TrailMaster 150 User manual

1
Move carton to a clean location with 3
or more feet of room around the unit.
2
Remove strapping and outer container.
3
Unpack parts and place near where
they are to be installed.
4
Lay out ALL hardware on a clean sur-
face and count.
5
Remove battery box from kart. Read all
precautions, filling instructions and
safety instructions. Make sure to wear safety
glasses and protective gloves.
6
Place the battery in a sink.

7
Remove the battery cell seal.
8
Carefully open the package containing
the battery acid and hardware. Set the
hardware package aside for later use.
9
Remove the plastic cap from the battery
acid container. IMPORTANT: DO NOT
DISCARD THE PLASTIC CAP. Set the plastic
cap aside for later use.
10
Place the battery acid container on
top of the battery. Be sure to properly
align the container with the battery cells.
11
Gently press the battery acid con-
tainer into the battery cells. This will
puncture the foil caps and allow the battery
acid to flow.
12
The battery acid container needs to
be vented to allow the acid to flow
from the container easier. With a sharp knife
or thumbtack, poke a hole in the TOP of each
of the battery acid container’s cells.

13
Allow the battery acid to fill the bat-
tery while putting the go kart togeth-
er or at least for 30 minutes. This will also al-
low the battery to absorb the acid and vent
properly.
14
Select the two short 8mm bar bolts.
These will be used to install the rear
rack.
15
Install 1 each of the cupped washers
to each bolt.
16
Remove the hose from the frame be-
hind the driver’s seat. This fuel hose
will connect to the fuel petcock on the fuel
tank later.
17
This hole will be used to mount the
rear rack.
18
With an assistant, sit the rack in place
and align it with the holes in the
frame.

19
Insert the bolt with washer through
the hole in the frame and turn the bolt
to tighten the threads (clockwise rotation)
into the rack. Do this procedure on both the
left and right sides. Then, tighten both bolts
securely with a 10mm wrench.
20
Now, it is time to mount the fuel tank
and install the fuel hoses. Sit the fuel
tank into place with the fuel cap on the driv-
er’s side.
21
The hardware necessary to mount
the tank. These are the (4) four longer
of the short bolts. Do not install 8mm yet.
22
Locate the vacuum hose that is al-
ready connected to the fuel valve.
23
Attach the vacuum hose to the ‘Y’
connector near the carburetor.
24
Push hose on completely and slide
the hose clamp to 1/4” from end of
hose.

25
Locate fuel hose with the fuel filter
and spring that is already attached to
the carburetor.
26
Push the hose onto the top fitting of
the fuel valve and slide the clamp to
1/4” from hose end.
27
After properly connecting the fuel
hoses, it is time to install the tank
hardware. The tank should be mounted with
the curve of the tank towards the rear of the
go kart.
28
Start all four bolts into the threads by
hand. Make sure that the steel bush-
ing is inserted into each rubber bushing.
29
This is the rear support for the rear
rack. There are two supports on the
rack. One on each side of the go kart.
30
Install the 4 shortest 8mm bolts with
nuts. Then, tighten all 4 bolts with a
10mm and 12mm wrenches.

31
It is time to install the main bars on
the cage. This step require 4 bolts, 4
nuts and 8 cupped washers.
32
Place the 2 long top bars into place.
33
The left and right bars are the same.
NOTE: May be necessary to use a medium
size Phillips screwdriver or punch to align the
mounting holes.
34
Insert the bolt, washers and nuts
through the bars at the front left side
and front right side. Nut should be to the in-
side.
NOTE: DO NOT TIGHTEN HARDWARE YET.
35
Install the right side rear bolt, wash-
ers, and nut. Nut should be to the in-
side.
NOTE: DO NOT TIGHTEN HARDWARE YET.
36
Install the left side rear bolt, washers,
and nut. Nut should be to the inside.
NOTE: DO NOT TIGHTEN HARDWARE YET.

37
Four (4) 8mm bolts and washers will
be used for the top weldment.
38
Two (2) long bolts, nuts and four (4)
washers along with two (2) long bolts
with washers only will be used to install the
side bars.
39
Side bar installation. Fit the left side
and right side bars into place.
40
Install the bolt with washer in the top
of the bar first.
41
Make sure the threads start into the
bar.
NOTE: DO NOT TIGHTEN HARDWARE YET.
42
Install the bolt, 2 washers and nut at
the bottom of the bar.
Repeat Steps 38-42 for other side bar.
NOTE: DO NOT TIGHTEN HARDWARE YET.

43
Place the rear cross bar into place
and align holes.
44
Start 8mm bolts with washers.
NOTE: DO NOT TIGHTEN HARDWARE YET.
45
With an assistant, hold the top weld-
ment in place.
.
46
Use the remaining four (4) long 8mm
bolts and washers to install the top
weldment.
47
Plastic end caps may need to be ro-
tated with pliers to fit properly
48
Start the four (4) bolts with washers
into the top weldment.
NOTE: DO NOT TIGHTEN HARDWARE YET.

