Fisher-Price Barbie VOLKWAGEN NEW BEATLE M3865 Use and care manual

Owner's Manual
Owner's Manual
with Assembly Instructions
with Assembly Instructions
For Model M3865
For Model M3865
Owner's Manual
with Assembly Instructions
For Model M3865
Product features may vary
from the picture above.
Please read this manual and save it with your original sales receipt.
Tools needed for assembly: Phillips Screwdriver, Hammer, Slotted
Screwdriver, Adjustable Wrench and Safety Scissors (all not included).
Use only with a Power Wheels®Type H, 6 Volt Rechargeable
Battery with Built-in Thermal Fuse and a Power Wheels®
Type H 6 Volt Charger (both included).

2
TABLE OF CONTENTS
A
M3865pr-0920
• Your new vehicle requires adult assembly. Please set aside at least
45 minutes for assembly.
• You must charge your battery for 18 - 30 hours before you use your
vehicle for the first time. We recommend that you start charging
your battery before beginning assembly. Please see Battery Charging
beginning on page 8 for detailed instructions.
• Read this manual carefully for important safety information and
operating instructions before using your vehicle. Keep this manual
for future reference as it contains important information.
• This vehicle is designed for use on: grass, asphalt, and other hard
surfaces; on generally level terrain; and by children 11/2- 4 years
of age.
• Use this vehicle ONLY outdoors. Most interior flooring can be
damaged by riding this vehicle indoors. Fisher-Price®will not be
responsible for damage to the floor if the vehicle is used indoors.
• To prevent damaging the motors and gears, be sure to stop the
vehicle before switching direction. Do not tow anything behind the
vehicle or overload it. Do not exceed the maximum weight capacity
of 50 lbs (23 kg).
• If you have any questions about your Power Wheels®vehicle, please
call our toll-free service lines at 1-800-348-0751 from 9 AM to 7 PM
(EST) Monday through Friday and 11 AM to 5 PM (EST) Saturday.
Trained customer service representatives are available to take your
call in English or French. Habla Español? Si usted tiene alguna
pregunta ó necesita asistencia llame gratis 1-800-348-0755 para los
Estados Unidos. Tenemos representantes que hablan español para
atender su llamada.
• For your convenience, Power Wheels®maintains an Authorized
Service Center Network with more than 300 independently owned
and operated authorized service centers nationwide. The authorized
service centers will repair or replace parts under warranty at no extra
charge, and can perform non-warranty repairs for a minimal charge.
To find the authorized service center nearest you, please visit us
on-line at www.powerwheels.com or call 1-800-348-0751.
• To register your vehicle, please visit us on-line at
www.powerwheels.com.
IMPORTANT INFORMATION
2
TABLE OF CONTENTS
M3865pr-0920
Important Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Warnings and Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Parts Picture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Decoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Battery Care and Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Safe Driving Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Vehicle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Vehicle Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Problems and Solutions Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

M3865pr-0920
• In the unassembled state, this package contains small parts. Adult assembly is required.
• Use the charger in dry locations only.
• Prevent Injuries and Deaths
• Direct Adult Supervision Required.
• Never Ride At Night.
• Keep Children Within Safe Riding Areas.
These areas must be:
- away from swimming pools and other bodies of water to prevent drownings
- generally level to prevent tipovers
- away from steps, steep inclines, cars, roads and alleys.
• Riding Rules
Make sure children know and follow these rules for safe driving and riding.
- Always sit on the seat.
- Always wear shoes.
- Only 1 (one) rider at a time.
ELECTRICAL HAZARD
WARNING
CAUTION
3
WARNINGS AND CAUTIONS
• Battery can fall out and injure a child if vehicle tips over. Always use battery retainer.
• PREVENT FIRE
- Never modify the electrical system. Alterations could cause a fire resulting in serious injury
and could also ruin the electrical system.
- Use of the wrong type battery or charger could cause a fire or explosion resulting in
serious injury.
- Use of Power Wheels®components in products other than Power Wheels®vehicles could
cause overheating, fire or explosion.
• The battery must be handled by adults only. The battery is heavy and contains sulfuric acid
(electrolyte). Dropping the battery could result in serious injury.
• Never allow children to charge the battery. Battery charging must be done by adults only. A
child could be injured by the electricity involved in charging the battery.
• Never lift or carry the battery by the wires or connector. This can damage the battery and
possibly cause a fire resulting in serious injury. Lift and carry the battery by the case only.
• Read the safety instructions on the battery.
• Examine the battery, charger and their connectors for excessive wear or damage each time
you charge the battery. If damage or excessive wear is detected, do not use the charger or the
battery until you have replaced the worn or damaged part.
• HOT motors. Handle carefully.
WARNING
RIDING HAZARD
M3865pr-0920

