Twister GT200IIR Owner'S Manual - Parts Manual Download

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READ THIS MANUAL CAREFULLY,

IT CONTAINS IMPORTANT SAFETY INFORMATION.

Owner's Manual

Parts Manual

This vehicle is designed and manufactured for off-road use only.

USA only:

It does not conform to Federal Motor Vehicle Safety Standards, and in regards

to operation on public streets, roads, or highways is illegal.

FOR OFF-ROAD USE ONLY

MINIMUM

RECOMMENDED

OPERATOR AGE:

Hammerhead

GT200IIR

Summary of Contents for GT200IIR

Page 1: ...nual Parts Manual This vehicle is designed and manufactured for off road use only USA only It does not conform to Federal Motor Vehicle Safety Standards and in regards to operation on public streets r...

Page 2: ...f seller was defective because of improper maintenance improper assembly alterations abuse negligence or accident Should warranty service be required on your GT200IIR during the 90 days warranty perio...

Page 3: ...ASSY 10 DRIVEN PULLEY AND CLUTCH SUBASSY 11 OIL COOLER ASSY TIMING CHAIN COMP 12 ELECTRIC SYSTEM 13 ELECTRIC STA RTER ASSY 14 DRIVE PULLEY SUBASSY 15 CARBURETOR 16 REVERSE GEARBOX ASSY 17 SHIFT YODE...

Page 4: ...death 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 instru...

Page 5: ...Kart You must use your own good judgment You will nd important safety information in a variety of forms including Safety Labels _ On the Kart Safety Messages _ Preceded by a safety alert symbol and on...

Page 6: ...red for o road use only The tires are not made for pavement and the Kart does not have turn signals and other features required for use on public roads If you need to cross a paved or public road get...

Page 7: ...se the possibility for an accident Never run your Kart indoors The exhaust from the engine contains a tasteless odorless and poisonous gas called carbon monoxide Keep away from moving parts of the Kar...

Page 8: ...own Pick the best spot for your comfort and retighten the adjusting knob Before attempting to run your kart make sure the adjusting knob has been tighten WARNING WARNING Steering adjustment STEERING A...

Page 9: ...NG WARNING ALL HAIR MUST BE TIED UP AND SECURED AT OR ABOVE SHOULDER LENGTH ALL LOOSE CLOTHING MUST BE SECURED ALL NECKLACES AND SCARVES MUST BE SECURED NO LONG HAIR READ OWNER S MANUAL AND ALL LABELS...

Page 10: ...ts 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 should you have an accident Th...

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Page 16: ...13 19...

Page 17: ...14 THROTTLE PEDAL PARKING BRAKE BRAKE PEDAL REVERSE LEVER IGNITION START SWITCH SPEEDOMETER...

Page 18: ...15...

Page 19: ...16 OPERATION Figure 2 REAR CARGO RACK FUEL TANK CAP TANK COMP FUEL SEAT BELT STEERING WHEEL Component locations...

Page 20: ...Figure 4 Figure 3 Before attempting to adjust the seat ensure that kart engine is stopped Never operate this Kart when the provided seat is not securely fastened to do so could result in a strong poss...

Page 21: ...an open space at the beginning to learn how to start turn and stop c Operate the Kart slowly until you are familiar with it d The turning radius of this Kart is small and agile so the centrifugal forc...

Page 22: ...y e Check oil level before each use of kart or a er each 10 hours of operation Add oil to bring up to proper level Do not mix various grades of oil C Spark Plug a Remove the spark plug and inspect it...

Page 23: ...reaches the top speed e Adjust the screw and adjust the idle speed to an ideal value f Recheck and readjust the idle speed if necessary E Cleaning Instructions Keep your kart clean With a clean rag wi...

Page 24: ...ase as you screw to le decrease as you screw to right Adjust according to the weight of the riders J Storage Instruction In the event your kart is not to be operated for a period in excess of 30 days...

Page 25: ...ts to remove the wheel See Fig 12 Tighten the nuts a er replacing the wheels Figure 12 B Rear Wheel Replacement Do not disassemble the castle nuts when you replace the rear wheels and hub assembly Rem...

