Kinroad 650GK -2 User manual

0
Owner’s manual
(EEC)
READTHISMANUALCAREFULLY
ITCONTAINSIMPORTANTSAFETYINFORMATION.
MINIMUM
RECOMMENDED
OPERATOR AGE
650、800、1100GK-2

1
650、800、1100GK -2 LimitedWarranty
The warranty policy applies to those cases where the new seller vehicle is unloaded
from its shipping container, set up and delivered by authorized dealer, and under normal
use and service is found to have defects in parts or workmanship under the following
terms and conditions. This warranty covers the engine and engine related components
for a period of 90 days.
This warranty does not apply to any part, which in opinion of seller was defective
because of improper maintenance, improper assembly, alterations, abuse, negligence or
accident.
Should warranty service be required on your 650GK-2 during the 90 days warranty
period, please contact your nearest authorized dealer for repairs.
Whatis not covered under thiswarranty
This warranty does not cover any seller vehicle that has been subjected to:
a. This warranty does not cover any seller vehicle in any way so to adversely affect its
safety or reliability.
b. Renting
c. Disassembly, adjusting, or repairing of the vehicle in any way so as to adversely
affect its safety or reliability.
d. Competition or racing
The warranty does not cover loss of use of the seller vehicle, loss of time,
inconvenience, or other consequential damage which includes, but is not limited to,
loss or damage to persons or property or any expense of returning any damaged
units to the seller distributor or itsauthorized dealer.
Seller has the right to make changes without notice.

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CONTENTS
Page
1. FOREWORD------------------------------------------------------------------------------------------------ 3
2. A FEW WORDSABOUTSAFETY--------------------------------------------------------------------- 4
3. IMPORTANTSAFETY INFORMATION------------------------------------------------------------ 5
4
.
SAFETY LABELS----------------------------------------------------------------------------------------- 7
5. AREYOUREADYTO DRIVE?-----------------------------------------------------------------------8
6. ISYOURVEHICLEREADYTO DRIVE?--------------------------------------------------------- 11
7. SAFEDRIVINGPRECAUTIONS ------------------------------------------------------------------- 12
8. SPECIFICATIONS ---------------------------------------------------------------------------------------14
9. OPERATIONS ---------------------------------------------------------------------------------------------15
10. SERVICEINSTRUCTIONS --------------------------------------------------------------------------- 20
11. REPAIR ---------------------------------------------------------------------------------------------------- 25
12. PERIODICAL CHECK AND SERVICE----------------------------------------------------------- 36
13. WIRING DIAGRAM ----------------------------------------------------------------------------------- 37

3
FOREWORD
Thank you for choosing this Go-kart. We hope you will have fun with it.
Before you start to operate the Go-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.
Be sure to follow the recommended maintenance schedule and service
your kart accordingly. Preventative maintenance is extremely important to
the longevity of your Go-Kart.
We believes in conservation and protection of earth’s natural resources.
To that end, we encourage every vehicle owner to recycle, trade in, or
properly dispose of, as appropriate, used motor oil, coolant, and other fluids,
batteries, and tires.
We hope you will have a pleasant experience with our products.

4
A FORWORDSABOUT SAFETY
In order to keep everyone safe, you must take responsibility for the safe operation
of your Go-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 Go-Kart.You must use your own good judgment.
You will find important safety information in a variety of forms,including:
Safety Labels -OntheGo-Kart.
Safety Messages – Preceded by a safety alert symbol and one of two signal
words:WARNING ,orCAUTION.
Thesesignal 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 Go- Kart Safety.
Instructions --- how to use this Go –Kart correctly and safely.
This entire manual is filled with important safety information----please read it
carefully.

5
IMPORTANT SAFETY INFORMATION
Your Go-Kart will provide you with many years of service and pleasure. Providing
you take responsibility for your own safety and understand the challenges you can meet
while driving.
There is a lot you can do to protect yourself when you drive. You’ll find many
helpful recommendations throughout this manual. The following are a few that we
consider most important.
FollowtheAgeRecommendation
It is strongly recommended that no one under the age of 16 be permitted to drive
this Go-Kart without adult supervision.
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 eyeprotection, sturdy boots, gloves, and other protective gear.
TakeTime to Learn & Practice
Even if you have driven other Go-Kart, take time to become familiar with how this
Go-Kart works and handles. Practice in a safe area until you build your skills and get
accustomed to this Go-Kart’s size and weight.
Because many accidents involve inexperienced or untrained drives, we urge all
drivers to take a training course approved by the Go-Kart Safety Institute. Check with
your dealer for more information on training courses.
BeAlertfor 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.
DrivewithinYourLimits
Pushing limits is another major cause of Go-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 driver safely.
Don’t Drink anddrive
Alcohol anddriving don’t mix. Even one drink can reduce yourability 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 anddrive either.
Never run your Go- Kart indoors.
The exhaust from the engine contains a tasteless, odorless and poisonous gas called
carbon monoxide.

