GoKa Sports GK1100-2 User manual

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CONTENT
Foreword -----------------------------------------------------------------------------------------------------------2
1. The performance, technical parameters and structure of Go Kart -----------------------------3
1.1 Performance and Specifications
1.2 Parts and their locations
2. The use of Go Kart------------------------------------------------------------------------------------6
2.1 Caution and safety note
2.2 Instrument and control
2.3 Before riding
2.4 Basic operation
2.5 Grinding-in
2.6 Circuit diagram
3. Maintenance ------------------------------------------------------------------------------------------12
3.1 Engine maintenance
3.2 Periodical maintenance
3.3 Torque of tightening of the main bolts and nuts
4. Trouble shooting--------------------------------------------------------------------------------------20
5. VIN number-------------------------------------------------------------------------------------------25

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FOREWORD
Congratulations on having this new kart.
We recommend that you read this owner’s manual before you ride the kart. This manual contains
the vehicle structure, operation instructions, safety information and some helpful suggestion. The manual
has a special section concerning maintenance. To protect your investment, we strongly recommend you to
keep your go-kart well maintained. In case of any problem on your Kart, please refer to the
trouble-shooting section. We hope you enjoy riding of your vehicle, and we would appreciate feedback or
comments from you.
Our company reserves all the right to revise and explain this manual, and we reserve the
right to improve, without notice beforehand, the product after publishing this manual. Some
pictures in this manual are sketch maps for reference. In case of any deviation from the material
objects, please refer to the actual items.
Copyright of this manual belongs to Shanghai GoKa Sports Motor Co., Ltd
Copyright Reserved ©

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1. Performance, Technical Parameter and Structure of Go Kart
1.1 Performance and Specifications

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1.2 Component location and structure
Aux, light
Headlight
Front wheel
Rear wheel
Back view mirror Rear shock
absorber
Steering wheel
Front shock
absorber
Fig 1
Fig 2 Fig 3
Seat

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2. The use of Go Kart
2.1 Caution and Safety Note:
Read this owner’s manual carefully and make sure you understand it completely before driving this
kart.
People under age of eighteen are not allowed to drive this kart.
Please make sure to wear an approved motorcycle helmet and have the seat belt well fastened before
driving the kart. Do not drive this kart at night. It’s dangerous to drive on an unknown road. Keep a safe
distance between your kart and other vehicles. Never risk drunken driving or drive the kart after taking
medicine, which will endanger your driving and result in injury even death. Check fuel level before the
kart is used. Never refuel the tank while the engine is hot or running. Spilled gasoline should be wiped off
prior to starting the engine. Don’t drive your kart indoors. Because exhaust contains a kind of tasteless,
odorless and poisonous gas called carbon monoxide.

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2.2 Instrument and control
(1) Major control switches are located on
the right side of the steering wheel.
(Fig 4)
(2) Light switch is located on the right side of
steering wheel. Horn button is located on
the right side of steering wheel (Fig 4)
(3) Fuel tank
Fuel tank is located above the engine and close to the
rear carrier of the kart. Turn the lid counterclockwise
to open and then refuel. The tank capacity is 20L.
(Fig 5)
Fuel tank lid
Fig 5
Switch panel
Gauge
Fig 4

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(4) Brake pedal (Fig 6)
Brake pedal is underneath the right side of steering wheel. It controls the front and rear brake discs,
operated by right foot. When you release your foot from the brake pedal, it will automatically
return to its normal position.
(5) Clutch pedal (Fig 6)
Clutch pedal is underneath the left side of steering
wheel, and controlled by left foot.
(6) Accelerator pedal (Fig 6)
Accelerator pedal is located to the right side of the brake pedal and controlled by right foot.
(7) Gear shifting (Fig 7)
(8) The gear shift lever controls velocity of the kart (Fig 7)
Gear shift leaver
Accelerator pedal
Clutch pedal
Brake pedal
Fig 6
Fig 7

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(9) Gear box: 5 forward shifts +1 reverse shift (Fig 8)
(10) The seat back lock lever is underneath
the seat, pull up the lever to adjust the seat,
when satisfied, release the lever to lock the
position.; seat location adjuster is in the
inner side of the seat, pull up to adjust ,
when satisfied, release the lever to lock.
(Fig 9, Fig 10)
(11) Steering side rod
Front wheel alignment can be accomplished
by actual use of steering side rod. (The angle
of inner obliquity is 1o, normally no need to adjust) (Fig 11)
Steering side rod
Seat back lock switch Seat location adjuster
Gear box
Fig 8
Fig 9 Fig 10
Fig 11

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2.3 Before riding
Please check all the following items before driving.
Items Purpose
Steering (1) Turning Smoothly (2) No obstacle (3) No clearance
Brake (1) Travel length of pedal is proper (2) No slippery.
Tyre (1) Proper pressure (3) No crack or cut.
Fuel Keep enough fuel for intended driving distance
Light Check all the lamps – headlights, tail lamps, stop lamps, turn lights etc.
Oil Check if the oil is enough
Battery Check the electrolyte lever, fill some if necessary
2.4 Basic operation guide
Driving this Go Kart is the same as driving a car.

