Hammerhead SUPER 250 2008 User manual

MINIMUM
RECOMMENDED
Operator age:
READ THIS MANUAL CARERFULLY,
IT CONTAINS IMPORTANT SAFETY INFORMATION.

Thank you for purchasing our kart. We hope you will enjoy it. Before
you start to operate the kart, please read through this Owner's Manual
carefully as it contains important safety and maintenance information. Failure
to follow the warnings contained in this manual can result in serious injuries
or death.
Be sure to follow the recommended maintenance schedule and service
your kart accordingly. Preventive maintenance is extremely important to the
longevity of your kart.
Beginners should seek instruction from their dealer or qualified
instructors before and during initial use of the kart. It is also recommended to
practice in a large flat open area to familiarize yourself with operations of this
kart.
We hope you will have a pleasant experience with our products and
thank you again for choosing our kart.

In order to keep everyone safe, you must take responsibility for the safe operation
of your kart.
To help you make informed decisions about safety, we have provided operating
procedures and other information on labels and in this manual. This information alerts
you to potential hazards that could hurt you or others.
It is not practical or possible to warn you about all hazards associated with
operating or maintaining a kart. You must use your own good judgment.
You will find important safety information in a variety of forms, Including:
These signal words mean:
!
Physical harm may result from failure to adhere to the instructions that are
described within the WARNING labels.!
!
Safety Headings - such as Important Safety Reminders or Important Safety Precautions.!
Safety Section - such as kart safety.!
Instructions - how to use this kart correctly and safely.
This entire manual is filled with important safety information - please read it all carefully.
!

Your kart will provide you with many years of use and pleasure. Providing you take
responsibility for your own safety and that of any one else using your kart or near to the
kart when it is being used and understand the challenges you can meet while driving.
There is much that you can do to protect yourself while operating your kart. You
will find many helpful recommendations throughout this manual. The following are a few
that we consider to be the most important.
Follow the Age Recommendation
The kart should not be driven by anyone under the age of 16.
Always Wear a Helmet
It's a proven fact: helmets significantly reduce the number and severity of head
injuries. Always wear an approved motorcycle helmet. We also recommend that you wear
eye protection, sturdy boots, gloves, and other protective gear.
Drive Off-Road Only
Your kart is designed and manufactured for off-road use only. The tires are not
made for use on pavements. and the kart does not have turn signals and other features
required for use on public roads. If you need to cross a paved or public road, get off and
walk your kart across.
Take Time to Learn & Practice
Even if you have driven other karts, take time to become familiar with how this kart
works and handles. Practice in a safe area until you build your skills and get accustomed
to this kart's size and weight.
Because many accidents involve inexperienced or untrained drivers, we urge all drivers to
take a training course, Check with your dealer for more information on training courses.
Be Alert for Off-Road Hazards
The terrain can present a variety of challenges when you drive off-road.
Continually "read' the terrain for unexpected turns, drop-offs, rocks, ruts, and other
hazards. Always keep your speed low enough to allow time to see and react to hazards.

!
Drive within Your Limits
Pushing limits is another major cause of hart accidents. Never drive beyond your
personal abilities or faster than conditions warrant. Remember that alcohol, drugs, fatigue,
and inattention can significantly reduce your ability to make good judgments and drive
safely.
Don't Drink and drive
Alcohol and driving don't mix. Even one drink can reduce your ability to respond to
changing conditions, and your reaction time gets worse with every additional drink. So
don't drink and drive, and don't let your friends drink and drive either.
Do not operate this Kart at night.
Operating in the dark vision can greatly reduce a driver's visibility and judgment.
Driving at night is dangerous and can increase the possibility for an accident.
Never ran your Kart indoors.
The exhaust from the engine contains a tasteless, odorless and poisonous gas
called carbon monoxide.
Keep away from moving parts of the Kart
The operator of the kart should never place their hands or other parts of their body
near any moving part of the Kart. Failure to adhere to this warning will cause physical harm
to your body.
Skidding or Sliding
The terrain surface can be a major factor affecting turns. Skidding in a turn is more
likely to occur on slippery surfaces such as snow, ice, mud and loose gravel. If you skid on
ice, you may lose all directional control. To avoid skidding on slippery terrain, keep your
speed low and drive carefully.!
!

!
This section presents some of the most important information and
recommendations to help you drive your kart safely. Please take a few moments to
read these pages.
The labels should be considered permanent parts of the kart. If a label comes off
or becomes hard to read, contact your dealer for a replacement.

