GOKARTS USA GY6 150 User manual

BUGGY SETUP GUIDE
Volume
1
GOKARTSUSA
GY6 150, CN250
Buggy Setup
Guide

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GY6 150, CN250 DUNE BUGGY
Buggy Setup Guide
GOKARTSUSA.COM
2000 Highway 50 • S. Lake Tahoe, CA 96150
Phone [phone]

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Table of Contents
CONTENTS
Factory Direct 4
Mechanic Advisory 4
Components to be Installed 4
Buggy Setup 5
Uncrate your Buggy 7
Attach Shock Absorbers 8
Install Wheels 9
Battery Installation 11
Seat Installation 13
Steering Wheel Installation 14
Roll Cage Installation 15
Install Radiator Coolant (250 models) 16
Install Engine Oil 17
Install Gear Oil 17
Fuel Line Installation 18
Vacuum Line Installation 19

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Buggy
SETUP
Factory Direct
When you purchase a Buggy Factory Direct, you can save a substantial amount of money.
However, this means you must perform the vehicle setup when your Buggy arrives.
Your Buggy is NOT A KIT. Your Buggy is assembled at the Factory, and then packaged for
shipping. It will arrive with ALL MAJOR COMPONENTS INSTALLED including,
Engine, Transmission, Brakes, Steering Systems, and Controls etc.
Your Buggy will arrive in a large crate. You must uncrate and setup your Buggy when you
receive it. This guide is indented to supplement the setup guide provided by the
manufacturer
Mechanic: Although the setup is not a particularly difficult task, it does require some
mechanical expertise. It is strongly recommended that if any setup task is beyond the scope
of expertise of the customer, that the customer seeks a qualified mechanic to perform the
setup of the vehicle. In addition to voiding the warranty, Damage, Serious Injury or Death
can result form improper setup of a vehicle.
COMPONENTS THAT MUST BE INSTALLED
•Wheels
•Seats
•Roll Cage
•Battery
•Lights
•Fuel Lines
•Fluids

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Buggy Setup
This manual serves as a general guideline and is not model specific
Buggies are assembled, tested and adjusted at the factory, and then
packaged for shipping
Your Buggy will arrive with ALL MAJOR COMPONENTS INSTALLED
including, Engine, Transmission, Brakes, Steering Systems, and
Controls etc
Setup generally requires installation of:
•Wheels
•Seats
•Roll Cage
•Battery
•Lights (if so equipped)
•Fuel Line
•Fluids
It is strongly recommended that setup of your Buggy be performed by
a Qualified Mechanic

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Your Buggy will arrive in a metal Crate

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Uncrate your Buggy
WARNING: Buggies weigh 500 pounds or more. Make sure to have some help
for this step
Remove all of the bottom bolts from around the crate and lift the upper part of
the crate frame as one piece.
.
COMPONENTS TO BE INSTALLED:
•2 Seats
•4 Wheel & Tire Assemblies
•Roll Cage Rails and Bars
•Steering Wheel
•Battery Kit

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Attach the Shock Absorbers
Line up the shock with its mount on the frame, insert the bolt,
thread on the nut and tighten
Repeat this process on the other side

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Install the Wheels
•Jack up one side of the buggy and insert jack stands
•Remove the 4 lug nuts and washers the hub
Some Buggies ship with uni-directional tires while others come
with bi-directional tires
•Uni-directional tires must be installed on a correct side. Find
the arrow on the tire sidewall. The arrow MUST point
towards the front of the buggy
•Bi-directional tires have a tread that more closely resembles
knobby tires for dirt motorcycles and can roll in either
direction

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Place the wheel onto the hub
Install the lug nuts. The flat washer goes on first, then the lock
washer, then the lug nut

