Hammerhead UM250IIR 2005 User manual

OWNER' S MANUAL Page
1. FOREWORD ------------------------------------------------------------------------------------------ 1
2. A FEW WORDS ABOUT SAFETY ------------------------------------------------------------- 2
3. IMPORTANT SAFETY INFORMATION------------------------------------------------------- 3
4. SAFETY LABELS----------------------------------------------------------------------------------- 5
5. ARE YOU READY TO DRIVE?----------------------------------------------------------------- 6
6. IS YOUR VEHICLE READY TO DRIVE?----------------------------------------------------- 7
7. SAFE DRIVING PRECAUTIONS--------------------------------------------------------------- 8
8. P.D.I.---------------------------------------------------------------------------------------------------- 10
9. SPECIFICATIONS---------------------------------------------------------------------------------- 11
10. OPERATION---------------------------------------------------------------------------------------- 13
11. SERVICE INSTRUCTIONS--------------------------------------------------------------------- 17
12. REPAIR---------------------------------------------------------------------------------------------- 20
13. PERIODICAL CHECK AND SERVICES---------------------------------------------------- 23
14. WIRING DIAGRAM ------------------------------------------------------------------------------ 23
PARTS MANUAL Figure
1. CYLINDER COMP.--------------------------------------------------------------------------------- Fig. 1
2. CYLINDER COVER ASSY.(1)-------------------------------------------------------------------- Fig. 2
3. CYLINDER COVER ASSY.(2)-------------------------------------------------------------------- Fig. 3
4. CRANKCASE ASSY.------------------------------------------------------------------------------- Fig. 4
5. RIGHT SIDE COVER ASSY.--------------------------------------------------------------------- Fig. 5
6. CRANKSHAFT CON'ROD & PISTON ASSY.------------------------------------------------ Fig. 6
7. VALVE TRANNYASSY.(1)--------------------------------------------------------------------------Fig. 7
8. VALVE TRANNY ASSY.(2)------------------------------------------------------------------------ Fig. 8
9. LEFT SIDE COVER ASSY.----------------------------------------------------------------------- Fig. 9
10. WATER PUMP ASSY.---------------------------------------------------------------------------- Fig. 10
11. CARBURETOR COMP.--------------------------------------------------------------------------- Fig.11
12. OIL PUMP ASSY.---------------------------------------------------------------------------------- Fig.12
13. CLUTCH ASSY.------------------------------------------------------------------------------------ Fig. 13
14. ELECTRIC STARTER ASSY.------------------------------------------------------------------- Fig.14
15. REDUCTION BOX ASSY.----------------------------------------------------------------------- Fig.15
16. GEARBOX ASSY.--------------------------------------------------------------------------------- Fig.16
17. MAGNETO COMP.-------------------------------------------------------------------------------- Fig.17
18. FRAME GROUP----------------------------------------------------------------------------------- Fig.18
19. STEERING SHAFT ASSY.---------------------------------------------------------------------- Fig.19
20. FRONT SUSPENSION ARM ASSY----------------------------------------------------------- Fig.20
21. FULL SHIFTING ASSY.------------------------------------------------------------------------- Fig.21
22. REAR CARGO RACK/ SEAT/ BELT---------------------------------------------------------- Fig.22
23. AIR CLEANER/ RADIATOR/ BATTERY/ MUFFLER ASSY.---------------------------- Fig.23
24. GEAR BOX ASSY.-------------------------------------------------------------------------------- Fig.24
25. REAR SUSPENSION ASSY------------------------------------------------------------------- Fig.25
26. WIRE HARNESS/ELECTRICAL -------------------------------------------------------------- Fig.26
27. WARNING STICKERS -------------------------------------------------------------------------- Fig.27

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.

A FEW WORDS ABOUT SAFETY
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:
Safety Labels - On the kart.
Safety Messages - Preceeded by a safety alert symbol and one of two signal
words: WARNING, or CAUTION.
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.

IMPORTANT SAFETY INFORMATION
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.

IMPORTANT SAFETY INFORMATION
Drive within Your Limits
Pushing limits is another major cause of kart 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. So driving at
night is dangerous and can increase the possibility for an accident.
Never run 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.

Safety Labels
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.
ARE YOU READY TO DRIVE ?
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.

ARE YOU READY TO DRIVE?
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.
IS YOUR VEHICLE READY TO DRIVE?
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 can not 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.
Pre-Drive Inspection
Always carry out the Pre-Drive Inspection detailed on Page 16 before getting in your kart.

SAFE DRIVING PRECAUTIONS
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.
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.
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.
Control Speed v --
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.