M3865pr-0920
4
PARTS
• If you experience a problem with this product, or are missing a part, please call us at 1-800-348-0751, rather than return this product to
the store.
• Please identify all parts before assembly and save all packaging material until assembly is complete to ensure that no parts are discarded.
• Metal parts have been coated with a lubricant to protect them during shipment. Wipe all metal parts with a paper towel to remove any
excess lubricant.
M3865pr-0920
Door
Seat
4 Hubcaps
TM
Vehicle
Windshield
(taped under vehicle)
4 Wheels
Steering Wheel
Note: The gearbox is
temporarily fastened to
the inside of the battery
compartment. Refer to
step 1 in the Assembly
section, page 10.
Gearbox
2 Front Wheel
Traction Bands
Driver

5
TABLE OF CONTENTS
A
M3865pr-0920 5
PARTS
M3865pr-0920
Not Shown: Label Sheet
6 Volt Type H Charger
6 Volt Type H Battery
®
Rear Axle
Steering Column
Steering LInkage Cover
(taped under vehicle)
Steering Linkage
2 Front Axles
Steering Bracket
4 Hubcap Covers Windshield Hinge
Spacer 2 Rectangular Bushings
2 Hex Bushings 6 Round Bushings
Steering Wheel Cap

M3865pr-0920
6
PARTS
M3865pr-0920
Lock Washer - 4
.437 (Large) White Cap Nut – 2
#8 x 3/4" Screw - 13
(Small Diameter Head)
#10 x 3/4" Trusshead Screw
(Large Diameter Head)
1/4" x 11/4" Screw - 2
#6 x 1" Screw - 2
5/16" Large Washer - 5
#10 Lock Nut
¼" Small Washer - 2
.354 (Small) Black Cap Nut – 1
Fasteners Shown Actual Size
For your convenience, we included extra fasteners!
Note: Tighten and loosen the screws with a Phillips screwdriver.
Do not over-tighten the screws.
.437"
.354"

7
TABLE OF CONTENTS
A
M3865pr-0920
Right Rear Wheel Assembly
7
PARTS PICTURE
M3865pr-0920
TM
®
1 Vehicle
2 Seat
3 Door
4 Wheel - 4
5 Rear Axle
6 Windshield
7 Driver
8 Front Axle - 2
9 Steering Linkage Cover
10 Steering Linkage
11 Steering Wheel
12 Steering Wheel Cap
13 Steering Column
14 Hubcap - 4
15 Hubcap Cover - 4
16 Hex Bushing - 2
17 Round Bushing - 6
18 Spacer
19 5/16" Large Washer - 5
20 1/4" x 11/4" Screw - 2
21 #8 x 3/4" Screw - 13
22 .437 White Cap Nut - 2
23 .354 Black Cap Nut
24 Lock Washer - 4
Note: Some parts are assembled on both sides of the vehicle. This
illustration shows assembly on left side only.
7
17
4
35
14
24
15
33
12
23
11
13
6
30
1
29
21
19
22
8
27
31 10
8
19
17
428
16
14
24 15
19
20
22
921
29
17
19
17
4
14 15
24
35
5
18
21
3
21
21
21
26
2
35
32
17
21
25
25 6 Volt Charger
26 6 Volt Battery
27 Steering Bracket
28 Front Wheel Traction Band - 2
29 ¼" Small Washer - 2
30 #10 x 3/4" Trusshead Screw
31 #10 Lock Nut
32 Windshield Hinge
33 #6 x 1" Screw - 2
34 Gearbox
35 Rectangular Bushing - 2
Part Not Shown
Label Sheet