6
IMPORTANT SAFETY INFORMATION
Keepaway from moving parts of the Go-Kart
The operator of the Go-Kart should never place their hands or other parts of their
body near any moving part of the Go-Kart. Failure to adhere to this warning will cause
physical harm to your body.
Skiddingor Sliding
The terrain surface can be a major factor affecting turns, Skidding 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
you speed low and drive carefully.

7
SAFETY LABELS
This section presents some of the most important information and recommendations
to help you drive your Go-Kart safely, please take a few moments to read these pages.
The labels are considered permanent parts of the Go-Kart. If a label comes off or
becomes hard to read, contact your dealer for warning labels replacements.

8
AREYOU READYTO DRIVE?
Before each drive, you need to make sure you and your Go-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 Go-Kart, and adjustments to make for
your comfort, convenience, orsafety.
Before you drive your Go-Kart for the first time, weurge you to:
■Read this owner’s manual and the labels on your Go-Kart carefully.
■Make sure youunderstandall the safety messages.
■Know how to operate all the controls.
■Never drive this Go-kart if under 16 years old.
Before each drive, be sure:
■You feel well andare in good physical and mental condition.
■You are wearing an approved motorcycle helmet (with chin strap tightened securely),
eyeprotection, and other protective clothing.
■You don’t have any alcohol ordrugs in yoursystem.
ProtectiveApparel
For your safety, we strongly recommend that you always wear an 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 when you drive.
The following suggestions will help you choose the proper driving gear.
Helmets and Eyes Protection
Your helmet is your most important piece of driving gear because it offers the best
protection against head injuries. A helmet shouldfit 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 DOT (Department of Transportation) sticker in any
helmet you buy.Always wear a face shield or goggles to protect your eyes and help your
vision.
Operating this Go-Kart without wearing an approved motorcycle helmet, eye protection,
and protective clothing could increase your chances of head and/or eye injury, possibly
death inthe eventof severe accident.
Always wear approved motorcycle helmet that fits properly and wear eye protection
(goggles or face shield), gloves, boots, long-sleeved shirtor jacket and long pants.

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AREYOU READYTO DRIVE?
Additional Driving Gear
In addition to a helmet and eyeprotection, we also recommend:
■Sturdy off-roadmotorcycle 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.
Drive Training
Developing your driving skills is an on-going process. Even if you have driven other
Go-Karts, take time to become familiar with how this Go-Kart works and handles.
Practice driving the Go-Kart in a safe area to build your skills. Do not drive in rough
terrain until you get accustomed to the Go-Kart’s controls, and feel comfortable with its
size and weight.
Age Recommendation
It is strongly recommended that no one under the age of 16 be permitted this Go-Kart
without adult supervision.
Operating Go-Kart without proper instruction could increase your risk of an accident
which could leadto serious injury or death.
Attempt supporting with your hands to the ground when the Go-cart turning over could lead
toseriousinjuryor death.
Never support with your hands to ground whenthe Go-catwill turn over.
A child driving a Go-Kart that is not recommended for his/her age could lose Go-Kart
control and result in severe injury or death.
A childunder16 should have adult supervision when operate on the Go-Kart.

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AREYOU READYTO DRIVE?
No Alcohol or Drugs
Alcohol, drugs and Go-Karts don’t mix. Even a small amount of alcohol can impair
your ability to operate a Go-Kart safely. Likewise, drugs, even if prescribed by a
physician, can be dangerous while operating a Go-Kart. Consult your doctorto be sure it
is safe to operate a vehicle after taking medication.
IS YOUR VEHICLE READY TO DRIVE?
Before each drive, it is important to inspect your Go-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, oreven a flat tire,can be a major inconvenience.
If your Go-Kart has overturned or has been involved in a collision, do not drive it
until your Go-Kart has been inspected by your dealer, There may be damages or other
problems you can not see.
Pre-drive Inspection
Check the following items before you get on the Go-Kart:
■Engine Oil
Check the level and add oil if needed. Check for leaks.
■Coolant
Check the coolant and add coolant if need. Check for the leaks.
■Fuel
Check the level and add fuel if needed. Also make sure the fuel fill cap is securely
fastened. Check for leaks.
■Tires
Use a gauge to check the air pressure. Adjust if needed. Also look for signs of
damages or excessive wear.
Operating this Go-Kart after consuming alcohol or drugs can seriously affect your
judgment, cause you to react more slowly, affect your balance and perception, and could
result in seriousinjury or death.
Never consume alcohol or drugs before or whileoperating this Go-Kart.
Improperly maintaining this Go-Kart or failing to correct a problem before driving can
cause a crash in which you can be seriouslyhurtor dilled.
Always perform a pre-drive inspection before every drive andcorrect any problems.

