American Sportworks 5210 User manual

5210 208cc FUN KART ASSEMBLY INSTRUCTIONS
15363R1

PN 15363R1 page 1 of 2
Step 3 Sides
Step 3 Sides
Step 1 End
Cross Supports
Step 1 End
Cross Supports
5210 208cc FUN KART ASSEMBLY INSTRUCTIONS
Congratulations on the purchase of your 5210 fun kart! These instructions will
guide you through the assembly process. Carefully read these instructions
and familiarize yourself with the tools and fasteners required before starting
the assembly of your fun kart.
Fasteners required for assembly
Please refer to the last page of instructions for a hardware list. Ensure that you
have all hardware before starting the assembly of your fun kart.
Tools required for assembly
Please gather the required tools and familiarize yourself with them before
starting the assembly of your fun kart. The tools will be mentioned in italic text
for easy recognition.
Hammer Box Cutters 10mm Socket
Safety Glasses Socket Wrench 13mm Wrench
12mm Wrench 14mm Wrench
8mm Socket Pry Bar
1 Uncrating the fun kart
• Wear your Safety Glasses to prevent eye injury.
• Using the Hammer and Pry Bar, remove cross supports at each end of
the crate and discard.
• Carefully pry and remove crate top and discard.
2 Remove crate sides and discard
• Using Box Cutters, cut and remove the hold down ties.
• Remove the kart from the crate base and discard base.
3 Unpacking the components
• Unpack all of the loose components from the unit and set aside.
• Remove protective plastic from each component and discard.
4 Rubber Connector Seals
• Locate the (6) Rubber Connector Seals (PN 15546).
• Slip the connector seal on the ends of each overhead bar where it will
connect to the main frame. Seals should be cupped in the downward
direction. Once the bar is installed, slide the seal down over the
connection joint.
• Rubber Fastener Caps will be installed on all overhead bar bolts once
all bars are installed and bolts tightened.
6 Overhead Front Bar Installation
• Locate the A-Pillars, fasteners, and the plastic end caps: (2) 15474, (2)
14086, (2) 14696, (6) 15114, (6) 14087, (2) 14088 and (2) 15475.
• Slip the bar end caps over the ends of the A-Pillars that attach to the
C-Pillar. Set the A-Pillars (shaded) in place and install the fasteners with
a 12mm Wrench and 10mm Socket Wrench. The 55mm long fastener
is used at the connection to the main frame and the 50mm long fastener
is used at the connection to the C-Pillar.
DO NOT tighten any
fasteners at this time.
5 Rear C-Pillar Installation
• Locate the C-Pillar assembly and fasteners: (1) 15470, (2) 14086, (4)
15114, (4) 14087 and (2) 14088.
• Set the C-Pillar assembly (shaded) in place and install the fasteners with
a 12mm Wrench and 10mm Socket Wrench.
DO NOT tighten any fasteners at this time.
Note: The seat belt shoulder mounts are pre-assembled to the C-Pillar.
Wear proper eye protection during the uncrating
and assembly process to avoid potential eye injuries.
WARNING
RISK OF SERIOUS INJURY OR DEATH
The Brush Bars and the Seat and Shoulder Belt
are critical parts of the Operator / Passenger safety
system on this kart. Do not attempt to operate the
kart until all components have been properly installed.
Step 2 Crate Top
Rubber Fastener Cap
PN 15113
Rubber Fastener Cap
PN 15113
Bar Bolt
PN 14086
Concave Washer
PN 14087
Concave Washer
PN 14087
Rubber Connector Seal
PN 15546
Flat Washer
PN 15114
Flat Washer
PN 15114
Locking Flange Nut
PN 14088
Overhead Bar
!
WARNING
!

PN 15363R1 page 2 of 2 5210 208cc FUN KART ASSEMBLY INSTRUCTIONS
7 Overhead Cross Bar Installation
• Locate the cross bar, fasteners, and plastic end caps: (1) 15471, (2)
14696, (2) 15114, (2) 14087, and (2) 15475.
• Slip the bar end caps over both ends of the cross bar (shaded) Set the
cross bar in place and install the fasteners with 10mm Socket Wrench.
DO NOT tighten any fasteners at this time.
8 B-Pillar Installation
• Locate the B-Pillars, fasteners, and the plastic end caps: (1) 15472, (1)
15473, (2) 14086, (2) 14696, (6) 15114, (6) 14087, (2) 14088 and (2) 15475.
• Slip the bar end caps over the ends of the B-Pillars that attach to the
A-Pillar. Set the B-Pillars (shaded) in place and install the fasteners with
a 12mm Wrench and 10mm Socket Wrench. The 55mm long fastener
is used at the connection to the main frame and the 50mm long fastener
is used at the connection to the A-Pillar.
DO NOT tighten any fasteners at this time.
9 Spoiler Installation
• Locate the spoiler, fasteners, and plastic end caps: (1) 15479, (2) 14696,
(2) 15114, (2) 14087, and (2) 15475.
• Slip the bar end caps over both ends of the spoiler (shaded) and set the
spoiler in place against the C-Pillar and install the fasteners with 10mm
Socket Wrench.
13 Final Preparation
• Fill the fuel tank with clean, fresh mid-grade gasoline.
• Check the engine oil level per the supplied Owner/Operator
manual.
• Refer to the supplied Owner/Operator manual prior to operating
your new Fun Kart.
10 Tighten Fasteners
• Use a 12mm Wrench and 10mm Socket Wrench to tighten all the
fasteners, starting with step 5.
• Install Rubber Fastener Caps on all tightened overhead bar bolts: (20)
15113
11 Safety Flag Installation
• The flag fasteners have been pre-installed onto the right rear corner of
the spoiler.
• Simply loosen the plastic nut from the top side of the rack and slip the
flag into place.
• Finger-tighten the plastic nut to retain the flag.
12 Steering Wheel Installation
• Locate the steering wheel and fasteners: (3) 14426.
• The steering wheel has three mounting holes on it. With the front wheels
aligned in the straight position, orient the steering wheel with one hole at
the 6:00 position, and the other holes at 10:00 & 2:00 positions.
• Using an 8mm Socket Wrench, install the bolts and tighten to secure
the steering wheel
• Align the steering wheel cover and snap into place. (1) 14631.
Orientation of wheel holes
Required Hardware
Part # Description Quantity
15546 SEAL, BAR CONNECTION - 1.125” 6
14086 BOLT, M8 X 1.25 X 55 (Flange Head) 6
15114 WASHER, BAR CONNECTION M8 X 24 X 1.25 20
14087 WASHER, CONCAVE CLAMP 20
14088 NUT, M8 X 1.25 LOCKING (Flange Head) 6
14696 BOLT, M8 X 1.25 X 50 (Flange Head) 8
15475 ENDCAP, BAR - 1.125" BLACK PLASTIC 8
14426 BOLT, M6 X 1.00 X 14 (Flange Head) 3
14631 COVER, STEERING WHEEL 1
15113 COVER, BOLT CAP 20