8
TABLE OF CONTENTS
A
M3865pr-0920
8
Important Notes
• Your new battery must be charged for at least 18 hours before
you use it in your vehicle for the first time.
• We recommend that you start charging your battery before beginning
assembly of your new vehicle.
• The battery must be upright while charging.
• The charger is not a toy.
• Do not short circuit the battery.
• You do not need to remove the battery from your vehicle to
recharge it.
• Before charging the battery, examine the battery case for cracks and
other damage which may cause sulfuric acid (electrolyte) to leak
during the charging process. If damage is detected, do not charge
the battery or use it in your vehicle. Battery acid is very corrosive
and can cause severe damage to surfaces it contacts.
• Do not charge the battery on a surface (such as a kitchen counter top)
which could be damaged by the acid contained inside the battery.
Take precautions to protect the surface on which you charge
your battery.
• Use only a Power Wheels®6 volt Type H charger (input 120 VAC
60 Hz with an output of 6 VDC 4.8W 800 mA) to charge your
Power Wheels®6 volt battery.
• Adults Note: Regularly examine the charger for damage to the
cord, plug, housing or other parts that may result in the risk of fire,
electric shock or injury. In the event of any damage, do not use the
charger until the damage has been properly repaired. Please call
1-800-348-0751.
• If your battery is old and will not accept a charge, do not leave it in
the vehicle. Always remove a dead battery from the vehicle.
About Thermal Fuses
Your Power Wheels 6 volt battery is equipped with a built-in thermal
fuse. The thermal fuse is a self-resetting safety device which
automatically “trips” and shuts down operation of the vehicle if the
vehicle is overloaded or the driving conditions too severe. Once a fuse
has “tripped”, remove your foot from the pedal and wait approximately
25 seconds before operating the vehicle again. To avoid repeated
automatic shut-downs, do not overload the vehicle by exceeding the
50 lbs (23 kg.) maximum weight capacity or by towing anything behind
the vehicle. Avoid severe driving conditions, such as driving up slopes
or running into fixed objects, which can cause the wheels to stop
spinning while power is still being supplied to the motors.
If a thermal fuse in a battery continually trips under normal driving
conditions, please contact your local Power Wheels®Authorized
Service Center. For the location of the Authorized Service Center
nearest to you, visit us on-line at www.powerwheels.com, or call
1-800-348-0751.
• Battery can fall out and injure a child if vehicle
tips over. Always use battery retainer.
• PREVENT FIRE
- Never modify the electrical system.
Alterations could cause a fire resulting
in serious injury and could also ruin the
electrical system.
- Use of the wrong type battery or charger
could cause a fire or explosion resulting
in serious injury.
- Use of Power Wheels®components in
products other than Power Wheels®
vehicles could cause overheating,
fire or explosion.
• The battery must be handled by adults
only. The battery is heavy and contains
sulfuric acid (electrolyte). Dropping the
battery could result in serious injury.
• Never allow children to charge the battery.
Battery charging must be done by adults
only. A child could be injured by the elec-
tricity involved in charging the battery.
• Never lift or carry the battery by the wires
or connector. This can damage the battery
and possibly cause a fire resulting in
serious injury. Lift and carry the battery by
the case only.
• Read the safety instructions on the battery.
• Examine the battery, charger and their
connectors for excessive wear or damage
each time you charge the battery. If
damage
or excessive wear is detected, do
not use the charger or the battery until you
have replaced the worn or damaged part.
WARNING
Use the charger in dry locations only.
CAUTION
BATTERY CHARGING
ELECTRICAL HAZARD
ELECTRICAL HAZARD

