Carter 2503 User manual

Owners Manual
Parts Manual
Mini Talon model 2503
This manual contains very important safety information.
Please read the entire manual prior to using your Mini
Talon. Maintain this manual for future reference.
Revision 03.22.06v1

MINI-Talon Limited Warranty
The warranty policy applies to those cases where the new vehicle is unloaded from its
shipping container, set up and delivered by an authorized dealer and under normal use
and service is found to have defects in parts or workmanship under the following terms
and conditions. This warranty covers the MINI-Talon and related components, except
engine, for a period of 90 days. The engine is warranted by the manufacturer. The engine
warranty can be found in the engine manual.
This warranty does not apply to any part, which in opinion of the seller, or
manufacturer, was defective because of improper maintenance, improper assembly,
alterations, abuse, negligence or accident.
Should warranty service be required on your MINI-Talon during the warranty
period, please contact your nearest authorized dealer for repairs.
What is not covered under this warranty?
Misuse, negligence, alterations, accidents or any abnormal use including non-Genuine
parts, renting or leasing, competition or racing. This warranty does not cover loss of use
of the unit or loss of time, inconvenience, or normal wear and deterioration caused by the
use or storage of consumable items such as spark plugs, chains, brake shoes, fuses, clutch
plates, sprockets, light bulbs, battery and tires.
Carter Brothers Manufacturing Co., Inc.
1871 US Hwy 231
Brundidge, AL 36010
(P) 1-800-523-5278
(F) 1-334-735-3500
1

Contents
OwnersManual Page
1. Foreword------------------------------------------------------------------------------------------3
2. Safety----------------------------------------------------------------------------------------------4
3. Ready to Drive?----------------------------------------------------------------------------------9
4. Operation----------------------------------------------------------------------------------------12
5. Adjustments-------------------------------------------------------------------------------------14
6. Periodic Checks and Services ----------------------------------------------------------------18
PartsManual Page
1. Frame Group -----------------------------------------------------------------------------------22
2. Steering Shaft Assembly ---------------------------------------------------------------------24
3. Suspension Arm Assembly -------------------------------------------------------------------26
4. Axle Section ------------------------------------------------------------------------------------28
5. Rear End ----------------------------------------------------------------------------------------30
6. Wire Elec. Seat ---------------------------------------------------------------------------------32
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Thank you for purchasing our MINI-Talon. We hope you will enjoy it. Before
you operate the Mini-Talon, please read through this Owner’s Manual carefully as it
contains important safety and maintenance information. Failure to follow the warnings
contained in this manual can result in serious injuries.
Be sure to follow the recommended maintenance schedule and service your
MINI-Talon accordingly. Preventive maintenance is extremely important to the
longevity of your MINI-Talon.
Beginners should seek instructions from your dealer or qualified instructors
before and during initial use of the MINI-Talon. It is also recommended to practice in a
large open area and to familiarize yourself with the operations of this MINI-Talon.
We hope you will have a pleasant experience with our products and thanks again
for choosing our MINI-Talon.
3