49
Tighten ALL of the hardware previ-
ously installed into the cage at this
time with a 10mm wrench and a 12mm
wrench.
50
It is time to install the lower shock
bolts at the rear of the go-kart. Re-
move the bolt and nut from the frame at the
shock mount.
51
Have an assistant lift up on the rear
rack to align the shock with the
mount.
52
Align the shock.
53
Insert the bolt and nut.
54
Tighten the bolt and nut with two (2)
14mm wrenches.
NOTE: Repeat Steps 50-54 for the other side.

55
At this time, the go-kart must be lift-
ed approximately 12” from the crate.
You may need an assistant or two. Place a
sturdy support under the kart frame i.e. jack-
stands. Be safe. Use caution. Make sure the
unit is stable and secure so that it doesn't fall.
56
Locate the rear axle.
57
Apply multi-purpose grease on the
spline of the axle. Remove nut and
washer.
58
Steps 58 & 59 are not necessary,
however, we recommend using a
quality lubricant with straw.
59
Carefully push the straw between the
seal and axle. Spray lubricant for
about 1 second.
60
Mounting rear fenders. Remove
mounting bolt from rear fender
bracket with a 10mm wrench.

61
Place bolt through rear swing arm
located just in front of rear shock.
62
Start bolt into fender bracket by
hand. Then, tighten firmly with a
10mm wrench.
NOTE: Repeat Steps 60-62 for the other side.
63
Slide rear wheel onto rear axle with
the valve stem to the outside. The
tread on top of the tire should be pointing
forward.
64
Install large washer and castle nut on
axle.
65
Tighten nut making sure to align with
holes in axle.
66
Install cotter pin. Bend and clip off
excess clip.
Repeat Steps 63-66 for the other side.

67
Locate front passenger side spindle.
Make sure rubber boot and square
washer are installed.
68
Align square stud with hole in A-arm.
69
Align square stud with lower A-arm.
70
Install stud in hole.
71
Make sure stud square is seated.
72
Install washer and castle nut.

73
Tighten nut. Align with hole in spin-
dle stud.
74
Install cotter pin in lower spindle nut.
Bend and clip excess.
75
Remove cotter pin from top of spin-
dle.
76
Check castle nut for tightness.
77
Install cotter pin in upper spindle
nuts. Bend and clip excess.
78
Remove cotter pin from ball joint.

79
Tighten nut. Align hole with stud.
80
Reinstall cotter pin. Bend and clip off
excess.
Repeat steps 67-80 for driver’s side.
81
Remove fender mounting bolts from
passenger side spindle.
82
Install fender and tighten bolts with
10mm wrench.
Repeat 81-82 for driver’s side.
83
Remove wheel nuts from passenger
side hub.
84
Install front wheel with valve stem
facing out and tread pointing forward
on top of tire.

85
Tighten lug nuts securely.
86
Bend and cut cotter pin in wheel hub.
Repeat Steps 83-86 on driver’s side.
87
You will need a valve stem tool to
tighten all valve stem cores. This tool
can be purchased at an auto parts store.
88
Tighten all valve stem cores.
89
Using a low pressure tire gauge, set
tires at 10 psi for front and 8 psi on
rear. Install valve stem caps.
90
Remove the acid container from the
top of the battery and properly dis-
card. Set the plastic cap (from Step 9 ) into
the top of the battery making sure that ...

91
Make sure cap lines up correctly. If
not properly aligned, the cap can be-
come damaged and it will not fit properly.
Firmly press cap into top of battery.
92
After making sure that the cap is
properly inserted, gently tap the cap
into place. Make sure to work your way from
one end to the other and the repeat until the
battery is flush to the top of the battery.
93
Insert the rubber … into the battery
tray located behind the driver’s seat.
94
The rubber … will lay flat in the bot-
tom of the tray and will help with re-
ducing battery movement and noise.
95
BEFORE YOU BEGIN BATTERY IN-
STALLATION: MAKE SURE KEY
SWITCH IS TURNED TO THE OFF POSITION.
Place battery in tray with terminals towards
the rear of the go kart.
96
Locate battery bolts and nuts.

97
First, insert one square nut into the
‘+’ terminal.
98
Locate the positive battery cable
(red).
99
With a Phillips head screwdriver,
mount the positive (red) cable to the
‘+’ terminal on the battery.
100
Place rubber cover over terminal.
101
Repeat Steps 97-100 for negative
battery cable (black).
102
Battery installation is complete.

103
Install battery cover.
104
Install rubber strap using a pair of
pliers to stretch .
*NOTE: WD40 sprayed on the rubber strap
will make this step easier.
105
Completed battery cover and
strap.
106
Find the 3 wire connectors from
the tail light and top of the engine
at the wiring harness and connect.
107
Remove bolts from steering
wheel mount.
108
Install steering wheel with center
spoke down.

109
Install and tighten bolts.
110
Install plastic cover.
111
Snap cover into place.
112
Install hub caps on front wheels.
113
Install hub caps on rear wheels
and check mounting nuts.
114
Make sure seat belts are to cen-
ter of seatback.

115
Install headrest into holes on
seat.
116
Push headrest all the way down.
117
Peel protective film from decals,
reflectors and seats.
118
Use electrical tape to secure top
padding.
*NOTE: May also use spray adhesive on all
padding and foot pads.
119
Install fabric top starting at front.
120
Secure and attach with Velcro.