M3865pr-0920 9
M3865pr-0920
BATTERY CHARGING
IMPORTANT! The battery must be removed from your vehicle for
the initial charge in order to complete assembly. After assembly is
complete, you do not need to remove the battery from your vehicle
to recharge it.
• Locate the lock fasteners in the back of the seat.
• Using a slotted screwdriver, turn the lock fastener 1/4turn to the
unlocked position .
Lock Fasteners
• Lift the seat to remove it from the vehicle.
Seat
Unlocked
2
1
Seat
®
• Remove the battery and the battery charger from the cardboard box.
Throw the cardboard box away.
• Remove the cardboard box containing the battery and battery
charger from the battery compartment.
REAR VIEW
Cardboard Box
Containing Battery
and Battery Charger
3
4

REAR VIEW
1
Children can be harmed by small parts,
sharp edges and sharp points in the vehicle's
unassembled state, or by electrical items.
Care should be taken in unpacking and
assembly of the vehicle. Children should not
handle parts, including the battery,
or help in assembly of the vehicle.
WARNING
10
ASSEMBLY
M3865pr-0920
• Plug the charger into a standard wall outlet.
Note: Use the charger only in a wall outlet. Do not plug the charger into
a ceiling outlet. If power flow to the wall outlet is controlled by a switch,
make sure the switch is ON. The power indicator on the charger does not
indicate the charge status of your battery. The power indicator allows you
to see that there is power from the wall outlet.
• Before first time use, charge the battery for at least 18 hours.
Never charge the battery longer than 30 hours.
• Recharge the battery after each use of your vehicle for at least
14 hours. Do not charge the battery longer than 30 hours.
• Once the battery is charged, disconnect the charger connector
from the battery connector. Unplug the charger from the wall outlet.
The battery is now ready to be installed in your vehicle. Please see
“Battery Installation” on page 23 for detailed instructions on installing
your battery. If your battery is already installed in your vehicle,
simply re-connect the battery connector and motor connector and
replace the battery retainer.
• Plug the battery connector into the charger connector.
®
5
Charger
Connector
6
®
BATTERY CHARGING
Battery
Connector
• Turn the vehicle upright.
• Using safety scissors, cut the plastic retainer holding the gearbox
in place.
• Throw the plastic retainer away.
Cut and Remove
Plastic Retainer
Plastic
Retainer
Gearbox

11
ASSEMBLY
M3865pr-0920
3
2
• Fit a round bushing, barrel side first, into the hole inside the
battery compartment.
• Position the gearbox with the teeth outward. Fit the gearbox through
the large opening in the side of the battery compartment.
Gearbox
Hole
Round
Bushing
Large
Opening
Teeth
• Fit a rectangular bushing, base end up, onto the rear axle.
• Position a hubcap, ridges down, onto the rear axle.
• Fit a lock washer, rounded side up, into the assembly tool. Make
sure it fits completely inside the assembly tool.
• Position the rear axle with the hubcap up, as shown. Fit the
assembly tool (with lock washer in it) onto one end of the rear axle.
• Tap the assembly tool with a hammer to secure the lock washer on
the end of the rear axle.
Hint: You may want to position the rear axle on a scrap block of wood
to protect the assembly surface.
• Pull on the lock washer to be sure it is secure on the rear axle.
Lock Washer
Rounded Side UP
Assembly Tool
Assembly
Tool with Lock
Washer Inside
Rear Axle
Rectangular
Bushing
Hubcap
Hole
Round
Bushing
Barrel Side
Barrel Side
Base End Up
Base End Up