SAFETY
2.1 Notes to Parents
We know that you, as parent, will have your youngster’s safety foremost in mind.
Serious injury can result from the improper use of MINI-Talons. Your youngster’s safety
will depend on you taking a “safety first” approach to MINI-Talon driving at all times. It
is important to carefully read and follow the instructions and warnings contained in this
manual and on the labels pasted on the MINI-Talon.
Once your youngster is ready to learn to drive, you must be familiar with this
MINI-Talon. You will be serving as teacher, coach, and safety supervisor for your
youngster. You must know the controls, handling characteristics, maintenance
requirements, and proper driving techniques. Read and understand this manual and labels
attached to this vehicle. You must supervise your youngster’s operation of this MINI-
Talon at all times and permit continual use only if you determine your youngster has the
ability and judgement to operate this MINI-Talon safely.
Teaching your youngster MINI-Talon safety is a step-by-step process. It begins
with safety rules and moves to actual driving procedures. Since youngsters learn at
different rates, it is up to you to set the pace of your youngster’s progress. At some point
you may decide that he or she is not ready to drive this MINI-Talon.
Always closely supervise your youngster’s driving. This is true even if your
youngster has learned and mastered the rules and skills of safe MINI-Talon driving.
Youngsters get tired and become careless easily. They do not always see everything that
is important around them. Your close supervision and good judgement are a must.
Show your youngster how to use each control as you describe its action. Refer to
this manual to learn control location and function before instructing your youngster. Test
yourself by operating the controls. Have your youngster dress in proper protective gear
and sit in the machine as you point out each control. It is important to have your
youngster wear protective gear whenever siting in this MINI-Talon.
2.2 Safety Introduction
In order to keep everyone safe, you must take responsibility for the safe operation of your
MINI-Talon.
To help you make informed decisions about safety, we have provided operating
procedures and other information on labels and in this manual. This information alerts
you to potential hazards that could hurt you or others. It is not practical or possible to
warn you about all hazards associated with operating or maintaining a MINI-Talon. You
must use your own good judgement. You will find important safety information in a
variety of forms, including:
Safety Labels On the kart
Safety Messages Proceeded by a safety alert symbol and one of two signal
words: WARNING or CAUTION
4

SAFETY
WARNING
Physical harm may result from failure to adhere to the instructions that are described
within the WARNING labels.
This entire manual is filled with important safety information. Please read it carefully.
2.3 Protective Gear
To parents: MINI-Talon driving demands that your youngster wears proper protective
gear. MINI-Talon drivers should ALWAYS wear a helmet, eye protection, gloves, long
pants, a long-sleeved shirt or jacket, and over-the-ankle boots. Anything less is not
adequate protection. NEVER let anyone drive a MINI-Talon without an approved
helmet. Be sure it fits correctly. It should be snug but not tight. It must be properly
fastened. Have your youngster wear safety gear whenever getting in a MINI-Talon. This
action will stress the importance of safety gear and help to develop safe driving habits.
Helmets and gloves can be purchased from your dealer. You can also purchase safety
gear from Carter Brothers Manufacturing Co. by calling 800-523-5278 or visiting us at
www.carterbro.com.
2.4 Safety Information
There is much that can be done to protect the operator of the MINI-Talon. You will find
many helpful recommendations throughout this manual. The following are a few that we
consider most important.
Always Wear Protective Gear
It’s a proven fact that helmets significantly reduce the number and severity of head
injuries. Always wear an approved motorcycle helmet, eye protection, sturdy boots,
gloves, and other protective gear. Always fasten seat belts. Correctly fastened and
adjusted seatbelts will protect the operator and passenger.
Drive Off-Road Only
Your MINI-Talon is designed and manufactured for off-road use only. The tires are not
made for pavement. If you need to cross a paved or public road, get off and walk your
MINI-Talon across.
Do Not Operate This MINI-Talon at Night
Darkness can greatly reduce a driver’s visibility and judgement. Driving at night is
dangerous and will increase the possibility of an accident
5

Never Run Your MINI-Talon Indoors
The exhaust from the engine contains a tasteless, odorless, and poisonous gas called
carbon monoxide.
SAFETY
Keep Away From Moving Parts of the MINI-Talon
No one should ever place their hands or other parts of their body near any moving part of
the MINI-Talon. Failure to adhere to this warning will cause physical harm to your body.
Skidding or Sliding
The terrain surface can be a major factor affecting turns. Skidding in a turn is more likely
to occur on slippery surfaces such as snow, ice, mud, and loose gravel. If you skid, you
may lose all directional control. To avoid skidding, keep your speed low and drive
carefully.
Hold On to the Wheel
Driving without holding onto the steering wheel is very hazardous.
Always drive at a safe speed, depending on the situation.
Driving down a slope too fast may result in the MINI-Talon overturning.
A wet road prolongs the stopping distance of your vehicle. Always take care that you
only drive at a speed at which you are able to stop in time.
Going downhill at considerable speed may be achieved, requiring a longer breaking time.
Taking sharp turns at a high speed may also cause the MINI-Talon to overturn.
2.5 Safety Labels
This section presents some of the most important information and recommendations to
help you drive your MINI-Talon safely. Please take a few moments to read the labels on
your MINI-Talon. (Fig. 1)
The labels should be considered permanent parts of the MINI-Talon. If a label comes off
or becomes hard to read, contact your dealer for warning label replacements.
6