11
ISYOUR VEHICLE READY TO DRIVE?
■
■Nuts & Bolts
Check the wheels to see that the axle nuts are tightened, Use a wrench to make sure
all accessible nuts, bolts, and fasteners are tight.
■Pre-drive Inspection
■Underbody & Exhaust System
Check for, and remove any dirt, vegetation or other debris that could be fire hazard
or interfere with the proper operation of the Go-Kart.
■Air Cleaner
Check the air filter. Replace it if needed.
■Leaks, Loose Parts
Walk around you Go-Kartand look for anything that appears unusual,such as a leak
or loose cable.
■Lights
Make sure the headlight, brake light and tail light are workingproperly.
■Throttle
Check the free play and adjust if needed. Press the throttle to make sure it moves
smoothly without sticking, and snaps back automatically whenit is released.
Clutch cable
Check the free play of clutch cable and adjust if needed. Press the clutch cable to
make sure it moves smoothly without sticking, and snaps back automatically whenit
is released.
■Brakes
Press the brake pedal several times, check for proper brake pedal free play. Make
sure there is no brake fluid leakage.
■Engine Stop
When engine is running, turn the switch key counterclockwise. Make sure engine
stops.
■Steering Wheel
Check that the wheels turn properly as you turn the steering wheel.
■Cable
Check the cable housingfor wear. Check the fittings are tight. Replace or tighten as
needed.
■Tie rod
Check the tie rod housing for wear. Check the fittings are tight. Replace or tighten
as needed.

12
SAFEDRIVINGPRECAUTIONS
KeepHandsandFeet onControls
Always keep bothhands on the steering wheel and bothfeet on the footcontrols. When
driving your Go-Kart. Itis important to maintain your balance and controlof the Go-Kart.
Removing hands or feet away from the controls can reduce your ability to react and
control the kart.
ControlSpeed
Driving at excessive speed increases the chance of an accident. In choosing a proper
speed, you need to consider the capability of your Go-Kart, the terrain, visibility and
other operating conditions, plus your own skills and experience.
Use Careon 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 Go-Kart
and other on-road vehicles. Always exercise caution and use extra care on rough,
slippery and loose terrain.
Removing handfrom Steering wheelor feet fromfoot controls during operation canreduce
your ability to control the Go-Kart or could cause you to lose your balance and fall off the
Go-Kart.
Always keep both handon the steeringwheel andboth feet on the foot controls of your Go-
Kartduring operation.
Operating this Go-Kart at excessive speeds increasesyour changes of losing control of the
Go-Kart, which can result in an accident.
Always drive at a speed that is proper for your Go-Kart, the terrain,visibility and other
operating conditions, and yourexperience.
Failure to use extra care when Operating this Go-Kart on unfamiliarterrain couldresult in
the Go-Kart overturning or going out of control.
Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changingterrain conditionswhenoperating the Go-Kart.

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SAFEDRIVING PRECAUTIONS
Do NotPerform Stunts
You should always operate your Go-Kart in a safe and reasonable manner. When
driving, always keep all four wheels onthe ground.
Failure to use extra care when operating on excessively rough, slippery or loose terrain
could cause loss of traction or vehicle control, which could result in an accident, including
an overturn.
Do not operateon excessivelyrough,slippery or loose terrainuntil you have learned and
practiced the skills necessary to control the Go-Kart on such terrain. Alwaysbe especially
cautiouson these kinds of terrain.
Attempting wheelies, and other stunts increases the chance of an accident, including an
overturn.
Never attempt stunts,suchas wheeliesorjumps. Don’t try toshow off.

