GSMOON KD260-1 Operating instructions

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GO-KART [XYKD260] Repair Manual

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1 Service Notice
Position of Identification Number Lubrication diagram
MainFeatures Structure Drawing
Standard Torque Rating Troubleshooting
Position of Identification Number
Vehicle Identification Number Engine Identification Number

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Main features
Vehicle Dimensions [mm] KD260-1 KD260-2 KD260-3
Overall Length………………………….………………………………………………..2470 2690 2550
Overall Width……………………………………………..……………………………..1570 1510 1670
Overall Height……………………………………………………………………………1535 1460 1440
Wheelbase………………………………………………………………………………..1870 1950 2010
Front Track……………………………………………………………………………….1345 1270 1485
Rear Track……………………………………………………………………………….1250 1250 1263
Ground Clearance…………………………………………………………………………200 220 200
ENGINE
Type…………………………………………………………………….……………..Water cooling, four stroke
Engine capacity……………………………………………………………………….260cc
Bore *Stroke………………………………………………………………………….70mm*66.8mm
Displacement………………………………………………………………………….257cm³
Corrected compression ratio…………………………………………………………9：1
Max output power…………………………………………………………………..11kw/7000rpm
Max Torque…………………………………………………………………………..17Nm/5000N.m/r/min
Starting………………………………………………………………………………..Electric Start
Ignition………………………………………………………………………………..C.D.I
Lubrication…………………………..………………………………………………..pressure splash
Transmission…………………………..………………………………………………. Automatic C.V.T System
Spark plug…………………………..……………………………………………….DPR5EA-9（NGK）
Plug gap…………………………..……………………………………………….0.6-0.8mm
Fuel type…………………………..……………………………………………….RQ90 (leadless)
Lubricate oil…………………………..……………………………………………….SAE15W-40/SF
Capacities
Maximum load…………………………..……………………………………………….Two seats/200Kg
Fuel tank…………………………..……………………………………………………...9.5L
Engine oil…………………………..……………………………………………………..1180mL
Starting Time…………………………..……………………………………………………..<10s
Climbing…………………………..……………………………………………………..20º-25°
Battery…………………………..……………………………………………………..12V 14Ah
Head Light…………………………..……………………………………………………..12V 35W
Tail Light…………………………..……………………………………………………..12V 21W/5W
Fuse…………………………..……………………………………………………..10A
Brake Track…………………………..……………………………………………………..7m at 30KM/h
Top speed…………………………..…………………………………..75KM/h (Or as customer requirement)
CHASSIS
Front/Rear brake ………………………………Hydraulic disc brake/ Left leg control
Front tire ……………………………………………… AT21X8-10
Rear tire ………………………………………………AT22X11-10
Front Suspension ………………………………………… Independent dual-A arm
Rear Suspension …………………………………Independent swing arm/ Double hydraulic shock

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Restraint System ……………………………………… Double quincunx safety belts
Final Drive ………………………………………………… shaft drive
TIRE PRESSURE[kPa] off-roadTire Road Tire
Front …………………………………………………… 25 200
Rear …………………………………………………… 30 225
WEIGHT[KG] KD260-1 KD260-2 KD260-3
Net Weight …………………………………355 346 365
G.W. …………………………………… 380 370 380

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Standard Torque Rating
SER
NUM Position
XYKD
Diameter of screw
（mm）
Torque（N.m）
1 Screw used between Exhaust pipe and Front Cylinder 8 20-26
2 Igniter plug 10 18-20
3 Screw used between Front wheel hub and front universal
joint
14 80-100
4 Screw used for Rear wheel hub and Constant-velocity joint 18 120-140
5 Universal joint fastening bolt 8 20-26
6 Bolt of protective parts of steering mechanism 8 30-40
7 Screws between handle ball and gimbal 10 50-60
8 Screws of wheel and wheel rim[Front and rear] 10 50-60
9 Screws of support parts[Front wheel] and vehicle body 10 50-60
10 Connection of brake pump parking brake and front gimbals,
elevation
8 20-26
11 Screws of handle adjusting line 10 30-40
12 Screws exhaust pipe and engine rear support part 8 20-26
13 Screw used on Front Vibration Damper 10 30-40
14 Screw used on Rear Vibration Damper 12 50-60
15 Connecting screws between rear support part and vehicle
body
16 110-130
16 Screws of rear support parts of engine 10 30-40
17 Screws of front support parts of engine 10 30-40
18 Screws of back brake disc and back wheel rim 8 30-40
19 Screws of front brake disc and front wheel rim 6 20-26