Fig. 1
SAFETY
2.6 Safe Driving Precautions
Off- Road Use Only
The MINI-Talon and its tires are designed and manufactured for off-road use only and
not for pavement use. Driving on pavement can cause poor handling and control. Your
youngster should not drive the MINI-Talon on pavement.
WARNING
Operating this MINI-Talon on paved surfaces
may seriously reduce effective handling and
control of the MINI-Talon, and may cause the
kart to go out of control. Never operate the MINI-
Talon on any paved surfaces, including sidewalks,
driveways, parking lots, and streets.
When driving off-road, remember to always obey local off-road driving laws and
regulations. Obtain permissions to drive on private property. Avoid restricted areas and
obey “no trespassing” signs.
Keep Hands and Feet on Controls
Feet must stay on the foot pedals at all times and hands must stay on the steering wheel.
Be sure to stress this important rule. It is important to maintain balance and to control
the MINI-Talon. Removing hands or feet away from the controls can reduce your ability
to react and control the MINI-Talon.
7

WARNING
Removing hands from Steering wheel or feet from
foot controls during operation can reduce your
ability to control the MINI-Talon or could cause
you to lose your balance and fall off the MINI-
Talon. Always keep both hands on the steering
wheel and both feet on the foot controls of your
MINI-Talon during operation.
Hot Components
Show your youngster the engine, exhaust pipe, and muffler. Tell him or her not to touch
these parts because they are hot. Explain that they will remain hot after the engine is
stopped. Also explain that hands and feet must be kept away from all moving parts of the
MINI-Talon.
Inspection
Your youngster’s safety depends in part on the condition of the MINI-Talon. Be sure to
inspect it before each use. Starting and refueling of the vehicle should only be done by
responsible adults. Follow a regular maintenance program.
SAFETY
Adult Supervision
Even after young drivers have learned the basic driving skills, direct supervision by an
experienced adult is necessary AT ALL TIMES. Make sure that all MINI-Talon users
under your supervision get proper driving instructions. Follow safety precautions strictly
to provide a “safety first” approach to MINI-Talon driving. Teaching your youngster
how to drive the MINI-Talon safely will increase the enjoyment of MINI-Talon.
Control Speed
Driving at excessive speed increases the chance of an accident. In choosing a proper
speed, you need to consider the capability of your MINI-Talon, the terrain, visibility and
other operating conditions, plus operator skills and experience.
WARNING
Operating this MINI-Talon at excessive speed in
creases your chances of losing control of the
MINI-Talon, which can result in an accident.
Always drive at a speed that is proper for your
MINI-Talon. Your speed will be affected by the
terrain, visibility and other operating conditions,
and your experience.
Use Care on Unfamiliar or Rough Terrain
Before letting your youngster drive in a new area, always check the terrain thoroughly.
Don’t let them drive fast on unfamiliar terrain or when visibility is limited. Watch out for
obstructions like hidden rocks, bumps, or holes.
8