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SPECIFICATIONS
DIMENSIONS
OverallLength--------------------------------------------------------------------------------------------------2800mm
OverallWidth ------------------------------------------------------------------------------------------------- 1900mm
OverallHeight-------------------------------------------------------------------------------------------------1720mm
Wheelbase ------------------------------------------------------------------------------------------------------ 2050mm
Front Track ---------------------------------------------------------------------------------------------------- 1400mm
RearTrack ------------------------------------------------------------------------------------------------------1450mm
Ground Clearance---------------------------------------------------------------------------------------------310mm
SPECIFICATIONS
Brake Track ----------------------------------------------------------------------------------------- < 7m @ 20miles/h
Top speed ------------------------------------------------------------ 50 miles/h(or limited as customersrequire)
CHASSIS
Front, Rearbrake --------------------------------------------------------------- Hydraulicdisc, rightfoot control
Front tire--------------------------------------------------------------------------------------------------------- 25×8-12
Reartire ----------------------------------------------------------------------------------------------------------- 25×10-12
Front Suspension --------------------------------------------------------------------------- Independent DualA-Arm
RearSuspension --------------------------------------------------------------------------- Independent DualA-Arm
FinalDrive --------------------------------------------------------------------------------------------------- shaft driven
TIRE PRESSURE
Front ----------------------------------------------------------------------------------------- 70kpa 0.7kg/c ㎡10psi
Rear------------------------------------------------------------------------------------------ 70kpa 0.7kg/c ㎡10psi

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OPERATION
A. Operation controls
WARNING Do not attempt to start or operate the engine until completely
familiar with the location and use of each control necessary to operate this vehicle. The
operator must knowhow to stop this machine before starting anddriving it.
a. Throttle
The right foot pedal is the throttle that controls the Go-Kart speed. To disengage the
clutch at any time, allow the throttle to return to the idle position. (See Fig.2)
b. Brake
The brake is located onthe middle of the three control pedals (SeeFig. 2). Applying
pressure to the pedal applies pressure to the brake caliper around the brake disc at the
front and rear wheels and slows orstops the kart.
c. Clutch
The left foot pedal controls the clutch cable (See Fig.2). With the pedal down,
you can shift the shift lever.
Figure 1
Each time prior to starting the engine, check the throttle assembly to ensure that when
pedal is pushed all the way forward the assembly is working smoothly and returns to idle
when released. Do not operate if pedal or engine throttle linkage fail to return to idle. If
unable to correct the problem th rough lu brication, adjustment or replacement of worn parts,
contact your dealerfor assistance.
Improper operation of the clutch willlead to excessive wear of the clutch friction surface.
L-LIGHT BUTTON LIGHT BUTTON
S
I
G
NAL B
U
TT
O
N
SPEED0METER FUEL METER SIGNAL METER IGNITION BUTTON
EME
RG
ENT B
U
TT
O
N
EME
RG
ENT
S
T
O
PB
U
TT
O
N
CAUTION BUTTON
H-LIGHT
BUTTON
SIGNAL BUTTON HORN BUTTON
V
-
OUTPUT
JAK

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CLUTCH PEDAL BRAKE PEDAL THROTTLE PEDAL
OPERATION
d. Start engine
1. Engage the park brake
2. Press the clutchpedal down,
put the shift lever in neutral
3. Insert the key into the
ignition-switch
If the engine is cold;
1. Pull the choke outfully
2. Press down the clutchpedal Figure 2
3. Turnthe key clockwise to the “on” position. Release the key and the clutch pedal
whenthe engine starts.
4. Push the choke back slowly to allow the engine to run smoothly. Keep engine
running for1-2 minutes.
5. Push the choke back fully.If the idle of engine is not smooth, pull out the choke
to find the best running position and keep running for a while long until the engine ryns
smooth without choke.
If theengine is warm;
Press the throttle slightly and turn the key clockwise to the “on” position, release
the key and the throttle whenthe engine starts.
Each time prior to starting the engine, check the throttle assembly to ensure that when
pedal is pushed all the way forward the assembly is working smoothly and returns to idle
when released. Do not operate if pedal or engine throttle linkage fail to return to idle. If
unable to correct the problem th rough lu brication, adjustment or replacement of worn parts,
contact your dealerfor assistance.
Before you start the engine, check that the parking brake is engaged, and the gear shift
lever is in neutral.Trying tostart the enginein gear may damage the starter motor, clutchor
gearbox.
Release the key at once if the engine starts. Holding the key in start position when the
engine isrunningwillcause damage tothe starter motor.
If the engine does not start after 10 seconds, a second attempt to start the engine can be
allowed. Improper operation will damage the engine.