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Lubricating oil and How to do lubrication
1、Engine
Position Description of Lubricating Oil Remark
Crankcase Only 15W/40SF Full capacity：1.0L
Gear case Only 15W/40SF or 85W/140 Full capacity：0.22L
Parts of Clutch Li oil ZL-3H（SY 1413）4.5~5.0g
2、Vehicle Body
The parts, described [not limited] as following, should be added lubricating oil.
If no special requirement, please use the multiple functions lubricating oil.
In order to prevent the unusual sound and improve the durability, lubricating oil also should be used in
other transmission parts.
Connection part
between Steering gear
parts and handle ball
Steering wheel nylon bushing
Brake pedal
Accelerator pedal
Accelerator cable
Parking brake cable Front lower swing arm
Front Wheel Support Part
Front wheel axle
Main seat slide rail
Constant speed
g
imbal
Rear wheel rim axle
Rear swing arm axle
Sub seat slide rail

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Structure Drawing
Pipe of
cooling liquid
kettle
Water tubing
Temperature
Control
Switch
Rear brake oil
tube
Brake cable

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Fuse 15A
Flash apparatus
Rela
y
CDI
BATTERY
I
g
nition coil
rectifie
r
Electric parts
case
Quadric air-intake
mechanism
Throttle cable
Reverse cable
Parking
brake cable

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Troubleshooting
Can not or difficult to start
Main cable Speed Sensor cable
Description Adjustment Reasons
Whether oil run in carburetor. Take
down vent bolt to check.
Take off spark plug to check
sparkle or not
Yes
●● No oil in oil tank
● Jam between oil tank and carburetor
● Oil tank hole jammed
● Oil filter jammed
● Oil cleaning net jammed
● Pressure oil switch not work
● Spark plug not work
● CDI parts not work
● Spark plug not clean
● Trigger not work
● Spark plug coil broken or short-circuit
● Ignition coil broken or short circuit
● Igniter switch not work
● Magneto coil not work
● Valve gap not enough
No
Yes No or not enough
Pressure Value

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Description Routine
Power is not strong, not speed up
● Damage of cylinder, piston rings
● cylinder head gasket works not well
● Valve is damaged
●Mixing air time not good
●EEV of carburetor not work
● Valve socket not good
●Air leakage of minus pressure tube
●Ignition time not good
●Vent bolt of carburetion not work
● 化油器过满溢出
OK No or not enough
Start accordin
g
ri
g
ht method
No explosion No start with explosion
Take off spark plug again
火花塞是干的 火花塞湿
●Too many oil in carburetor
●EEV of carburetor not work
●Value of throttle is unusual.
Dry Wet
◆
Reasons
Check Ignition
time [Ignition led]
● Battery connection badness
● Air filter jammed
● Vent hole of oil tank cover jammed
● CDI parts not work
● Trigger not work
Yes No
● Valve gap not good
● Shape of valve changed
Yes No
Check Valve Gap
Check Compress pressure Value in Plunger
Yes
●
● oil tube jammed
● minus Pressure line not connected well
● Carburetor jammed
No
Let engine work
at high speed