12
ASSEMBLY
M3865pr-0920
• Fit a round bushing, barrel side first, into the hole in the inside of a
wheel (ribbed side).
• Repeat this procedure to insert a round bushing into the inside of
another wheel.
• Identify the inside and the outside of a wheel.
• The inside of the wheel has ribs on its surface. The outside of the
wheel has a smooth surface.
Smooth Surface
4
INSIDE
OF WHEEL
OUTSIDE
OF WHEEL
5
Round Bushing
Inside of
Wheel
Peg
Rear Axle
6
• Insert the rear axle into the hole in the outside (smooth side) of
the wheel.
• Be sure to align the rectangular bushing with the rectangular opening
in the outside of the wheel.
• Fit the peg on the inside of the hubcap into the small hole in the
outside of the wheel.
Outside of
Wheel
Small Hole
Ribs
• Fit a round bushing, barrel side first, into the hole in the rear wheel
well, as shown.
• Slide a
5/16" large washer onto the rear axle assembly.
• Slide a spacer onto the rear axle assembly.
• Fit the rear axle assembly through the round bushing and into the
hole in the rear wheel well.
7
Round
Bushing
Spacer
Large
Washer
Rear Axle
Assembly
Rear Wheel Well
Barrel Side
Barrel Side
Barrel Side
Barrel Side

11
13
ASSEMBLY
M3865pr-0920
• Turn the vehicle on its side.
• Fit a lock washer, rounded side up, into the
assembly tool. Make sure it fits completely
inside the assembly tool.
• Fit the assembly tool (with lock washer in it) onto the end of the
rear axle.
• Tap the assembly tool with a hammer to secure the lock washer on
the end of the rear axle.
• Pull on the lock washer to be sure it is secure on the rear axle.
Rear
Axle
Assembly Tool with
Lock Washer Inside
10
BOTTOM VIEW
Assembly Tool
Lock Washer
Rounded Side UP
• Turn the vehicle upright (or keep on its side).
• Insert one of the tabs on the hubcap cover into a slot in the hubcap.
• Then, push with your fingernail (or carefully with a slotted
screwdriver), the other two hubcap cover tabs into the slots
in the hubcap.
• Repeat this procedure to assemble another hubcap cover to the
other hubcap.
Hubcap
Hubcap
Cover
Tab
Tab Tab
Slots
9
• Fit another wheel (with a round bushing inserted) onto the end of the
rear axle. Make sure the outside of the wheel (smooth side) faces out
and the ribs on the inside of the wheel fit in the grooves in the driver.
• Fit a rectangular bushing, base side out, onto the rear axle.
• Push the rectangular bushing so that it fits into the rectangular
opening in the wheel.
• Fit a hubcap to the outside of the wheel. Make sure the peg on the
hubcap fits into the small hole in the outside of the wheel.
Outside of Wheel
Rectangular
Bushing
Driver
Grooves
Peg
Small
Hole Hubcap
8
• Fit the driver onto the end of the rear axle.
• Align the ribs on the inside of the driver with the gearbox teeth. Fit
the driver to the gearbox.
Rear Axle Driver
Gearbox
Teeth
Base
Base

15
14
ASSEMBLY
M3865pr-0920
12
14
TM
• Fit the door peg into the hole in the top of the vehicle.
Hole
• Insert eight #8 x 3/4" screws into the door.
• Tighten the screws.
Door
13
Door Peg
• Turn the windshield face down on a
flat surface.
• Fit the windshield hinge to the corner
of the windshield.
Windshield
Windshield Hinge
• Insert two #8 x 3/4" screws through the windshield hinge and into
the windshield. Tighten the screws.
Windshield
Windshield
Hinge