WARNING
Failure to use care when operating this MINI-
Talon on unfamiliar terrain could result in the
MINI-Talon overturning or going out of control.
Go slowly and be extra careful when operating on
unfamiliar terrain. Always be alert to changing
terrain conditions when operating the MINI-
Talon.
Never let your youngster drive past the limit of visibility. Maintain a safe distance
between their MINI-Talon and other off-road vehicles. Always exercise caution and use
extra care on rough, slippery, and loose terrain.
Ready to Drive?
WARNING
Failure to use extra care when operating on
excessively rough, slippery, or loose terrain could
cause loss of traction or vehicle control, which
could result in an accident, including an overturn.
Do not operate on excessively rough, slippery, or
loose terrain until you have learned and practiced
the skills necessary to control the MINI-Talon on
such terrain. Always be especially cautious on
these kinds of terrain.
Do Not Perform Stunts
Your youngster should always operate their MINI-Talon in a safe and reasonable manner.
When driving, they should always keep all four wheels on the ground.
WARNING
Attempting wheelies, jumps, and other stunts
increases the chance of an accident, including an
overturn.
Never attempt stunts, such as wheelies or jumps.
Before the MINI-Talon is driven for the first time, we urge you to:
♦Read this owner’s manual and the labels on your MINI-Talon carefully.
♦Make sure you understand all the safety messages.
♦Know how to operate all the controls and insure your youngster has been taught and
understands how to operate all the controls.
9

♦Before each drive, be sure your youngster:
9Wears their seat belts at all times while driving, or sitting in, the MINI-Talon.
9Feels well and is in good physical and mental condition.
9Is wearing an approved motorcycle helmet (with chinstrap tightened securely),
eye protection, and other protective clothing.
9Do not have any alcohol or drugs in their system.
WARNING
Operating this MINI-Talon without wearing an
approved motorcycle helmet, eye protection, and
protective clothing could increase your chances of
head and/or eye injury. Always wear an approved
motorcycle helmet that fits properly and wear eye
protection (goggles or face shield), gloves, boots,
long sleeved shirt or jacket and long pants. Driver
and passenger must always fasten seat belts.
Ready to Drive?
WARNING
Operating this MINI-Talon without correctly
fastening your seat belt could cause you to be
thrown from the vehicle.
To parents: One indicator that youngsters are ready to drive a MINI-Talon is when they
show a safety-conscious attitude and are aware of the dangers of MINI-Talon operation.
If the youngster has a habit of rashness or is involved in accidents often while using a
bicycle or skateboard, the youngster is not ready to drive this MINI-Talon.
A. The following questions can help parents further pinpoint whether youngster is ready
to drive:
1. Can youngster place his or her feet firmly, easily on the foot pedal?
2. Can youngster’s hands reach the steering wheel comfortably? Can your youngster
operate the steering wheel?
3. Can youngster push the brake foot pedal brake downward with enough strength to
stop the kart?
4. Does your youngster understand the controls of the MINI-Talon?
B. PRE-DRIVE INSPECTION (to Parents)
Before you continue:
1. Have you determined your youngster’s readiness to drive this MINI-Talon? Do not let
your youngster drive if you have any doubt.
2. Have you read this manual and reviewed it with your youngster?
3. Have you inspected the vehicle and maintained it accordingly?
10