!
Before each drive, you need to make sure that you and your kart are both ready to
drive. To help get you prepared, this section discusses how to evaluate your driving
readiness, what items you should check on your kart, and adjustments to make for your
comfort, convenience, or safety.
Before you drive your kart for the first time, we urge you to:
▪Read this owner's manual and the labels on your kart carefully.
▪Make sure you understand all the safety messages.
▪Know how to operate all the controls.
Before each drive, be sure:
▪You wear your seat belt at all times while driving your kart
▪You feel well and are in good physical and mental condition.
▪You are wearing an approved motorcycle helmet(with chin strap tightened securely),
eye protection, and other protective clothing.
▪You don't have any alcohol or drugs in your system.
Protective Clothing
For your safety, we strongly recommend that you always wear an D.O.T. approved
motorcycle helmet, eye protection, boots, gloves, long pants, and long-sleeved shirt or
jacket whenever you drive.
Although complete protection is not possible, wearing proper gear can reduce the
chance of injury should you have an accident. The following suggestions will help you
choose the proper protective gear.
Helmets and Eyes Protection
Your helmet is your most important piece of protective gear because it offers the
best protection against head injuries. A helmet should fit your head comfortably and
securely.
An open-face helmet offers some protection, but a full-face helmet offers more.
Regardless of the style, look for a D.O.T. (Department of Transportation)sticker on any
helmet you buy. Always wear a face shield or goggles to protect your eyes and help your
vision.

Pre-Drive Inspection
Always carry out the Pre-Drive Inspection detailed on Page 16 before getting in your kart.
Before each drive, it is important to inspect your kart and make sure any problems you find
are corrected. A pre-drive inspection is a must. not only for safety, but because having a
breakdown, or even a flat tire, can be a major inconvenience.
If your kart has overturned or has been involved in a collision, do not drive it until your kart
has been inspected by your dealer. There may be damage or other problems that you cannot see .
No Alcohol or Drugs
Alcohol, drugs and karts don't mix. Even a small amount of alcohol can impair your ability to
operate a kart safely. Likewise, drugs-even if prescribed by a physician-can be dangerous while
operating a kart. Consult your doctor to be sure it is safe to operate a vehicle after taking
medication.
Additional Driving Gear
In addition to a helmet and eye protection, we also recommend:
▪Sturdy off—road motorcycle boots to help protect your feet, ankles, and lower legs.
▪Off-road motorcycle gloves to help protect your hands.
▪Driving pants with knee and hip pads. a driving jersey with padded elbows, and a chest /
shoulder protector.
Driver Training
Developing your driving skill is an on-going process. Even if you have driven other karts,
before take time to become familiar with how this kart works and handles. Practice driving the kart
in a safe area to develop your skills, Do not drive on rough terrain until you get accustomed to the
kart's controls, and feel comfortable with its size and weight.

Off-Road Use Only
Your kart and its tires are designed and manufactured for off-road use only, not for
use on paved surfaces. Driving on paved surfaces can affect the kart handling and control.
You should not drive your kart on paved surfaces.
When driving off-road, also remember to always obey local off-road driving laws and
regulations. Obtain permission to drive on private property. Avoid posted areas and obey “no
trespassing” signs.
You should never drive your kart on public streets, roads or highways, even if they are
not paved. Drivers of street vehicles may have difficulty seeing and avoiding you, which
could lead to a collision. In many states it is illegal to operate karts on public streets, roads
and highways.
Keep Hands and Feet on Controls
When driving your kart. always keep both hands on the steering wheel and both feet on
the foot controls. It is important to maintain your balance and to control the kart. Removing
hands or feet away from the controls can reduce your ability to react and control the kart.
Control Speed
Driving at excessive speed increases the chances of an accident. In choosing an
appropriate speed. you need to consider the capability of your kart. the terrain, visibility and
other operating conditions, plus your own skill and experience.

Use Kart on Unfamiliar or Rough Terrain
Before driving in a new area, always cheek the terrain thoroughly. Don't drive fast
on unfamiliar terrain or when visibility is limited (it's sometimes difficult to see obstructions
like hidden rocks, bumps, or holes in time to react).
Never drive past the limit of visibility. Maintain a safe distance between your kart and other
off-road vehicles. Always exercise caution and use extra care on rough, slippery and loose
terrain .
DO Not Perform Stunts
You should always operate your kart in a safe and reasonable manner. When
driving, always keep all four wheels on the ground.
Radiator Indicator Lamp
During the driving, you should always keep close contact with this red indicator
lamp. This indicator lamp will tell you when your engine coolant system is getting too hot.
To keep from causing any damage, you should stop the kart and turn the key off. Check if
there is any leak. At this time do not open the radiator cap, allow your coolant system and
engine to cool down before opening the radiator cap.
If you find the coolant completely gone, you should check if the radiator hoses or
engine has leaks .

