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.