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Description Routine
◆
● Plunger ring is damaged
● Air leakage from gasket position
Yes No or Lower
●Parts of Carburetor jammed
No Yes
● Spark plunger polluted/damaged
● Temperature of spark plunger wrong
Clean Dirt
● Valve socket not work well
● Mix air time not good
Check spark plunger
Check Carburetor jammed.
Engine is too hot or not
● Oil is not replaced
● Mix air rare
● Quality of oil bad
No Yes
Speed up or work at high
speed
Check oil quantity
level and quality
OK
●
● Too many oil
● Oil is not enoughNo
● Plunger or Cylinder damaged
● Too many carbon powers in firebox
● Ignition time wrong
● Mix air rare
● Ignition time wrong
● Quality of oil is bad
●Too many carbon powers in firebox
● Cooling liquid not enough
Reasons

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Description Routine
Egine works unusually（such as idle and low speed）
No sound Unusual
sound
Ignition Time OK?
Yes
●
● CDI parts not good
● Magnetor not good
No
●Mixed air is rare[Take screws down]
●Mixed air is thick[Take screws up]
Yes No
● Carburetor is loosed
● Airproof parts not good
No Yes
● “O” gasket not good
● Air leakage in vacuum parts
Vent screw of
carburetor OK?
Air leakage in
carburetor gasket?
Sparks OK?
Reasons

13
Description Routine
Engine works unusually [High speed]
OK No or less spark ● Ignition coil not good
● Ignition coil is broken or in short
● CDI parts not good
● Spark plunger not good or polluted
● Ignition trigger not good
● Air tube jammed or damaged
Yes
● Cut Air Valve not good
● Vacuum line jammed or damaged
No
◆
Cut Air Valve OK?
Ignition time OK?
Yes
●
● CDI parts not good
● Magnetor not good
No
● Adjustment not good
● Value socket damaged
Yes No
● Oil line or oil filter jammed
● Vent hole is jammed
OK Unusual
● Not enough oil in oil tank
● minus Pressure line switch not work
Handspike gap OK?
Check oil automatic
screw function?
● Clean carburetor socket
No Yes
Carburetor socket jammed?
Reasons

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Description Routine
Not move with high speed
● Protruding sprocket wheel and magneto
flywheel position not match
Yes No
Mixed time right?
● Spring not goodYes No
Spring of valve good？
◆
Engine works at high
speed or easy to stop?
Engine works at
high speed
●
● Ignition coil wrong connection
● Spark plug bad connection
No high speed or easy to
stop
reverse gear OK
Check reverse operation system
●Length of reverse cable is not suitable
reverse position wrong
● Connection of battery not good
● Oil line not good
No Yes
Any unusual sound of engine
gear case
●Differential gear damaged
●reverse gear damaged
●Connector sheath of reverse gear damaged
●Differential damaged
Reasons

15
Description Adjustment
No power in battery
◆
Open side cover of engine and check
clutch strap broken or not
Start engine and check
voltage of battery
Battery can not charging
●
●Check battery whether out of usage
●Battery not good
Normal
● Connection of line is not good
Normal
● Stator not good
●Yellow line is broken
Unusual
Resistance value
of coil
Yes ● Blue/yellow or Green line is broken
No
Voltage between Blue/yellow and Green
li
Yes
● Booster not good
● connection-peg not good
No
Whether any looseness of booster and connection-peg？
● Magneto not good
Reasons

16
Description Adjustment
The charge is not good ( Overcharge )
No spark
●Measure of voltage between
rectifier polarities
Voltage is usual when
ignition switch is “On” No voltage when ignition switch is “On” ● black line of main cable
is broken
Any looseness or default of booster connection-peg
No Yes ● connection-peg not
good
● booster not good
Use a new spark plunger then check
i
No or less sparks
●
Sparks OK
No
Any looseness between lid of spark and
between high-voltage lines
● Lid of spark is loosen
Yes
● previous Spark Plunger broken
Connection of CDI parts
OK?
Yes No ● Connecter is not good
Check statement and features of connecter of CDI and measure
the resistance
Reasons

