Masters of motion Fun Kart Owner's/ Owner's manual

FUN KART
Owner's/Operator's Manual
Clutch and Torque Converter Models
WARNING: Read Engine Owner's Manual, Vehicle Operator's Manual and any Supplements
Carefully and View "Operations and Safety" Video Before Operating Vehicle.
- Assembly
• Operation
• Maintenance
• Warranty
THIS VEHICLE IS FOR OFF-ROAD USE ONLY.
THIS VEHICLE IS NOT DESIGNED FOR USE ON RENTAL TRACKS OR RACING.
BEFORE OPERATING THIS VEHICLE, THE OWNER AND EACH OPERATOR MUST UNDER.
STAND THIS VEHICLE WAS NOT DESIGNED OR MANUFACTURED TO MEET SPECIFICATIONS
FOR USE ON PUBLIC ROADS, STREETS, HIGHWAYS, AND THOROUGHFARES+THE OWNER
AND EACH OPERATOR MUST READ AND UNDERS'fAND ALLTHE INSTRUCTIONS FOR PROP-
ER ASSEMBLY AND SAFE OPERATION, AS WELL AS THE INSTRUCTIONS CONCERNING THE
ENGINE AND ALL OTHER PORTIONS OF THE VEHICLE. CHILDREN MUST BE OF AGE 8 OR
OLDER AND SUPERVISED BY AN ADULT AT ALL TIMES WHEN USING THE FUN-KAR I.
Part Number 12834 1/1/03

TABLE OF CONTENTS
SAFETY ............................................................................... 3
Important Rules for Safe Operation ..................................................... 3
Terminology ....................................................................... 7
Qualifications for Fun-Kart Users ....................................................... 7
Consumer Responsibility for Safe Use and Maintenance of Fun-Karts ........................... 8
MANGO POWERSPORTS, LIMITED WARRANTY ........................................ 10
COMBINATION LAP AND SHOULDER BELT RESTRAINT SYSTEM ............................ 11
SAFETY FLAG ....................................................................... 14
PRE-RIDE INSPECTION ............................................................... 15
Engine Stopped Inspections.......................................................... 16
Engine Started Inspections .......................................................... 17
OPERATION ........................................................................ 18
Operating Controls ................................................................. 18
Throttle ...................................................................... 18
Brake ........................................................................ 18
Steering ..................................................................... 18
Engine Stop Switch ............................................................. 18
Parking Brake ................................................................. 18
Clutch ....................................................................... 19
Control Console ............................................................... 19
Operating Instructions .............................................................. 20
Pre-Ride Inspection ............................................................ 20
Engine Fluids ................................................................. 20
Tire Pressure ................................................................. 20
Testing ...................................................................... 20
Seat Adjustment ............................................................... 21
Passenger Restraint System and Handhold ........................................... 22
Operation .................................................................... 23
Turning ...................................................................... 24
Slippery Surfaces and Skids ...................................................... 25
Passengers ................................................................... 25
MAINTENANCE ...................................................................... 26
Tool List ........................................................................ 26
Locknuts ........................................................................ 26
Engine Service ................................................................... 27
Drive Components ................................................................. 27
Chains ....................................................................... 27
Clutch ....................................................................... 31
Torque Converter .............................................................. 32

ChassisandSteering........................................................... 33
Decals................................................................. -......... 37
BrakeService.................................................................... 37
DiscBrake................................................................... 37
Band/DrumBrake.............................................................. 40
ThrottleCable.................................................................... 42
Inspection.................................................................... 42
ThrottleCableHousingAdjustment................................................. 42
Battery........................................................................... 43
LightBulbs...................................................................... 44
ReplacementBulbs.............................................................. 44
Head/TailLightFuse..... _...................................................... 44
ReplacementFuse............................................................. 44
STORAGE ......................................................................... 45
HOWTOORDERREPAIRPARTS........................................................ 45
PERIODIC MAINTENANCE SCHEDULE .................................................... 46