Page 26: ...n dimension B b To adjust the alignments loosen the lock nuts on both sides of Front Tie Rods To make Dimension B smaller turn the rod to le Adjust the rod to right direction to make Dimension B large...

Page 27: ...ng Time of service Initial service first week Monthly Quarterly Yearly Items A adjust C clean I inspect clean or replace if necessary L lubricate R replace Tire pressure wear Brake performance Tightne...

Page 28: ...FIG 1 CYLINDER HEAD ASSY 10 13 13 15 23 22 21 20 19 23 22 21 20 19 18 24 8 2 1 9 7 14 14 5 6 4 12 16 4 4 11 17 11 3...

Page 29: ...CYLINDER HEAD BOLT FLANGE M6X100 IN VALVE VALVE STEM SEAL VALVE SPRING OUTER SEAT VALVE OUTER INNER SPRING VALVE SPRING RETAINER VALVE COTTER EX VALVE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19...

Page 30: ...1 2 3 4 5 6 7 8 1 1 1 2 1 1 1 2 M150 1002200 M150 1002001 90442 06000 KAT M150 1001007 96001 06012 KAT M150 1002002 M150 1002100 96001 06020 KAT CYLINDER COMP CYLINDER GASKET WASHER SEALING 6 DOWEL PI...

Page 31: ...150 1003005 96001 06032 KAT M150 1003012 M150 1003007 M150 1003008 M150 1003034 M150 1003106 92101 05012 OH R CRANKCASE COVER COMP CRANKCASE COVER GASKET CAP TAPPET ADJUSTING HOLE OIL FILTING SCREEN O...

Page 32: ...FIG 4 PARTS MANUAL CRANKCASE ASSY 8 7 4 2 7 8 1 3 14 12 11 14 2 6 9 11 10 12 13 13 5 24 22 23 21 22 20 20 20 18 19 18 19 19 17 4 14 16 15 15...

Page 33: ...OWEL PIN 8 14 STUD BOLT M8 200 STUD BOLT M8 209 BOLT M6 50 BOLT M6X20 DOWEL PIN 9X14 RUBBER TUBE CONNECTOR BOLT M7 52 BOLT M7 72 BOTL M7 65 BEARING 6203 BEARING 6202 BEARING 6204 OIL SEAL 20 32 6 1 2...

Page 34: ...1 12 13 1 1 1 1 1 1 1 1 2 2 1 1 1 M200 0501 M150 1004007 M150 1004011 M150 1004009 M150 1004013 M200 0506 M150 1040005 M150 1004008 M150 1004002 M150 1004003 M150 1004006 M150 1004001 M150 1004200 CRA...

Page 35: ...1 1 1 1 1 2 1 M150 1005004 M150 1005003 M200 0603 M200 0604 M200 0605 M200 0606 M200 0607 M200 0608 M150 1001007 M200 0610 TAPPET ADJUSTING NUT TAPPET ADJUSTING SCREW VALVE ROCKER ARM EX ROCKER ARM S...

Page 36: ...SSY 1 2 3 4 5 6 7 8 9 8 8 2 1 4 7 6 5 9 3 3 9 9 9 9 9 9 9 9 M200 0701 M200 0702 M200 0703 M200 0704 M200 0705 M200 0706 M200 0707 M200 0708 M200 0709 LFFT CRAKCASE COVER LEFT COVER GASKET DOWEL PIN 8...

Page 37: ...AMPER CARBURETOR COOLING DUCT LOWER SHROUD LOWER SHROUD SEAL UPPER SHROUD COMP HIGH TENSION CORD CLIP UPPER SHROUD SEAL SCREW ST4 8X16 F BOLT M6X25 SCREW ST3 5 13 F DUST COVER BOLT M6X14 FAN COVER AND...

Page 38: ...P ASSY 1 2 3 4 5 1 1 1 2 1 CHAIN OIL PUMP FLANGE NUT M6 SPROCKET OIL PUMP DRIVEN BOLT M6X30 OIL PUMP SUBASSY REF NO REGD NO DESCRIPTION PART NO OIL PUMP ASSY 5 3 2 1 4 4 M150 1021000 M150 1020002 M150...

