Go Kart 500 User manual

READ THIS MANUAL CAREFULLY!
It contains important safety information.
500 Go-kart
OWNER’S MANUAL
4 × 4
This Go-kart should not be ridden by anyone under 16 years of age.

INTRODUCTION
Congratulations on your purchase of the 500GO-KART. With the purchase of this GO-KART, you
can now appreciate the high degree of craftsmanship. This manual will provide you with a good basic
understanding of the features and operation of this GO-KART. This manual includes important safety
information. It provides information about special techniques and skills necessary to ride your
GO-KART. It also includes basic maintenance and inspection procedures. If you have any questions
regarding the operation or maintenance of your GO-KART, please consult you dealer.
AN IMPORTANT SAFETY MESSAGE:
●READ THIS MANUAL FOR THE GO-KART RIDER CAREFULLY AND COMPLETELY
BEFORE OPERATING YOUR GO-KART. MAKE SURE YOU UNDERSTAND ALL INSTRUCT-
IONS.
●PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE GO-
KART.
●NEVER OPERATE A GO-KART WITHOUT PROPER TRAINING OR INSTRUCTION.
FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW GO-KART.
●THIS GO-KART, AND ANY OTHER GO-KART OVER 90cc, SHOULD NOT BE RIDDEN
BY ANYONE UNDER 16 YEARS OF AGE.

INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN
RESULT IN SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME
ALERT!
Failure to follow WARNING instructions could result in severe
injury or death to the machine operator, a bystander or a person
inspecting or repairing the machine.
A CAUTION indicates special precautions that must be taken to avoid
damage to the machine.
NOTE: A NOTE provides key information to make procedures easier or clearer.

IMPORTANT NOTICE
This GO-KART is designed and manufactured for OFF-ROAD use only. It is illegal and
unsafe to operate this GO-KART on any public street, road or highway. This GO-KART
complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations
in effect at the time of manufacture. Please check your local riding laws and regulations
before operating this GO-KART.

TABLE OF CONTENTS
Introduction……………………………………………………………………………………1
SAFETY………………………………………………………………………………………2
Features and Controls…………………………………………………………………………20
Component Locations…………………………………………………………………………20
Indicator and warning lights…………………………………………………………………22
Switch…………………………………………………………………………………………23
Seats……………………………………………………………………………………………24
Seat Belts………………………………………………………………………………………24
Seat Belt Inspection……………………………………………………………………………25
Fuel cap …………………………………………………………………………………26
Ignition Switch ………………………………………………………………………………27
Gear Selector…………………………………………………………………………………28
Brake Pedal……………………………………………………………………………………29
Throttle Pedal…………………………………………………………………………………29
OPERATION…………………………………………………………………………………30
Vehicle brake-in period………………………………………………………………………30
Pre-ride inspection……………………………………………………………………………32

Safe operation practices………………………………………………………………………33
Starting the engine……………………………………………………………………………34
Stopping the engine……………………………………………………………………………35
Braking…………………………………………………………………………………………35
Parking the vehicle……………………………………………………………………………35
New operator driving procedures……………………………………………………………36
Driving with a passenger………………………………………………………………………38
Driving on slippery surface……………………………………………………………………39
Driving uphill…………………………………………………………………………………41
Driving on a side hill…………………………………………………………………………42
Driving downhill………………………………………………………………………………43
Driving through water…………………………………………………………………………43
Driving over obstacles…………………………………………………………………………44
Driving in reverse………………………………………………………………………………45
Parking on an incline…………………………………………………………………………46

MAINTENANCE………………………………………………………………………………47
Periodic maintenance chart …………………………………………………………………47
Engine oil ……………………………………………………………………………………50
Transmission (main gearcase)………………………………………………………………54
Spark plugs……………………………………………………………………………………55
Constant variable transmission (CVT)system ………………………………………………56
Filter system …………………………………………………………………………………58
Cooling system …………………………………………………………………………………60
Throttle system ………………………………………………………………………………61
Carburetor ……………………………………………………………………………………63
Brakes…………………………………………………………………………………………65
Steering wheel inspection ……………………………………………………………………67
Shock spring adjustment ……………………………………………………………………67
Tires……………………………………………………………………………………………68
Vehicle immersion……………………………………………………………………………69