4. Is your youngster wearing the proper protective gear?
5. Has your youngster learned to locate the MINI-Talon controls without help?
6. Does he or she know how to operate the controls smoothly?
7. Does your youngster understand he or she must always drive off-road?
8. Have you stressed to your youngster the importance of keeping his or her feet on the
foot pedals and their hands on the steering wheel?
C. Practice area (to parents)
The best place for learning is a level area 100’ x 200’ that is free from obstacles
such as rocks, stumps, or holes. The learning area may have a loose or hard dirt surface.
A grassy surface is also acceptable. It should not have two different surfaces. Be sure
there is enough room to maneuver, and that no other people or obstacles are close by.
D. Getting used to the vehicle in motion (to parents)
Be sure your youngster is wearing all of the proper protective gear. With the
engines still OFF, have your youngster sit in the MINI-Talon. Physically push the
vehicle slowly. Practice this several times until you are sure your youngster’s driving
skill is developed. Remind your youngster to keep his or her head up and look
forward and to keep both feet on foot pedals.
Ready to Drive?
With the engine off, have your youngster practice smoothly moving the foot pedal
throttle control. Your youngster will learn how much pressure it takes to start moving
in a later exercise. Explain that pushing the throttle will increase speed. Releasing
the throttle and applying the brake will slow the kart down. Ask your youngster to
tell you how throttle control and braking affect kart’s speed.
With MINI-Talon stopped, and engine OFF, have your youngster look in the
direction of the turn and turn steering wheel in the direction of the turn. Repeat this
exercise while you are slowly pushing your youngster on the MINI-Talon. Make sure
he or she can turn the vehicle in both directions using this technique.
Pre-Drive Inspection
Check the following items before you allow anyone on the MINI-Talon:
Engine Oil
Check the level and add oil if needed. Check for leaks.
Fuel
Check the level and add fuel if needed. Also make sure the fuel cap is securely fastened.
Check for leaks.
Tires
Use a gauge to check the air pressure. Adjust if needed. Also look for signs of damages
and excessive wear.
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Nuts and Bolts
Check the wheels to see that the axle nuts are tight. Use a wrench to make sure all
accessible nuts, bolts, and fasteners are tight.
Underbody & Exhaust System
Check for and remove any dirt, vegetation, or other debris that could be a fire hazard or
interfere with the proper operation of the MINI-Talon.
Seat Belt
Make sure seat belt locking mechanism is working.
OPERATION
A. Operation controls WARNING
Do not attempt to start or operate the engine until
completely familiar with the location and use of
each control necessary to operate this vehicle.
Your youngster must know how to stop this
machine before starting and driving it.
Steering Horn Not Used Kill Key
Wheel Button Button Switch
12

Brake Pedal Throttle Pedal
Fig.2
a. Throttle
The right foot pedal is the throttle that controls the MINI-Talon speed. As the engine
speed increases above idle, the vehicle moves forward.
WARNING
Each time, prior to starting the engine, check the
throttle and brake to ensure that when the pedals
are pushed all the way forward the assembly is
working smoothly and returns when released. Do
not operate if pedals fail to return. If unable to
correct the problem through lubrication,
adjustment, or replacement of worn parts, contact
your dealer for assistance.
OPERATION WARNING
When starting your MINI-Talon the kart should
never “buck” or move forward. As the rope is
pulled to start the engine, the inertia wheel spins.
If the kart moves or pulls forward as the rope
start is pulled, the rubber-molded disc is making
contact with the inertia wheel and must be
correctly adjusted prior to operation. If you are
unable to adjust, or feel uncomfortable
performing the adjustment, contact your dealer
for assistance.
b. Brake
The brake is located on the left side of the MINI-Talon. Applying pressure to the pedal
pulls the caliper to the brake disc and slows or stops the kart.
WARNING
Prior to starting the engine, push the kart forward
then apply the brake. If the kart does not stop,
the brake is not adjusted correctly. Adjust the
brake for correct operation prior to using the
MINI-Talon. If you are unable to adjust, or feel
uncomfortable performing the adjustment,
contact your dealer for assistance.
c. Start the engine in accordance with the engine manual.
13

ADJUSTMENTS
Checking For Correct Operation of the
Throttle (Fig. 3-1 and 3-2)
With no pressure on the throttle pedal, there
should be approximately 1/16” of space between
the rubber molded disc (A) and the inertia
wheel. (B). When the throttle pedal is depressed,
the throttle cable (C) pulls the throttle actuating
arm (D) up causing the rubber molded disc (A)
to make contact with the inertia wheel (B).
Fig. 3-1
Adjusting the Throttle Cable
(Fig. 3-1 and 3-2)
Remove the bottom cover of the rear
end. Loosen the throttle cable
retaining nuts (E). Insure that the
throttle cable (C) is attached to the
throttle actuating arm (D) as shown.
Adjust the position of the throttle
cable sleeve (F) so that, with no
pressure on the throttle pedal, there is
1/16” of space between the rubber
molded disc (A) and the inertia wheel
(B). Tighten the throttle cable
retaining nuts (E). Check to insure
there is a 1/16” of space between the
rubber molded disc (A) and the
inertia wheel (B). Remove the
bo
ttom cover of the rear end.
14

