 cup washers and 2 nuts GOKARTMASTERS COM 24It is necessary to tap the plastic cap all the way onto the bar Use a plastic or rubber mallet or a block of wood with a standard hammer GOKARTMASTERS COM ...

Page 6: ...OKARTMASTERS COM GOKARTMASTERS COM 27Install the second washer and nut on the bottom bolt NOTE DO NOT TIGHTEN THE HARDWARE GOKARTMASTERS COM 28Repeat steps 20 27 for the driver s side bar 29Locate the top bar weldment assem bly GOKARTMASTERS COM GOKARTMASTERS COM 30Locate 4 large bolts and 4 chrome cupped washers GOKARTMASTERS COM ...

Page 7: ...TMASTERS COM GOKARTMASTERS COM 34Locate 2 long bolts and 2 chrome cupped washers 35Install the short bar behind the seats Start the bolts with washers into the threads GOKARTMASTERS COM GOKARTMASTERS COM 33Locate the short rear bar GOKARTMASTERS COM 36Tighten ALL of the bar bolts previ ously installed with a 10mm 12mm wrenches GOKARTMASTERS COM ...

Page 8: ...38Locate 4 long bolts and nuts and fuel hose clamp GOKARTMASTERS COM GOKARTMASTERS COM 40Install the 4 bolts and nuts into the tank 41Tighten with a 10mm 12mm wrenches GOKARTMASTERS COM GOKARTMASTERS COM 39Place the fuel tank onto the rear rack with decal to the rear GOKARTMASTERS COM 42Locate the end of the fuel hose on top of the engine GOKARTMASTERS COM ...

Page 9: ...e filter approximately 1 4 from the end of the hose GOKARTMASTERS COM GOKARTMASTERS COM 45Turn fuel valve to ON position GOKARTMASTERS COM 46Now it s time to install the rear shocks Remove the metal shipping bar from the passenger s side shock mounts NOTE SAVE THE BOLTS NUTS 47Discard this bar GOKARTMASTERS COM GOKARTMASTERS COM 48Locate one 1 shock GOKARTMASTERS COM ...

Page 10: ...n the rear swing arm GOKARTMASTERS COM GOKARTMASTERS COM 52Tighten top and bottom shock bolts with wrenches 53Repeat Steps 48 52 for the driver s side rear shock GOKARTMASTERS COM GOKARTMASTERS COM 51Install bottom shock bolt and nut GOKARTMASTERS COM 54At this time lift the rear of the go kart with the help of an assistant Place the kart on a jackstand Be safe Use caution GOKARTMASTERS COM ...

Page 11: ...RTMASTERS COM 58Place rubber battery strap over bat tery hook to the front of the battery tray first Then pull the strap over the battery and place it on the rear hook of the battery tray If necessary use pliers GOKARTMASTERS COM 57Place gray plastic cover over bat tery GOKARTMASTERS COM 59Locate the set bolt on the sprocket hub and tighten securely 60Locate the rear passenger s side wheel This is...

Page 12: ...d castle nut onto the axle 63Tighten the castle nut securely and align the holes in the axle with the nut GOKARTMASTERS COM GOKARTMASTERS COM 61Place the wheel onto the rear axle GOKARTMASTERS COM 65Install rubber hubcap over axle nut NOTE Repeat Steps 60 65 for the driver s side rear wheel GOKARTMASTERS COM 66Lift front of go kart and support with jack stands GOKARTMASTERS COM ...

Page 13: ... COM 69Tighten both nuts securely with a 17mm wrench GOKARTMASTERS COM 70Make sure the hole in the spindle lines up with the castle nut 71Reinstall cotter pins Bend and cut off excess Repeat Steps 67 71 on the driver s side spindle GOKARTMASTERS COM GOKARTMASTERS COM 72Locate outer steering joints and tight en the nut securely using a 12mm socket on the nut and a 12mm wrench on the top GOKARTMASTE...

Page 14: ...epeat Steps 72 75 on the driver s side GOKARTMASTERS COM 76Check tire pressure in all 4 tires Set to 10 PSI You will need a low pres sure gauge to check the tire pressure GOKARTMASTERS COM 77Locate the throttle stop and tighten the jam nut securely NOTE Lowering this bolt will restrict the top speed of the go kart GOKARTMASTERS COM 78Locate the steering box clamps and tighten all four 4 bolts and ...

Page 15: ... does not line up cor rectly with the front wheels continue mounting the steering wheel as close as possible GOKARTMASTERS COM 82Tighten bolts securely with two 2 10mm wrenches 83Install the plastic steering wheel cap by snapping it into place GOKARTMASTERS COM GOKARTMASTERS COM 84 If the steering wheel is not straight when the front wheels are pointing straight locate the plastic gearcase on the ...

Page 16: ...with a screw driver GOKARTMASTERS COM GOKARTMASTERS COM 87 Remove steering shaft nut with 17mm socket GOKARTMASTERS COM 88 Pull steering wheel and shaft out of the gear You may need to bump the steering wheel gently 89 Hold the gear in place with your finger GOKARTMASTERS COM GOKARTMASTERS COM 90 Turn the steering wheel straight and push the shaft back down into the gear GOKARTMASTERS COM ...

Page 17: ...n front of the go kart and look at the front passenger wheel in relationship to the rear passenger wheel GOKARTMASTERS COM 96 Adjust the passenger tie rod ac cordingly to align the wheel GOKARTMASTERS COM 94 The front wheel should be in a straight line with the rear wheel or parallel NOTE The front of the go kart is wider than the rear 95 The measuring tape in the pictures is for sight reference O...

Page 18: ...S COM 99 Now adjust the wheel in or out by turning the rod GOKARTMASTERS COM 100Hold the rod with a wrench and tighten the jam nuts securely 101Repeat Steps 92 100 for the driv er s side GOKARTMASTERS COM GOKARTMASTERS COM 102For final front end alignment pro cedure the front wheels should turn toward each other approximately 1 4 to 1 2 GOKARTMASTERS COM ...

Page 19: ...ide bars of the go kart GOKARTMASTERS COM GOKARTMASTERS COM 105Remove air filter nut and cover GOKARTMASTERS COM 106Tighten inner air filter nut secure ly with fingers Reinstall cover and nut 107Locate the shift cam Tighten both cables with a 12mm wrench NOTE This is ONLY on the Mini XRX R 108Cut and remove all strings on can opy top and pad covers and dis pose GOKARTMASTERS COM GOKARTMASTERS COM ...

Page 20: ...ith premi um high octane fuel NOTE Follow all gasoline handling pre cautions and fuel can GOKARTMASTERS COM GOKARTMASTERS COM GOKARTMASTERS COM 112It is highly recommended to use a fuel additive or fuel stabilizer such as Seafoam or Stabil Follow manufactur er s instructions on the bottle 113If there is no passenger in the go kart keep the seat belt buckled to keep it from dragging the ground or f...

Page 21: ...rt ignition key and turn to the ON position GOKARTMASTERS COM GOKARTMASTERS COM GOKARTMASTERS COM 118Pull the choke control out firmly and hold 119Push the red Start Button 120It may be necessary to run the engine on choke or partial choke halfway pulled out for 30 seconds to 1 mi nute to warm up the engine GOKARTMASTERS COM GOKARTMASTERS COM GOKARTMASTERS COM ...

Page 22: ...121Turn the key to OFF or push the stop button and hold to turn the go kart engine off GOKARTMASTERS COM ...

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