17
OPERATION
e. Enginestop key
Important-stop key test.
Before driving this vehicle, test the Engine Stop key to assure that it is operating
properly. With the engine running, turnthe key counterclockwise to the “off” positionfor
the engine to shut down.
B. Pre-DriveInspection
1. Check for Engine Oil Level. Check for transmission Oil Level. Check for leaks, add
oil if required.
2. Check the coolant. Check for leaks, add the coolant if required.
3. Check for Fuel Level. Add fuel as necessary and do not overfill. Check for leaks.
4. Check for Brakes. Depress the brake pedal several times, and then check for proper
brake pedal free play. Make sure there is no brake fluid leakage. Adjust if necessary.
5. Check the clutch cable, Assure the cable snaps back and has a smooth operation.
Ensure the clutch can operate smoothly. Adjust if necessary, or replace the clutch if
necessary.
6. Check Tires. Check tires condition and pressure. The pressure on both Front and Rear
tire is 12psi.
7.Check Throttle. Check for smooth operation.Ensure the throttle “snaps” back to idle.
8. Check Engine Stop key. Perform engine stop key test. Repairas necessary.
9. Check all Nuts, Bolts,and fasteners. Check wheels to see that all axle nuts and lug nuts
are tightened properly. Check and tighten as necessary all other fasteners to specified
torque.
10. Check Roll Cage Bars. Ensure all protective roll cage bars are in place before
operating the Go-Kart.
12. Check Brake Light. Check for proper operation.
13. Check Wheels. Check for tightness of wheel nuts and axle nuts; check that axle nuts
are secured by cotter pins.
14. Check Steering. Check for free operation andfor any unusual looseness in any area.
Perform this pre-drive inspection everyday before driving vehicle. If not performed,
serious damage to the vehicle or personal injury may result.
Alwaysfollow rulesfor safeoperation and wear a helmet.

18
OPERATION
C. Passengers
The vehicle allows for two riders only.
Combined maximum weight of driver
and the passenger should notexceed 180kg
or400Ibs.
D. SeatAdjustment
The seat must always be securely
fastened in theposition which best
allows theoperator control of thefoot
pedals,steeringwheel,andtheremote Figure4
stop key.
a. Pull seat adjustment handle upward to disengage seat slide.
b. Moveseat to desired position.
c.Be sure seat adjustment handle snaps back into place and that seat is locked into
position.(See Fig. 4 )
E. ParkingAdjustment
Park brake “OFF” Park brake “On”
Figure 6
a. Pull the park brake lever up so that the unit can engage park brake.
b
. To release the unit, press buttonon front end of parking lever then push the parking
lever to the bottom.
c. Adjustthe parking cable if necessary.
Before attemptingto adjustthe seat ensure that engine of the Go-Kart is stopped.
Never operate this Go-Kart whenthe providedseat is not securely fastened, to do so could
result in a strong possibility of severe personal injury or loss of life. Before attempting to
adjustthe seat ensure that engineof Go-Kart is stopped.

19
OPERATION
F.Gear ShiftAdjustment
1. Loosen the bolts.
2. Press down the clutchpedal fully.
3. Operate the shift lever as to
change gearshift from 1 to 4 and
reverse smoothly.
4. First,tighten bolt 1 with
thread glue. Then second,tighten
bolt 2 with thread glue.
(See Fig. 7)
Figure 7
G. Break-in
The first monthis most important in the life of your vehicle. Proper operation during this
break-in period will help assure maximum life and performance from your new vehicle.
The following guidelines explain proper break-in procedures.
1.After the engine starts, the engine is notallowed in high speed in the neutral gearshift.
2. Drive vehicle from stop to low speed slowly.
3.Avoid braking strongly.
4. Do not exceed the vehicle speed on the below schedule
H. Starting And Operating Instructions
a. Before starting the engine, be sure that the driver is seated properly in the Go-Kart
and tighten the seatbelt.
b
. Testing the Go-Kart in a open place at the beginning to learn how to start, turn and
stop.
c. Operate the Go-Kart slowly until you are familiar with it.
d. The turning radius of this Go-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 Go-Kart from rolling over.
e. To prevent vehicle from rolling over,be sure to only turn the vehicle at a slow more
controllable speed.
The spee
d
o
f
vehicle The firs
t
1000 k
m
Max speed in each gear
1s
t
Gea
r
15 km/h
2n
d
Gea
r
25km/h
3r
d
Gea
r
40 km/h
4th Gea
r
70km/h