15
ASSEMBLY
M3865pr-0920
19
16
• Position the windshield upright, as shown.
• Remove the backing and position label #27 on the right side of the
windshield, as shown.
Hint: Align the dotted line on the label with the back edge of
the windshield.
• Fold the back end of the label around the back edge of
the windshield.
Fold around
back edge of
windshield
Label 27
Back Edge
of Windshield
Dotted Line
TM
• Note the location of six tabs and one peg on the windshield.
•First insert the tab on the side of the windshield (that is opposite the
door) into the slot in the vehicle.
• Then fit the remaining five tabs and peg on the windshield into the
slots and hole in the vehicle.
• When you are sure all six tabs and one peg are inserted, push
down on the windshield to snap the tabs in place.
Peg
Windshield
Tabs
Tabs
IMPORTANT!
Insert side tab into
this slot FIRST
Tabs
Tabs
17
Tabs
Tabs
• Turn the vehicle over so that the bottom faces you.
• Insert one #8 x 3/4" screw through the front hole in the vehicle and
into the windshield, as shown.
• Fit a ¼" small washer to two #8 x 3/4" screws. Insert these screws
with washers through the other holes in the vehicle and into the
windshield, as shown.
• Tighten the screws.
BOTTOM VIEW
18
• Turn the steering linkage so that
the inside (grooved side) is facing
up and the curve is toward you.
• Position each front axle so that the
short end is facing up.
• Insert the short end of the front
axles up through the ends of the
steering linkage, as shown.
Short End of
Front Axle
Front
Axle Front
Axle
Steering Linkage
Steering
Linkage
Steering Linkage
Curve TOWARD You
Front
Hole

23
21
20 22
16
ASSEMBLY
M3865pr-0920
• Slide a
5/16" large washer onto the
short end of each front axle.
• Position the steering linkage cover
over the steering linkage. Make sure
the Aand Bmarkings in the steering
linkage cover match the Aand B
markings in the steering linkage. Fit
the steering linkage cover onto the front axles.
Note: The steering linkage curve should still face you.
Front
Axle
Front
Axle
Steering
Linkage
Cover
Large
Washer
Large
Washer
A Marking
A Marking
B Marking
B Marking
Steering
Linkage Curve
TOWARD You
• Fit a .437 white cap nut onto the end of a front axle.
• Tap the cap nut with a hammer to secure it to the front axle.
• Repeat this procedure to fasten another .437 white cap nut to the
other front axle.
Front
Axle
Cap
Nut
• Turn the steering assembly
over, with the smooth side up.
• Fit the steering linkage
assembly to the front end of
the vehicle.
IMPORTANT! Make sure the notch on the steering linkage assembly
aligns with the notch in the front end of the vehicle.
Notch
Steering Linkage
Assembly
(Smooth Side Up)
Notch
NotchNotch
• Insert two
1/4" x 1 1/4" screws through the deep holes in the steering
linkage assembly and into the vehicle.Tighten the screws.
• Pull up on the steering linkage assembly to be sure it is secure. If it is
not secure, tighten each screw a few more turns.
Deep
Holes
.437"
Steering
Linkage

17
ASSEMBLY
M3865pr-0920
24
26
• Fit a
5/16" large washer onto each front axle.
Large
Washer
Front Axle
• Identify the inside and the outside of a wheel.
• The inside of the wheel has ribs on its surface. The outside of the
wheel has a smooth surface.
Smooth Surface
25
INSIDE
OF WHEEL
OUTSIDE
OF WHEEL
Ribs
• Fit a round bushing, barrel side first, into the hole in the inside of a
wheel (ribbed side).
• Fit a hex bushing, barrel side first, into the hole in the outside of a
wheel (smooth side).
• Repeat this procedure to insert a round bushing and hex bushing
into the remaining wheel.
Round
Bushing
Inside
of Wheel
Outside
of Wheel
Hex
Bushing
• Fit the wheel (with a round bushing and hex bushing inserted) onto
the end of the front axle. Make sure the outside of the wheel (smooth
side) faces out.
• Fit a hubcap to the outside of the wheel. Make sure the peg on the
hubcap fits into the small hole in the outside of the wheel.
Outside of Wheel Hubcap
Front
Axle
Peg
Small Hole
27
Front
Axle
Assembly
Tool with Lock
Washer Inside
• Turn the vehicle on its side.
• Fit the lock washer, rounded side up, into the assembly tool. Make
sure it fits completely inside the assembly tool.
• Fit the assembly tool (with lock washer in it) onto the end of the
front axle.
• Tap the assembly tool with a hammer to secure the lock washer on
the end of the front axle.
• Pull the wheel up to be sure it is secure on the front axle.
Assembly Tool
28
Barrel Side
Barrel Side
Barrel Side
Barrel Side
Lock Washer
Rounded Side UP