!
a. Install RR.(rear) Shocks and tighten the nuts.
b. Install Ball Head, Tie Rod, tighten the Castle Nut and insert the cotter Pin,
c. Install Dust Seals, align the Ball Head Bolt, Knuckle Support to the square hole on
the Lower A-Arm.
d. Install Flange Nut and tighten it (>88.9 foot lbs).
e. Install Front Tires and tighten the nuts.
f. Install Rear Tires, tighten the nuts, insert cotter Pin and put on the Rubber Cover.
g. Raise the C.B.C. bar as the picture shows.
h. Install C.B.C. bar RR., put on R-Washer.
i. Install Head-Rest.
j. Check all nuts and bolts, wiring, cables, fuel line, switches, and tire pressure.
k. Fill battery with Acid and charge, check and fill the engine with the recommended
oil. Replace and dispose the original packing/shipping oil that came in the engine
in an appropriate container.
l. Fill fuel tank with Unleaded Gasoline, and turn on the ignition switch to start the
engine.

DIMENSIONS
Overall Length …………………………………………………………………………
Overall Width …………………………………………………………………………
Overall Height…………………………………………………………………………
Wheelbase …………………………………………………………………………….
Front Track ……………………………………………………………………………
Rear Track ……………………………………………………………………………
Ground Clearance ……………………………………………………………………
ENGINE
Type …………………………………………………………………………………..
Engine Capacity ………………………………………………………………………
Bore/Stroke……………………………………………………………………………
Displacement …………………………………………………………………………
Corrected compression ratio ………………………………………………………….
Carburetor ……………………………………………………………………………
Output Power …………………………………………………………………………
Maximum Torque ……………………………………………………………………
Starting ………………………………………………………………………………
Ignition ………………………………………………………………………………
Lubrication …………………………………………………………………………
Transmission …………………………………………………………………………
Spark plug ……………………………………………………………………………
Plug glug ……………………………………………………………………………
Fuel Type……………………………………………………………………………
Lubricate oil …………………………………………………………………………
DRIVE COMPONENTS
Gear box oil ……………………………………………………………………………
CAPACITIES
Maximum load …………………………………………………………………………
Fuel tank ………………………………………………………………………………
Engine oil ……………………………………………………………………………
Starting ………………………………………………………………………………
Climbing ………………………………………………………………………………
Battery …………………………………………………………………………………
Head Light ……………………………………………………………………………
Tail Light ………………………………………………………………………………
Fuse ……………………………………………………………………………………
Water cooled.4-Stroke
250cc
72mm * 60mm
244cc
10:1
VEKS4 & CV30
10.5Kw/6000rpm
17.6N,m/5500rpm
Electric
C.D.I.
Force & Splash
Automatic (C.V.T system)
DPR8EA-9 (NGK)
0.6-0,7mm
RQ90 (Unleaded)
SAE 15W-40/SF
75W90 gear oil
Double Seats / 4001bs
2.25 Gallons
30 Oz / 9/10 quart
<5s
20-25°
12V 10 Ah
12V 35W/35W
12V 21W/5W
10A
87in. (2210mm)
53.5in. (l346mm)
56.6in. (1438mm)
66.1in. (1680mm)
45.7in, (l160mm)
42,7in. (l085mm)
8.5in. (215mm)

Brake Track …………………………………………… <7m @ 20 miles / h
Top speed ……………………………………….. 75km/h (or limited as customers require)
CHASSIS
Front, Rear brake …………………………………….. Hydraulic disc. Left foot control
Front tire ……………………………………………….. 20*7-8
Rear tire ………………………………………………... 22* 10-10
Front Suspension ……………………………………… Independent Dual A-Arm
Rear Suspension …………… Full Independent Rear Suspension/Oil Damped Shocks
Restraint System ……………………………………… Dual 4-point Harness
Final Drive ……………………………………………… CV-Shafts
TIRE PRESSURE
Front ……………………………………………………. 150kPa l.5kg/cm2 21.3psi
Rear …………………………………………………….. 200kPa 2.0kg/cm2 28.4psi
WEIGHT
Net Weight ……………………………………………… 280kg
Gross Weight ………………………………………….. 326kg

A. Operation controls
WARNING- Do not attempt to start or operate the engine until complete familiar with the
location and use of each control necessary to operate this vehicle. The operator must
know how to stop this machine before starting and driving it
!" #$%&''()*
!The right foot pedal is the throttle that controls the kart speed. As the engine speed
increases above idle, the clutch automatically engages and moves the vehicle forward.
(See Fig. 1)
b) Brake
The brake is the left foot pedal (See Fig. 1). Applying pressure to the pedal slows or stops
the kart
c) Start engine
Insert the key into key-switch, turn the key
clockwise, release the key when the engine
starts. The engine will warm up within 5
minutes and the choke will close
automatically allowing operation at normal
RPM. (Warning: Don't crank the starter for
more than 5 seconds at one time).
d) Engine stop button!
Important stop button test: !
Before driving this vehicle, test the Engine Stop Button to ensure that it is operating
properly. With the engine running, push and hold the Engine Stop Button for two
seconds for the engine to shut down.