SAFE DRIVING PRECAUTIONS
Use Kart on Unfamiliar or Rough Terrain
Before driving in a new area, always check 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.
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 such leaks.
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.

P.D.I. (Post Delivery Inspection and assembly)
a) Install RR. 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.
l) Fill fuel tank with Unleaded Gasoline, and turn on the ignition switch to start the engine.

Specifications
DIMENSIONS
Overall Length-------------------------------------------------------------------------- 87 in. (2210mm)
Overall Width--------------------------------------------------------------------------- 53.5 in. (1346mm)
Overall Height-------------------------------------------------------------------------- 56.6 in. (1438mm)
Wheelbase------------------------------------------------------------------------------ 66.1 in. (1680mm)
Front Track------------------------------------------------------------------------------ 45.7 in. (1160mm)
Rear Track------------------------------------------------------------------------------- 42.7 in. (1085mm)
Ground Clearance--------------------------------------------------------------------- 8.5 in. (215mm)
ENGINE
Type--------------------------------------------------------------------------------------- Water cooled. 4-Stroke
Engine capacity------------------------------------------------------------------------ 250cc
Bore / Stroke---------------------------------------------------------------------------- 72mm x 60mm
Displacement--------------------------------------------------------------------------- 244ml
Corrected compression ratio-------------------------------------------------------- 10:1
Carburetor------------------------------------------------------------------------------- VEKS4 & CV30
Output Power--------------------------------------------------------------------------- 10.5Kw/7000rpm
Maximum Torque---------------------------------------------------------------------- 17.6N.m/5500rpm
Starting----------------------------------------------------------------------------------- Electric
Ignition------------------------------------------------------------------------------------ C.D.I.
Lubrication------------------------------------------------------------------------------- Force & Splash
Transmission---------------------------------------------------------------------------- Automatic (C.V.T system)
Spark plug-------------------------------------------------------------------------------- DPRSEA-9(NGK)
Plug gap---------------------------------------------------------------------------------- 0.6-0.7mm
Fuel Type -------------------------------------------------------------------------------- RQ90 (unleaded)
Lubricate oil----------------------------------------------------------------------------- SAE 15W-40/SF
DRIVE COMPONENTS
Gear box oil ----------------------------------------------------------------------------- M0S2 & W-2DW-4D
CAPACITIES
Maximum load----------------------------------------------------------------------------Double Seats/4001bs
Fuel tank ----------------------------------------------------------------------------------2.25 Gal
Engine oil----------------------------------------------------------------------------------30 Oz
Starting-------------------------------------------------------------------------------------<5s
Climbing------------------------------------------------------------------------------------20 ° - 25 °
Battery--------------------------------------------------------------------------------------12V 10Ah
Head Light---------------------------------------------------------------------------------12V 35W/35W
Tail Light------------------------------------------------------------------------------------12V 21W/5W
Fuse-----------------------------------------------------------------------------------------10A

Specifications
Brake Track------------------------------------------------------------------------------- < 7 m@20miles/h
Top speed----------------------------------------------------- 75 km/h(or limited as customers require)
CHASSIS
Front, Rear brake--------------------------------------------------------- Hydraulic disc, left foot control
Front tire-------------------------------------------------------------------------------------------------- 20 x 7-8
Rear tire---------------------------------------------------------------------------------------------- 22 x 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 1.5kg/cm2 21.3psi
Rear--------------------------------------------------------------------------------200kPa 2.0kg/cm2 28.4psi
WEIGHT
Net Weight --------------------------------------------------------------------------------------------------280 kg
Gross Wight-------------------------------------------------------------------------------------------------326 kg

Operation
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.
a. Throttle
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.
:igure 1
Figure 1!

Operation
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 burn 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.

Operation
Component locations
Figure 2

Operation
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
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.
Figure 3
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 "D" position for the kart to move forward.
c. Each time you need to apply the brake to change the setting to
go backwards apply the brake and move the lever to the "R" for the
kart to go backwards,
Note: Your kart is set up with 3 settings (See Fig.4):
"D" Forward
"N" Neutral
"R" Reverse Figure 4

OPERATION
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.
POSITION FOR HEEL Figure 5
SERVICE INSTRUCTIONS
A, Air Cleaner
Service the air cleaner every 20 hours
NOTE: Service is required more often in dusty
conditions.
a. Remove cleaner cover 1.
b. Remove air cleaner element 2 (See Fig.6)
c. Fill the non-flammable cleaning agent into
a basin and dip the element in it.
d. Dry it after cleaning. Replace check for
cracks or holes. It needs to be replaced with
new filter. Figure 6