SAFETY
'_ -[his is the safety alert symbol. When you see
this symbol on your machine or in thismanual, be
alert to the potential for personal injury.
_Read and follow all instructions in this
Owner's/Operator's manual, any accompanying
supplements, and the Engine Owner's Manual before
attempting to operate this Fun-Kart. Make sure to
view the Operations and Safety video.
_1_ WARNING: Indicates a potentiai hazard
which could result in severe personal injury or
death.
,_1_ CAUTION: Indicates a potential hazard which
may result in personal injury or damage to the
Fun-Kart.
NOTE: Use of the word "NOTE" will alert you to key
information or instructions.
Important Rules for Safe Operation
,_ WARNING: Exhaust fumes are toxic.
California Proposition 65 WARNING: Gasoline
engine exhaust from this FUN-KART contains
chemicals known to the State of California to
cause cancer, birth defects or other reproductive
harm. The engine exhaust contains carbon
monoxide, which is a tasteless, odorless,
poisonous gas.
• NEVER operate this FUN-KART indoors or in an
enclosed area without adequate ventilation.
_WARNING: This Fun-Kart is not licensable.
DO NOT operate it on any public road, street,
highway, sidewalk or alley.
This Fun*Kart may be operated only on private
property and areas approved by local law.
,_ WARNING: This Fun-Kart may have been
supplied to you completely assembled. To prevent
possible injury or death read and follow the
assembly instructions to make sure the Fun-Kart
was assembled properly.
_IL WARNING: Always perform Daily Pre-Ride
inspections as outlined in this manual.
,_ WARNING: Check tire pressure before each
use.
Prior to operating the vehicle check and adjust tire
pressure to the proper operating pressure as
indicated on the sidewall of each tire. A tire pressure
gauge is required to obtain accurate reading&
_WARNING: Fun-Kart modification or removal
of original equipment or safety decals can render
the Fun-Kart unsafe for operation.
_WARNING: Safety decals must be replaced if
they become unreadable or detached from the
Fun-Kart.
If decals are unreadable or missing, warning of
potential hazards or safety requirements may be
lacking.
_1_ WARNING: This FUN-KART is not designed or
intended for stunt riding,spinouts, donuts, racing,
or any form of competition.
_1_ WARNING:This FUN-KART is not designed
to be used on rental tracks of any kind.
_tL WARNING:The safe operation of this Fun-
Kart is dependent upon the operator's ability to
exercise proper judgment.
Operator must not be too small or too large for
controlled operation.
Operator must be of sufficient age,
understanding, mental capacity and physicai
capability to safely operate this Fun-Kart.
Safe operation includes responsibility for the
safety of any passenger in a two seat Fun*Kart.
• Fun-Kart should only be operated after mature,
supervised, instruction and sufficient practice in
an uncongested area.
_IL WARNING: One passenger is allowed only in
a specifically designated double seat Fun-Kart.
• Passenger must be of sufficient age,
understanding, mental capacity and physical
capability to act to protect himself/herself. To
qualify as a passenger, a person must meet the
requirements listed in OPERATION-OPERATING
INSTRUCTIONS.

AWARNING: Operator (and any passenger) of
this Fun-Kart MUST always wear a properly
fitting motorcycle type helmet approved by
agencies such as the Department of
Transportation (DOT), Safety Helmet Council
of America (SHCA), or Snell Memorial
Foundation (SNELL).
, Most Fun-Kart accident fatalities are due to head
injuries.
Operator (and any passenger) should also wear
face shields or goggles, boots, gloves and other
appropriate protective clothing. (See
OPERATION-OPERATING INSTRUCTIONS.)
,_ WARNING: Long hair, loose clothes, or
jewelry can get caught in moving parts below and
behind the seat or surrounding environment.
Remove or tie back anything loose that can reach
below and behind the seat before riding.
AWARNING: NEVER place hands, feet, any
body parts or clothing near the engine, wheels,
chain and other rotating parts of the Fun-Kart
while riding or running the engine.
Use caution in performing required maintenance
on or near operating engine.
oUse caution after the engine has been running,
since the engine and other drive components
may be extremely hot.
A
li WARNING: NEVER adjust, repair or clean the
Fun-Kart while it is in motion.
d_l_ WARNING: STOP the engine if the Fun-Kart
makes unusual noises or vibrations.
• Checkthe Fun-Kart for damage.
• Excessive noise or vibration is a sign of loose or
worn parts.
_WARNING: Keep guards and pads in place at
all times.
Prevent accidental contact by the operator or service
personnel while the FUN-KART is running. The
guards over the brake, clutch or torque converter,
axle and drive sprockets also help prevent mud and
debris from coming in contact with those items.
_1= WARNING: Be sure the passenger restraint
system is properly adjusted and fastened at all
times during operation.
If the passenger restraintsystem is not properly
used by the operator and/or passenger, loss of
control and possible personal injury and/or Fun-
Kart damage can occur.
_li_ WARNING:When there is no passenger in a
two seat kart, the passenger's seatbelt must be
securely fastened within the Fun-Kart.
• Unused and unsecured seat belts pose a safety
risk by snagging on the surrounding environment
or becoming entangled in the running gear of the
Fun-Kart.
_WARNING: All screws, nuts and bolts must
be properly tightened to make sure the FUN-
KART is in safe operating condition.
NOTE: Overtightening hardware where parts are
required to move, such as front wheels, spindles, a-
arm pivots, etc., can restrict movement and cause a
loss of control and possible injury.
_WARNING: Prevailing-torque-type Iocknuts
must be replaced with new after the old Iocknuts
have been removed.
Replace with the same type of Iocknut to make sure
they function properly. Refer to the maintenance
section for more information on Iocknuts.
_1_ WARNING: Keep the engine free of dirt and
debris, especially in the throttle linkage area.
,_ WARNING: NEVER start the engine without
checking to see that the throttle control is in idle
position and parking brake is set.
_k WARNING: NEVER start the engine without
the operator properly seated and the restraint
system properly adjusted and secured.
_WARNING: NEVER tamper with, alter or
change the Fun-Kart's engine governor settings,
The governor as set by the engine manufacturer,
limits maximum engine speed and protects the
engine from damage.
Excessive engine speed is potentially dangerous
to operator, passenger, bystanders and engine.