Battery…………………………………………………………………………………………70
Clearing and storage…………………………………………………………………………73
SPECIFICATIONS……………………………………………………………………………75
Circuit Diagram, Wiring Diagram and troubleshooting chart ……………………………81

INTRODUCTION
Failure to follow the warnings and safety precautions contained in this manual can result in severe
injury or death. Your vehicle is not a toy and can be hazardous to operate. This vehicle handles
differently than cars, trucks or other off-road vehicles. A collision or rollover can occur quickly, even
during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper
precautions.
●Read this owner’s manual. Understand all safety warnings, precautions and operating procedures
before driving the vehicle. Keep this manual with the vehicle.
●Never operate this vehicle without proper instruction.
●Always follow the age guidelines for your vehicle. Operation is prohibited for anyone age 16 and
under. Never operate with a passenger age 12 and under.
1

Equipment Modifications
SAFETY
Your vehicle is designed to provide safe operation when used as directed. Modifications to your
vehicle may negatively impact vehicle stability. Failure of critical machine components may result
from operation with any modifications, especially those that increase speed or power. This vehicle
may become less stable at speeds higher than those for which it is designed. Loss of control may
occur at higher speeds. Do not install on a vehicle any equipment that may increase the speed or
power of the vehicle, or make any other modifications to the vehicle for these purposes. Any
modifications to the original equipment of the vehicle create a substantial safety hazard and increase
the risk of bodily injury. The warranty on your vehicle is terminated if any equipment has been added
to the vehicle, or if any modifications have been made to the vehicle, that increases its speed or power.
The addition of certain accessories may change the handling characteristics of the vehicle. Use only
our company approved accessories, and familiarizes yourself with their function and effect on the
vehicle.
2

Safe Riding Gear
Always wear appropriate clothing when riding this vehicle. Wear
to reduce the chance of injury.
3
SAFET Y
protective clothing for comfort and

Safe Riding Gear
Helmet
SAFETY
Wearing a helmet can prevent a severe head injury. Whenever riding this vehicle, always wear a
helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a vehicle, always
wear shatterproof goggles or use a shatterproof helmet face shield.
Gloves
Wear gloves for comfort and for protection from sun, cold weather and other elements.
Boots
Wear sturdy footwear. Do not ride a vehicle with bare feet.
Clothing
Wear long sleeves and long pants to protect arms and legs.
4

Safety Warnings
SAFETY
Failure to operate this vehicle properly can result in a collision, loss of control, accident or overturn,
which may result in serious injury or death. Be sure to read all of the following warnings about driving
hazards and how to avoid them. These warnings are provided for your safety.
Operating Without Instruction
Operating this vehicle without proper instruction increases
the risk of an accident. The operator must understand how to
operate the vehicle properly in different situations and on
different types of terrain.
Age Restrictions
Operation is prohibited for anyone age 16 and under. Never
operate with a passenger age 12 and under. Make sure any
passenger is tall enough to comfortably and safely reach the
hand holds and place both feet on the floor.
5

Safety Warnings
Rider Height
Some riders may be too tall to ride safely in this vehicle.
Do not operate or ride in this vehicle if the clearance
between the top of your helmet and the overhead cab
frame is less than 2 inches (5 cm).
Failure to Inspect Before Operating
Failure to inspect and verify that the vehicle is in safe
operating condition before operating increases the risk
of an accident. Always inspect the vehicle before each
use to make sure it's in safe operating condition. Always
follow the inspection and maintenance procedures and
schedules described in the owner's manual.
Accessories
Installing non-approved accessories may seriously affect
vehicle handling and stability, which could result in loss
of control or an accident. Never install accessories not
approved by our company for use on this vehicle.
6
SAFETY

Safety Warnings
Protective Apparel
Riding in this vehicle without wearing an approved
helmet and protective eyewear increases the risk of
serious injury in the event of an accident. Operator
and passenger must always wear an approved helmet
that fits properly and eye protection (goggles or face
shield).
Seat Belts
SAFETY
Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of
an accident or sudden stop. Riders must wear seat belts at all times. Seat belts reduce the severity of
injury in the event of a sudden stop or accident. Always make sure the seat belts are secured for both
the operator and passenger before riding.
Using Alcohol or Drugs
Riding in this vehicle after consuming alcohol or drugs
could adversely affect operator judgment,reaction time,
balance and perception. Never consume alcohol or drugs
before or while operating or riding in this vehicle.
7

