TrailMaster 150XRS Manual

TrailMaster 150XRS
Set up instruction
Version: 1.0
2011/11/28
This set up instruction guides our customer to set up the go kart TrailMaster 150XRS step by
step to ensure a correct assembly for safe driving.

150XRS Set up instruction
1
1. Check the components after opening the box.
1.1 Battery (pic.1): type YTX12-BS (12V10Ah), includes one battery,
one battery liquid, two bolts and nuts for installation.
Pic. 1
1.2 One set of front fenders for left and right (pic. 2)
Pic. 2

150XRS Set up instruction
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1.3 One set of rear fenders for left and right, two bolts M8x45 screwed in
the brackets (pic.3)
Pic. 3
1.4 One fuel tank (pic. 4): preassembled with auto fuel lock, vacuum tube,
tank cap, tank collars, tank rubber mounts and sticker.
Pic. 4
1.5 One set of awning and two foam paddings (pic.5)
Pic.5

150XRS Set up instruction
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1.6 One steering wheel (pic.6)
Pic.6
1.7.1 one standard parts package, one manual, one flag, one battery cover,
one battery strap, one battery lower cushion, four hub coves, plastic
fixing bolt and nut for flag and 10 cable bundles (pic.7)
Pic.7
1.7.2 In the standard parts package: 16 bolts M8x55, 4 bolts M8X25, 4
bolts M8X20, 2 cotter pins 3X40, 2 cotter pins 2.5X25, 22 R-washers, 2
washers ∮8, 10 self-locking nuts M8 (pic.8)
Pic.8

150XRS Set up instruction
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1.8 Two head rests (pic.9)
Pic.9
1.9 Two bar cages (pic. 10)
Pic.10
1.10 One top cross bar preassembled with tube seats and rear mirror
(pic.11)
Pic.11

150XRS Set up instruction
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1.11 Two side bars for left and right side with tube seats (pic. 12)
Pic.12
1.12 One top cross bar with tube seats (pic.13)
Pic.13
1.13 One rear cargo rack preassembled with tube seats and rail light
(pic.14)
Pic.14

150XRS Set up instruction
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1.14 Two support arms of rear cargo rack (pic.15)
Pic.15
1.15 front wheels left and right; rear wheels left and right (pic.16)
Pic.16

150XRS Set up instruction
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2. Assembly
2.1 Assemble the rear shocks (pic.17): take down the bolts from the
shocks, lift the rear swing arm to let the top of shock into the fixing seats
of frame, use 37-44NM torque to fix the shocks attached the frame. (Note:
1NM = 0.74 lb ft)
Pic.17
2.2 Assemble the rear wheels (pic.18): screw the castle nut M16x1.5
tightly with 98-103NM, then open the cotter pin 3X40 for fixing, take
down the nuts on the rear axle hub, lift the frame to install the wheel
(please pay attention to the right direction of wheel installation as shown
in the pic. 18), screw the tire nuts tightly with torque 37-44NM, cover the
hub cover.
Pic.18

150XRS Set up instruction
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2.3 Assemble the front lower suspension arm (pic.19): lift the frame over
the ground, take down the bolts and washers on the bulbs of strut, attach
the lower suspension arm to the strut, put on the washer and castle nut in
order, screw the nut with 55-62NM torque, fix the cotter pin 2.5X25
through the castle nut.
Pic.19
2.4 Assemble the front shock absorber (pic.20): Take down the bolt on the
shock absorber, attach the shock absorber to the front lower suspension
arm, and fix the bolt with 37-44NM torque.
Pic.20

150XRS Set up instruction
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2.5 Assemble the front wheel (pic.21): Take down the tire bolts on the
hub, set up the front wheel on the right position of hub, fix the tire bolts
with 37-44NM torque, put on the hub cover.
Pic.21
2.6 Assemble the rear cargo rack (pic.22): After the front and rear wheels
have been assembled correctly, push the kart out from the bottom board.
Hold the rear cargo rack aiming installation positions on the cargo rack
and the frame (to avoid bumping between frame and cargo rack, please
lay on some air bubble on the frame for better protection!), put the
R-washers onto the bolts M8X55, screw on the bolts 3circle. Then put on
the bolts M8x20 and M8 self-locking nuts to the rack support arms, attach
the arms with rear cargo rack and frame together, tightening all the bolts.
Pic.22

150XRS Set up instruction
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2.7 Assemble the long bar cages (pic.23): put two sides of long bar cages
onto the connection rods on frame and rear cargo rack fixing with bolt
M8x55, R-washer and M8 nut. Tightening the bolt.
Pic.23
2.8 Assemble the side bar (pic.24): Put one side of side bar onto the
connection rod of frame, connect the side bar with frame together with
bolt M8x55, R-washer and M8 nut, do not tightening the bolts. Connect
another side of side bar with long bar cage together with R-washer and
bolt M8x55. Screw on all the bolts tightly.
Pic.24

150XRS Set up instruction
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2.9 Assemble the cross bar (pic.25): Connect the cross bar with two long
bar cages with bolt M8X55 and R-washer, do not tightening the bolts at
this step.
Pic.25
2.10 Assemble the roof rack bars (pic.26): fix the rear cross bar with long
bar cage together using bolt M8x55, R-washer, screw on the bolts
M8x115 with torque 22-29NM.
Pic.26
2.11 Screw on the bolts from step 2.6 to 2.10 with torque 22-29NM.
2.12 Assemble the awning (pic.27): Put the foam padding around the top
of long bar cage, cover the awning on the right position, fasten the
string.

150XRS Set up instruction
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Pic.27
2.13 Assemble the head rest (pic.28): Insert the assembly bars of head rest
into the mount holes of seat.
Pic.28
2.14 Assemble the fuel tank (pic.29): fix the tank on the mount position
of rear cargo rack with M8x25 bolts using 22-29 NM torque.
Pic.29

150XRS Set up instruction
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2.15 Connect the fuel tubes: connect the fuel tube and vacuum tube as
shown in pic.30.
Vacuum tube t-cock, fuel tube, connect fuel tube, vacuum tube
Pic.30
2.16 connect the tail light (pic.31): insert the 3-pin terminal of tail light
into the 3-hole terminal of wire harness, bundle the cables.
Pic.31
2.17 Assemble the front fender (pic.32): take down the bolts on the strut,
assemble the fender, fix the bolt with torque 11-16NM.
Pic.32

150XRS Set up instruction
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2.18 Assemble the rear fender (pic.33): take down the M8x45 bolts from
the fender bracket, assemble the rear fender, screw on the bolts with
torque 22-29NM.
Pic.33
2.19 Assemble the yellow flag and flagpole: use the plastic bolt and nut to
fix the flagpole on the rear cargo rack.
2.20 Install the battery, battery cover: put the battery liquid into the
battery body, close the battery cover. Put the cushion plate into the battery
mount box. Connect the battery wires to the battery poles “+ to +; - to –”,
cover them. Put the wired battery into the battery mount box covered with
the plastic protection cover, put the wires out through the protection cover
slot, fasten the battery with battery strap. (Note: because the battery liquid
and wiring of battery poles are dangerous, only experienced adult can
carry out this carefully with protection measures (protective glove,
Prevent electric screwdriver).

150XRS Set up instruction
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Before driving please read the user manual of TrailMaster Go-kart
150XRS carefully, you will be given with important safety information
and advices.
Thanks a lot for choosing TrailMaster Go-kart 150XRS.
For more other products of TrailMaster, please visit
www.bvpowersports.com !
BV Powersports, LLC