B. Pre-Drive Inspection
"
a) Check the engine oil level is between the bottom of the dipstick and the "0” mark. Check
for leaks. Add oil if required.
b) Check the Fuel Level. Add fuel as necessary and do not overfill. Check for leaks. Ensure
the fuel filler cap is securely fastened.
c) Check the Brakes. Depress the left brake pedal several times, and check for adequate
brake pedal freeplay. Make sure there is no brake fluid leakage.
d) Check the tires. Check their condition for damage or excessive wear and pressure.
e) Check the Throttle Cable. Check for smooth operation. Ensure the throttle snaps back to
idle when released and moves smoothly without sticking.
f) Check the Engine Stop Button. While the engine is running press and hold the engine
stop button for 2 seconds. Make sure the engine stops.
g) Check all Nuts. Bolts. and Fasteners. Check the wheels to see that all axle nuts and lug
nuts are tightened properly. Check and tighten as necessary all other nuts. bolts and
fasteners.
h) Check the C.B.C. Bar. Ensure all C.B.C. bars are in place before operating the kart.
i) Check the Lights. Check the headlights, brake light and tail light are all working.
j) Check the Steering. Check that the steering wheel moves freely in both directions but
without any unusual looseness.
k) Check all Cable Housings. Check these for wear and the fitting for any looseness.
l) Check the underbody and exhaust system. Remove all dirt, vegetation and mud and
check for any damage due to impact with rocks or uneven terrain.
m) Check the Air Cleaner Housing Drain Tube. Check the deposits in the drain tube. If
necessary, check the tube and air cleaner housing.
n) Check Leaks and Loose Parts. Walk around your kart and look for anything that appears
unusual, such as a leak or loose cable.
o) Check the Parking Brake. Make sure the kart does not move forward or backward when
the parking brake is applied.
p) Check the Radiator. Make sure there is no leak of radiator or hoses before you start the
engine. Check the water level.
q) Check the radiator to see if the level of the coolant is full. Refill the coolant as needed or
your engine would bum up and cost you in repairs. Never open the radiator cap when
engine is running. Allow the engine to cool down, and then refill the coolant.

Component Locations

!
C. Passengers
The vehicle is designed for two people only. The
combined maximum weight of the driver and the
passenger should not exceed 200kg or 440lbs.
D. Seat Adjustment
1) The seat should be securely fastened in the
position which gives the operator best control of
the foot pedals. steering wheel, and the remote
stop button.
a. Pull the seat adjustment handle upward to
disengage the seat slide.
b. Move the seat to the desired position
c. Be sure that the seat adjustment handle snaps
back into place and that seat is locked into
position.
E. Forward and Reverse Gear
a. Push the brake pedal down. The brake pedal
must be pushed in to change the gear settings.
b. Push the lever forward to the "H" or “L” position
for the kart to move forward.
c. You must apply the brake every time to change
the setting from one gear to another. To go
backwards, apply the brake and move the lever to
the “R”.
Note! Your kart is set up with 4 settings (See Fig.4):
H = Forward / High Gear; L = Forward / Low Gear
N = Neutral
R = Reverse

F. Starting and Operating Instructions
a. Before starting the engine, the driver must be seated properly in the kart with the seat
belt on.
b. Practice in the kart in an open space at the beginning to learn how to start, turn and
stop the vehicle,
c. Drive slowly until you are familiar with the operation of the kart.
d. The turning radius of this kart is small and
agile, so the centrifugal force is very high
when turning at high speed. Slow down to a
more controllable speed when turning to
prevent the kart from rolling over. The driver
should keep their heels on the ramp of the
main board when turning.
(See Fig.5) Keeping their leg on the foot
pedal, the driver can feel that the kart is
stable and won't roll over.
A. Air Cleaner
Service the air cleaner every 20 hours!
NOTE: Service is required more often in dusty
conditions.
a. Remove cleaner cover. (See Fig. 6, part #1)
b. Remove air cleaner element. (See Fig. 6, part #2)
c. Fill the non-flammable cleaning agent into a basin and
dip the element in it.
d. Dry it after cleaning, checking for cracks or holes. If
any are found, it will need to be replaced with new
filter.