Safety Warnings
Carrying a Passenger
Never carry a passenger until you have operated this vehicle for at least four hours.
Carrying Multiple Passengers
Carrying more than one passenger in this vehicle can
affect the operator’s ability to steer and operate the
controls, which increases the risk of loss of control and
accident or overturn. Never carry more than one passenger
in this vehicle.
Operating on Pavement
Operating this vehicle on paved surfaces (including sidewalks, paths,
SAFETY
Parking lots and driveways) may seriously affect handling and control of the vehicle, and may cause
the vehicle to go out of control. This vehicle's tires are designed for off-road use only, not for use on
pavement. Avoid operating the vehicle on pavement. If you must operate on a paved surface, travel
slowly and do not make sudden turns or stops.
Operating on Public Roads
Operating this vehicle on public streets, roads or highways
could result in a collision with another vehicle. Never
operate this vehicle on any public street, road or highway,
including dirt and gravel roads. In many areas it's unlawful
to operate vehicles of this type on public streets, roads and
highways.
8

Safety Warnings
Operating at Excessive Speeds
Operating this vehicle at excessive speeds increases the
operator's risk of losing control. Always operate at a speed
that's appropriate for the terrain, the visibility and operating
conditions, your skills and your passenger’s skills.
Turning Improperly
SAFETY
Turning improperly could cause loss of traction, loss of control, accident or overturn. Never turn
abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before
attempting to turn at faster speeds.
Physical Control of the Vehicle
Removing hands from the steering wheel or hand holds or removing feet from the floor while riding
increases the risk of loss of control and accident or overturn. The operator should always keep both
hands on the steering wheel during operation. A passenger should always be seated in the passenger
seat with both feet on the floor and with both hands securely grasping the hand holds. Always keep
hands and feet inside the vehicle at all times.
9

Safety Warnings
Jumps and Stunts
Exhibition driving increases the risk of an accident or
overturn. DO NOT do power slides, “donuts”, jumps
or other driving stunts. Avoid exhibition driving.
Driving Downhill Improperly
Driving down a hill improperly could cause
loss of control or overturn. Always follow
proper procedures for driving down a hill as described in the owner's manual.
●Always drive down a hill with the transmission in
forward gear. Never drive down a hill with the
transmission in neutral.
●Never operate the vehicle on hills steeper
than 25 degrees.
●Always check the terrain carefully before driving down a hill
●Never travel down a hill at high speed.
SAFETY
●Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side.
Travel straight downhill.
10

Safety Warnings
Improper Hill Climbing
Improper hill climbing could cause loss of control or overturn.
Use extreme caution when operating on hills. Always follow
proper procedures for hill climbing as described in the owner's
manual.
Stalling While Climbing a Hill
Stalling or rolling backwards while climbing a hill could cause
an overturn. Maintain a steady speed when climbing a hill.
If you lose all forward speed:
Apply the brakes gradually until the vehicle is fully stopped.
Place the transmission in reverse and slowly allow the vehicle
to roll straight downhill while applying light brake pressure to
control speed.
Crossing Hillsides
Driving on a sidehill is not recommended. Improper procedure
could cause loss of control or overturn. Avoid crossing the side
of any hill unless absolutely necessary.
11
SAFETY

Safety Warnings
Operating in Unfamiliar Terrain
Failure to use extra caution when operating on unfamiliar terrain
could result in an accident or overturn.
Unfamiliar terrain may contain hidden rocks, bumps, or holes that
could cause loss of control or overturn.
Travel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.
Operating on Sand or Slippery Terrain
Operating on sand or on excessively rough, slippery or loose
terrain could cause loss of traction, loss of control, accident
or overturn. Always use extra caution when operating on
sand or on rough, slippery or loose terrain. Do not operate on
excessively rough, slippery or loose terrain.
12
SAFETY