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Item
2 Inspections and Adjustment
Check & Repair method Transmission System BrakeSystem
Electronic System Wheel System Engine
CushionSystem Others
Check & Repair method
Maintenance period List
Maintainedtime ITEM
Requirements
Km ( remark )
1000Km 4000Km 8000Km 12000Km remark
Oil System I I I
Carburetion System I I I
Carburetor I I I I
Core of air filter often R
Spark plug I R I
Lubricating oil in engine First time1000Km; then per 2000 Km
Clean net of lubricating oil Per year R C C C
Gap of valve I I I I
Battery I I I
Brake system I I I I
OK No
Yes No
Related
p
arts OK?
● Ignition switch not good
● Magneto coil not good
● Trigger not good
● Ignition coil not good
●cable is broken
● Connection of coupling
p
arts not good
● CDI not good

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Brake DISC. I I I
Brake lighter switch I I I
Main lighter Per month I I I I
Clutch I
Suspend parts I I I
Support parts I I I
Screw and bolt Per month I I
Wheel/spoke Trimester I I I
Vent hole of crankcase C C C
Idle of carburetor I I I I
The vehicle should carry on the periodic maintenance according to the stipulation time.
Before the maintenance the vehicle should be cleaned thoroughly.
Definition of Letters：
I: to check, clean, adjust lubricate or change apart.
C：cleaning
R：use a new part
A：make an adjustment
L：Lubricating
Note: When the odometer reading surpasses the maximum features listed in the table,
the maintenance should be done repeatedly according to the table.
Brake System
Adjustment
Checkpedalfreetravel:
20~30mm
If it is beyond of this distance, please take down/up
adjustment screw.
When air enters the brake cylinder piston or the brake oil pipe, resulting in
brake failure, it is necessary to discharge the air in the brake in the following
manner: first step on the brake pedal with foot, loosen the exhaust screw
of the brake cylinder, open the brake cylinder oil cup, screw up the exhaust
screw until there is no brake liquid and air outflowing, release the accelerator
pedal and repeat the procedures until there is no air out-flowing.
Vent bolt
20~30mm
Adjustment Bolt

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Parking Brake System
When stop vehicle on 20º-25°ground and can not park it.
Please check parking brake system for safety:
1 Take down/up adjustment bolt near by brake handle
2 Take down/up adjustment bolt near by brake caliper
Parking Brake system is complexes; adjust parts in a whole system to
Make PB system work well.
Wheel System
Wheel
Check tire with air pressure gauge.
Standard information：
Spec. of Tire Pressure Value
（off-road）
Pressure Value
（Road）
Front AT21X8-10 28kPa 200kPa
Rear AT22X11-10 35kPa 225kPa
Check mental hexad flange screws of front wheel and axle.
tight them as per required torque.
Cushion System
Brake oil pump
Attention!
When exhaust, you must guarantee that there is
enough brake fluids in brake pump oil cup.
Adjustment bolt of brake
Attention! Please make sure that length of rear wheel
brake line is out about
3
-
5mm
.
Attention! Please make sure that tire is cold before checking.
Metal hexad flange screws
Front/rear axe screws
Brake Handle
Ad
j
ustment bolt

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Leakage or Damage of Vibration Damper
Steps on with foot to the vehicle forehead, compress several times, inspect
its movement, and whether or not any oil leak, damage, loose or unusual sound;
Steps on with foot to the vehicle back position, compress several times, inspect its
its movement, and whether or not any oil leak, damage, loose or unusual sound
Transmission System
Transmission case leakage and capacity
Stop the engine and take down oil position screw. If oil level reach at standard position it is OK;
otherwise pour in oil.
OIL TYPE：85W-140 or 15W/35S
Put on oil position screw after checking airproof gasket
Replacement of lubricating oil
Take down oil position screw
Take down vent bolt and put oil out
Put on vent bolt with revolving
Pour oil according to standard value：
Attention! Make sure that ground is plainness.
Oil position screws Air proof
gasket
Attention! Make sure that no damage in airproof gasket