Page 39: ...MANUAL 10 REF NO PART NO DESCRIPTION REGD NO 1 2 3 1 1 1 CLUTCH ASSY OUTER DRIVE BELT DRIVE PULLEY ASSY DRIVE PULLEY AND CLUTCH SUBASSY DRIVE PULLEY AND CLUTCH SUBASSY 2 1 3 M150 1032000 M150 1033000...

Page 40: ...ER ASSY TIMING CHAIN COMP 1 2 3 4 5 6 7 8 M200 1101 M200 1102 M200 1103 M200 1104 M200 1105 M200 1106 M200 1107 M200 1108 3 4 2 2 2 2 5 5 2 2 2 2 8 7 6 5 5 1 OIL COOLER ALUMINUM WASHER OIL TUBE 1 OIL...

Page 41: ...FIG 12 12 PARTS MANUAL REF NO PART NO DESCRIPTION REGD NO ELECTRIC SYSTEM ELECTRIC SYSTEM 1 1 1 4 STATOR COMP FLYWHEEL COMP COOLING FAN COMP FLANGE BOLT M6x18 M150 1051200 8 M150 1051100 M150 1051100...

Page 42: ...ION REGD NO 1 1 1 2 1 1 2 3 4 5 FLANGE STARTING CLUTCH STARTER REDUCTION GEAR SHAFT STARTER REDUCTION GEAR FLANGE BOLT M6X16 STARTER MOTOR ASSY ELECTRIC STARTER ASSY ELECTRIC STARTER ASSY FIG 13 M150...

Page 43: ...NO 1 DRIVE PULLEY SUBASSY DRIVE PULLEY SUBASSY 1 1 M150 1071000 M150 1071002 MOVABLE DRIVE PULLEY ASSY FIG 14 PARTS MANUAL 14 REF NO PART NO DESCRIPTION REGD NO 1 2 DRIVE PULLEY SUBASSY DRIVE PULLEY S...

Page 44: ...3 22 28 24 4 26 22 26 20 10 14 20 13 17 25 27 25 23 11 15 31 1 2 2 1 1 1 1 1 8 6 9 7 19 5 16 29 21 FIG 15 CARBURETOR 18 12 30 3 22 28 24 4 26 22 26 20 10 14 20 13 17 25 27 25 23 11 15 31 1 2 2 1 1 1...

Page 45: ...16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 4 2 2 2 2 2 1 1 1 1 PARTS MANUAL REF NO PART NO DESCRIPTION REGD NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17...

Page 46: ...00 1603 M200 1604 M200 1605 M200 1606 M200 1607 M200 1608 M200 1609 M200 1610 M200 1611 M200 1612 M200 1613 1 2 4 5 6 7 8 9 10 9 8 9 3 11 13 12 1 1 2 1 1 1 1 2 3 1 1 1 1 GEARBOX COVER GEARBOX COVER GA...

Page 47: ...703 M200 1704 M200 1705 M200 1706 M200 1707 M200 1708 M200 1709 M200 1710 M200 1711 M200 1712 M200 1713 12 11 10 8 7 9 6 4 3 2 5 1 LOCKING FLANGE NUT SHIFT YOKE HEAD WASHER CIRCLIP SHIFT YOKE SHIFT YO...

Page 48: ...0 24 25 26 21 22 23 15 FRAME GROUP FIG 18 20 20 20 24 25 26 21 22 23 29 29 17 28 15 FRAME GROUP 27 30 32 14 33 33 33 32 31 30 27 27 33 11 1 7 7 8 5 12 3 4 2 10 13 13 8 7 5 3 7 10 8 11 6 9 34 10 7 16 1...

Page 49: ...E NUT M8 1 1 2 1 1 8 8 16 4 4 2 1 2 1 2 2 2 2 2 6 1 1 1 1 1 1 6 4 2 2 1 2 10 PARTS MANUAL 18 REF NO PART NO DESCRIPTION REGD NO FRAME GROUP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23...

Page 50: ...43 40 39 26 30 29 32 31 33 34 28 27 19 18 20 21 22 23 10 49 52 4 1 2 38 37 3 36 26 44 45 30 FIG 19 STEERING SHAFT ASSY 12 5 6 6 7 8 9 11 13 26 26 25 14 15 16 17 47 46 35 48 42 41 43 40 39 26 30 29 32...