30
31
18
ASSEMBLY
M3865pr-0920
29
• Fit the notches on the inside of a front wheel traction band to the
ridges on a front wheel, as shown.
Hint: Soak the traction band in hot water for about two minutes to
soften it.
Front Wheel
Traction Band
Wheel
Ridges Ridges
Notches Notches
• Slide the other side of the front wheel traction band around the
front wheel.
TM
• Turn the vehicle upright (or keep it on its side).
• Insert one of the tabs on the hubcap cover into a slot in the hubcap.
• Then, push with your fingernail (or carefully with a slotted screwdriver),
the other two hubcap cover tabs into the slots in the hubcap.
• Repeat assembly steps 27 - 31 to assemble the remaining wheel
(with round bushing and hex bushing) lock washer, front wheel
traction band, hubcap and hubcap cover.
Hubcap
Hubcap Cover
Tab
Tab Tab
Slots

34
33
32
19
ASSEMBLY
M3865pr-0920
• Cut the steering wheel labels (#29, #30 and #31) from the larger
label sheet. Now, position the steering wheel labels, as shown in the
illustration, around the steering wheel.
Hint: These labels will be applied around the spokes on the steering
wheel. Carefully apply the center portion of each label to the topside of
each spoke. Gently smooth the label around each spoke.
• Remove the backing from label 29 and apply the label to the left spoke.
• Remove the backing from label 30 and apply the label to the
bottom spoke.
• Remove the backing from label 31 and apply the label to the right spoke.
Steering Wheel
Left
Spoke
Bottom
Spoke
Right
Spoke
Label 30
Label 29 Label 31
• Position the steering wheel with the large opening upright.
• Position the steering column so that the bend is upright, as shown.
• Fit the steering column through the center hole in the steering wheel.
Large Opening Upright
Steering Wheel
Steering Column
Bend
Upright
• Fit a .354 black cap nut onto the end of the steering column.
• Tap the cap nut with a hammer to secure it on the steering column.
Hints:
- You may need the help of another adult to keep these two parts in
the correct position.
- You may want to position the steering column on a scrap block of
wood to protect the assembly surface.
Steering
Column
.354 Black
Cap Nut
• With the large opening in the steering wheel upright, fit the curved
end of the steering column down into the large hole in the windshield.
• Continue to insert the curved end of the steering column through the
small, rectangular opening in the floor of the vehicle.
Curved End
of Steering
Column
Small
Rectangular
Opening
Windshield
Large Hole
35
.354"

37
36
20
ASSEMBLY
M3865pr-0920
• Turn the vehicle on its side, so that the
bottom faces you.
• Position the steering bracket behind the steering linkage, as shown.
• Fit the steering column through the hole in the steering bracket to
the second bend.
Steering
Bracket
Steering
Column
2nd Bend
Steering
Linkage
Steering
Bracket
• Fit the end of the steering column
through the hole in the steering
linkage A.
• Turn the steering bracket and fit it into place B.
Steering
Bracket
Steering
Column
Steering
Linkage
A
B
• Insert a #10 x 3/4" trusshead screw through
the front end of the vehicle and through
the hole in the bracket.
• Attach the #10 lock nut to the end of the trusshead screw.
• While holding the lock nut in place with an adjustable wrench, tighten
the screw with a Phillips screwdriver. Do not over-tighten.
#10 x 3/4"
Trusshead
Screw
#10 Lock Nut
38
Screw
Lock Nut
• Turn the vehicle upright.
• Fit the steering wheel cap into the center of the steering wheel.
• Insert two #6 x 1" screws through the steering wheel cap and into the
steering wheel. Tighten the screws.
Steering Wheel Cap
Steering
Wheel
TOP VIEW
39