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Battery Installation
Battery Kit:
•Battery
•Battery Acid
•Battery Cell Caps
•Rubber Battery Cushion
•Battery Cover
•Terminal Screws
Battery Setup:
1. Follow the enclosed instructions to fill the battery with the
battery acid
2. Charge the Battery for 8 hours
3. Place the battery on the cushion in the tray
4. Connect the Battery Cables to the battery using the terminal
screws provided in the battery kit

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The RED wire connects to the POSITIVE (+) terminal,
The BLACK wire connects to the NEGATIVE (-) terminal
NOTE: Do NOT reverse these connections, or you will damage the electrical
system and void your warranty

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Install Seats
Place the seat in the buggy and use the seat adjustment rails to
align the mounting bolts with the mounting tabs
Thread the mounting nuts onto the bolts and tighten them

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Install Steering Wheel
Remove the nuts from the steering wheel mounting screws
Line up the screws with the holes in the steering wheel mount
NOTE: Ensure that your front wheels are aimed straight ahead
before attaching the steering wheel

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Install Roll Cage
Remove the roll cage mounting bolts and adaptors from the front
and rear mounts
Insert the front of the bar into the front mount first, then insert
the rear of the bar into the rear mount
Insert the screws and thread the adaptor nuts onto them, but do
not tighten at this time
NOTE: Sometimes it takes a bit of jockeying the bar around to get
it onto the mounts
Once all bolts are inserted and well started, you can tighten all the
bolts, starting from the bottom and working your way upwards

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Install Radiator Coolant (250 Models)
Your Buggy ships from the factory with NO coolant in the cooling
system. If anything, it is shipped with water only. BEFORE operating
your buggy, you MUST:
1. Purchase a bottle of automotive antifreeze
2. Remove the radiator cap from the radiator
3. Disconnect the lower radiator hose from the radiator and
allow the water to drain from both the hose and radiator
4. Re-attach the lower radiator hose to radiator
5. Fill the cooling system with the same ratio of antifreeze to
water that you would use in your full-size automobile. This
ratio will vary according to the region/climate in which you
live
6. Bleed the air from the cooling system as follows:
a. Leave the cap OFF of the radiator
b. Start the engine
c. After the engine warms and the thermostat opens, an
air bubble will surface in the radiator and the coolant
level will go down
d. Top off the cooling system so that the coolant level is
at the bottom of the radiator filler neck
e. Replace the radiator cap on the radiator
f. Now fill the coolant overflow tank about 1/4 full with
coolant.
WARNING: Running the engine without the cooling system being properly filled
voids your warranty!

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Install Engine Oil
Engine Oil
Even though your Buggy is shipped from the factory with some oil in the
crankcase, there is almost always leakage during transit. You must check and
fill your engine to the proper oil level using the dipstick on the engine oil filler
plug before operating your engine.
Also go through all the nuts and bolts and ensure that they are tight.
Sometimes they come loose during the trip from China.
WARNING: Running the engine without the crankcase being properly filled
voids your warranty!
Install Gear Oil
The final step is installing a proper level of Gear Oil. Open the filler cap on the
Reverse Gear Box and fill with Gear Oil. There is no dipstick on the gear box.

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Install the Fuel Line
Fuel Line
Identify the Fuel Line. Most 150 and 250 Buggies have 2 lines coming out of the Fuel Valve.
One Line, usually the one with a Fuel Filter connected to it, is the Fuel Line.
The other line is the Vacuum Line.
First, connect the fuel line to its nipple on the carburetor and fasten with the butterfly clamp
provided.
1

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Install the Vacuum Line
Vacuum Line
The remaining line connected to the Fuel Valve is the Vacuum Line. Proper installation of
the Vacuum Line is important because it opens the Fuel Valve with Vacuum.
Connect the Fuel Valve’s vacuum line to the engines vacuum Y-connector as shown below:
NOTE: Sometimes, the factory will plug the Y-connector into the Carburetor drain hose for
shipment. If this is the case, disconnect the Y-connector, and then insert the Y-connector
into the fuel tank's vacuum line.