Page 51: ...00 076 9 108 035 7 020 036 7 020 037 8 070 044 8 010 220 8 010 221 9 108 110 7 010 003 8 010 222 PARTS MANUAL 19 REF NO PART NO DESCRIPTION REGD NO STEERING SHAFT ASSY 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 52: ...20 21 25 24 27 28 29 13 11 10 32 26 26 30 30 7 33 34 12 35 36 37 15 26 9 39 6 5 4 3 2 1 8 14 FIG 20 SUSPENSION ARM ASSY 31 16 15 17 18 19 20 21 22 25 24 27 23 28 29 13 11 10 32 26 26 30 30 7 33 34 12...

Page 53: ...SPINDLE SUPPORT R FLANGE BOLT M8x1 25x105 UPPER SUSPENSION ARM COLLAR UPPER SUSPENSION ARM BUSHING UPPER SUSPENSION ARM LOCKING FLANGE NUT M8 LOCKING FLANGE NUT M12 BALL HEAD DUST SEAL BALL HEAD SPAC...

Page 54: ...1 27 28 30 26 FIG 21...

Page 55: ...OMP L SPECIAL BOLT M7 16 x28 BELT WASHER 12 BELT NUT M7 16 SEAT RAIL SET LOCKING FLANGE NUT M8 TAIL LIGHT BULB TAIL LIGHT BOLT SHARP M8X1 25X40 COVER TUBE 2 000 064 7 010 017 8 080 053 9 108 020 9 220...

Page 56: ...FIG 22 14 15...

Page 57: ...OCKING NYLON NUT M6 BOLT WASHER M10x1 25x45 ENGINE MOUNTING BOLT PLATE COLLAR PAN SCREW M6x55 ELECTRIC ASSY COVER REAR SWING ARM ASSY UPPER FLANGE BOLT M12x1 25x60 LOCKING FLANGE NUT M12 SWING ARM DOG...

Page 58: ...15 13 9 12 7 25 24 17 26 19 2 6 20 21 22 4 5 23 22 1 1 3 18 FIG 23 14 16 19...

Page 59: ...6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 AIR CLEANER ASSY TAPPING SCREW M5X16 AIR CLEANER COVER AIR CLEANER ELEMENT AIR CLEANER CASE COMP AIR CLEANER BREATHE TUBE AIR CLEANER DUCT AI...

Page 60: ...FIG 24...

Page 61: ...010 064 4 4 2 1 1 12 2 12 1 1 1 4 2 1 1 1 1 1 1 1 1 2 2 2 2 FLANGE BOLT M10x1 25x40 LOCKING FLANGE NUT M10 CUSHION ASSY RR BOLT STRAP M8x1 25x100 REAR FENDER BRACKET L LOCKING NYLON NUT M6 FLANGE BOL...

Page 62: ...FIG 25 REAR HOUSING 13 8 7 6 2 1 4 3 3 3 5 17 16 15 14 23 22 21 20 18 24 19 3 9 10 11 12 13 11 12 9 10 8 25 26 27...

Page 63: ...RR 16 CASTLE NUT M16 COTTER PIN 4X30 COVER RR HUB REAR WHEEL ASSY L CHAIN MASTER LINK SCREW M3X8 MAGNETIC STEEL REF NO PART NO DESCRIPTION REGD NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2...

Page 64: ...6 FIG 26 WIRE HARNESS ELECTRICAL 2 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 15 16 17 18 1 19 23 20 22 21...

Page 65: ...4 8 020 197 9 210 006 6 000 268 1 1 1 1 1 1 2 2 1 1 1 1 1 1 4 4 4 4 1 1 1 1 1 SWITCH PANEL COVER HEADLIGHT SWITCH ENGINE STOP BUTTON IGNITION START SWITCH WIRE HARNESS SOCKET COMP BOLT M6x20 NYLON LOC...

Page 66: ...3031105 NO RIDING WARNING Moving parts can crush and cut Keep hands clear Do not operate with guard removed PARKING PARKING BRAKE R D REVERSE LEVER WARNING The vehicle must be stationary and the engi...

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