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2.5 Grinding in
Proper grinding-in of a new kart is very important to prolong the life
span of the vehicle and achieve its best performance. During your
driving of the first 600 miles, limit the driving speed as suggested
below to avoid early damage of parts due to high driving speed
Gear steps Max. speed
1 6 miles/h
2 12 miles/h
3 21 miles/h
4 34 miles/h
5 40 miles/h

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2.6 Circuit diagram:

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3. Go Kart Maintenance
3.1 Engine maintenance
（1） #93 or above unleaded gasoline is recommended.
Note: using unleaded gasoline can extend the life of engine.
（2） A. How to choose lubricating oil
User should choose proper type of engine oil according to the
local temperature.
Use SF SAE15W/40 oil in environment temperature above -20 C
Use SF SAE5W/30 oil in environment temperature below -20 C
B. Oil Level: The level of engine oil should be between
upper scale and lower scale.
Upper scale
Lower scale

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C. Changing Oil: Unscrew the oil drain bolt to let out
old oil ; screw down the bolt when all the old oil is let
out before new oil is filled in. (Fig 13)
D. Oil Filling: Oil should be filled through filling
port. After oil filling, let the engine run in
idle for 3-5minutes and then check the oil level;
add enough if it’s inadequate(Fig 14)
E. Gear oil 85W/90 API/GL-4 GL-5 are
recommended for gearbox；the amount required is 2 L;
and the oil level should be between upper scale and
lower scale.
Fig 13
Fig 14
Oil drain bolt
Oil filling port

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（3） Cooling liquid
A. Cooling system of the engine must be filled with
adequate cooling liquid. The freezing point of
the cooling liquid should be 9°F lower than the
freezing point of the applied area.
B. After 5-minute running of the engine, stop it and
wait for 15 minutes before you inspect the cooling
water level.If it is still not enough, add more cooling
water to the limit line.
The filling port of the radiator
Fig 16
Auxiliary tank

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3.2 PERIODICAL MAINTENANCE
The maintenance intervals in the following table are based on average riding conditions. Unusual
condition requires more frequent service.
Time
of service
Items
Initial service
(First week)
Monthly Quarterly Yearly
Tyre pressure/wear I I
Brake performance I I
Tightness of fasteners I I
Air cleaner (C or R)/200miles
Carburetor I A C
Spark plug C, A
Engine oil I R
Gear box oil I R

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Oil filter screen C
Chassis C, I L
Fuel switch/Fuel tank I C
Battery I
Valve clearance of
engine
A
Control cables I
Cooling liquid I R
Note: A: To adjust; C: To clean; I: To inspect, clean or replace if necessary;
L: To lubricate; R: To replace.
The following are some instructions on periodical check:
1). Lubricating oil check (Fig 18)
Check the oil gauge. Make sure there is enough lubricating oil; the capacity
is 4.5L. (Engine 2.5L, Transmission: 2L).
Oil gauge
Fig 18

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2.) Fuel tank check
Check for enough fuel in the fuel tank. The fuel tank capacity is 20L.RQ93 unleaded gasoline is
recommended. Do not fill too much fuel, or the fuel may overflow and cause a fire.
3.) Tire pressure check
Check if the tire pressure is normal. The recommended tire pressure is 200kpa; Check if there are
any metal fragments or nails stuck in the tire; if so, remove them immediately. Check if there is any
crack or severe tear on the tire, replace the tire if necessary.
4.) Battery check
The normal voltage should be above 12.8V; Keep the terminals clean and the connections tight. ; If
the voltage is below the normal condition, remove the battery to recharge
5.) Chassis check
After cleaning the chassis, inspect the body, front and rear suspensions, rocker arm, rear axle and

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fasteners and check if there is any weld failure, crack or loose connections.
6.) Brake system check
The brake pedal must have proper length of travel. Length
of travel is the distance from brake pedal’s idle position
to its working position, and it is about 15-25mm.
Periodically inspect the thickness of the brake disc. It should
be replaced in case of any wear of over 1mm.
Periodically inspect the level of the brake fluid in the oil
cup. When the brake fluid is below the required level,
fill new DOT4 brake fluid.
Always keep the brake discs and the brake pads clean.
Fig 19
Fig 20
Brake master cylinder Clutch master cylinder
Brake cylinder Sphero joint

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7) Maintenance guide
Repair should be done by professional service center, unless the owner possesses repair expertise and
a complete set of repairing tools. Stop the engine before repairing the kart.
3.3 Required torque for tightening the bolts and nuts:
number Item Required torque
N. M Kgf m
1 Front swing arm bolt 50~60 5~6
2 Rear swing arm bolt 95~105 9.5~10.5
3 Rear swing arm nut 95~105 9.5~10.5
4 Nuts at front and rear hub 65~75 6.5~7.5
5 Nuts at front and rear rim 65~75 6.5~7.5
WARNING: If your kart has experienced a collision or overturn, please carefully inspect
each part of the kart, such as the frame, suspension and steering device; Driving damaged
kart is forbidden as it will endanger yourself.