Fig. 3-2
WARNING
When starting your MINI-Talon the kart should
never “buck” or move forward. As the rope is
pulled to start the engine, the inertia wheel spins.
If the kart moves or pulls forward as the rope
start is pulled, the rubber-molded disc is making
contact with the inertia wheel and must be
correctly adjusted prior to operation. If you are
unable to adjust, or feel uncomfortable
performing the adjustment, contact your dealer
for assistance.
ADJUSTMENTS
Fig. 4-1
WARNING
Prior to starting the engine, push the kart forward
then apply the brake. If the kart does not stop,
the brake is not adjusted correctly. Adjust the
brake for correct operation prior to using the
MINI-Talon. If you are unable to adjust, or feel
uncomfortable performing the adjustment,
contact your dealer for assistance.
Adjusting the Brake Cable
Fig. (4-1) depicts the brake caliper with the
brake cable correctly installed. The brake
cable sleeve (A) must fit inside the keeper (B)
as shown.
Remove the bottom cover of the rear end.
With a #5 Metric Allen head, loosen the brake
cable retaining bolt (C). Push up on the brake
actuator (D) as shown (Fig. 4-2) and pull the
brake cable (E) until it is tight. While
maintaining pressure on the actuator, tighten
the cable retainer bolt (C).
15

Fig. 4-2
ADJUSTMENTS
Adjusting the Foot Pedals
This MINI-Talon has been made with foot pedals that can be moved depending
on the size of your child. First remove the bolts (A) and (D) (Figure 5-1 and 5-2). Once
you have done this, you are able to move the cable holder and the pedal rod with the
pedals together. There is only one bolt that holds the pedal rod in place. On the brake
pedal side there is a slot for the pedal rod to fit into, once you have picked out the holes
for the new setting, just slide the pedal rod and cable holder together and fasten all bolts
and nuts. Remember not to take pedals off the rod. By doing so the spring may come
loose. Make sure after you have done the adjustments, the pedals are working and will
return to their original position.
Fig. 5-1 Fig. 5-2
16

Adjusting Front Wheel Alignment
a. The front wheels should be “toe-in” from 1/8” to ¼”. To check for alignment,
measure distance A and B (Fig. 6-1) between the centerline of the wheels. The proper
ten the lock against the rod end. Recheck the dimensions for proper
Fig. 6-2 Fig.6-3
toe-in dimension “A” should be 1/8” to 1/4” greater than dimension “B”.
b. To adjust the alignment, loosen the lock nuts (C) on both sides of Front Tie Rods (D).
(Fig. 6-2 And 6-3) To make dimension B smaller, turn the rod to the left. Adjust the
rod to right direction to make dimension B larger. After adjusting to the desired
length, tigh
alignment.
Fig. 6-1
ADJUSTMENTS
nel
increase stiffness. Point (B) is the softest setting and point (C) is the hardest
tting.
Adjusting the Shocks
Changing the settings of all shocks from hard to soft: With a pair of vice grips or chan
locks, turn the adjustment knob (A) to the right to decrease stiffness and to the left to
stiffen or
se
17
Fig. 6-2

Fig. 7-1
PERIODIC CHECKS AND SERVICES
The maintenance intervals in the following table are based upon average driving
conditions. Driving in unusually dusty areas require more frequent servicing.
Items Prior to Each use Monthly Quarterly Yearly
Tire pressure/wear I
Brake Performance I
Tightness of I
Air Cleaner C R
Drive Chain I C,L
Brake Pad I R
Chassis I C,I L
Fuel tank I
Battery I
A: adjust C: clean I: inspect, clean , adjust, replace if necessary L: lubricate
R: replace
Engine should be maintained in accordance with the engine manual.
18

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