TrailMaster 300xrx User manual

CONLENTS
,
OWNER S MANUAL
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 24
Page

1
.
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 thekart. It is also recommended to practice in a large flat
open area to familiarise yourself with operations of this kart.
We hope you will have a pleasant experience with out products and thank you
again forchoosing our kart.
FOREWORD

AFEW WORDS ABOLLT 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:
WARNING
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 imformation-please read it all carefully.
2

IMPORTANT SAFETY INFORMATION
Your kart will provide you with many years of use and pleaseur. 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 ismuch 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 alldrivers
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 unexpectedturns, drop-offs,rocks, ruts, and other hazards. Always
keep your speed low enough to allow time to see and react to hazards.
3

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.
,
Dno 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.
,
Openating in the dark visinon 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
T he ter rain surface can be amajor 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.
4

WARNING
CAUTION
3031105
Seat Belt Must Be Wom At All Times
THIS VEHICLE MANUFACTURED
FOR OFF-ROAD USE ONLY.
DO NOT OPERATE ON PUBLIC
STREETS,ROADS OR HIGHWAYS.
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.
WARNING
NO LONG
HAIR
ALL HAIR MUST BE TIED UP AND
SECUREDAT ORABOVE SHOULDER
LENGTH.
ALL LOOSE CLOTHING MUST BE
SECURED.ALL NECKLACES AND
SCARNES MUST BE
SECURED.
WARNING
THIS GO-KART CAN BE HAZARDOUS TO OPERATE
if driven carelessly.
IN JURIES can result if you do not follow these
instructions:
,
READ OWNERS M ANUAL ANDALL LABELS BEFORE
YOU OPERATE THIS GO-KART.
NEVER OPERATE THIS GO-KARTWITHOUT PROPER
INSTRUCTIONS.Beginners require adult
supervision.
NEVER OPERATE THIS GO-KART ON PUBLIC ROADS.
It is intended for off-road use only.
ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET.
eye protection and protective clothing.
NEVER OPERATE THIS GO-KART AT EXCESSIVE
SPEEDS.You increase your risk of losing control if
you operate it at speeds too tast for the terrain,
visibility ocnditions or your experi3wence.
NEVER ATTEMPT WH EELIES,JUMPS,OR
OTHER STUNTS.
303115
WARNING
3031107
Loss of c ontrol, collision,or getting caught in moving parts
can result in serious injuries.
Not to be operated by person under 16 years old
Wear a D.O.T. approved motorcycle helmet
Secure long hair and loose clothing
wear protective eye wear and clothing
keep arms,legs and feet inside kart
Do not use alcohol or drugs
WARNING
YOUR ENGINE IS WATER COOLED!
YOU MUST CHECK THERADIATOR
OFTEN TO SEE IFTHE LEVEL OF
THE COOLENT IS FULL.IFNOT,
REFILL AS NEEDED.IF YOUDO
NOT DO THIS,YOUR ENGINE
COULD BURN UP ANDCOST
YOU IN REPAIRS.
NEVER OPEN THE RADIATOR
CAP WHEN ENGINE ISRUNNING.
ALLOW THE ENGINE TOCOOL
DOWN!
WARNING
NO RIDING
WARNING
ALWAYS CHECK GEARCASE
OIL AND REPLACE AS
NEEDED .IF NOT DOING
SO.YOU TAKE THE
CHANCE OF BURNING
THE GEARS UP AND
COSTLY REP AIRS.
WARNING
Do notshift gearswhen the
vehicle isin motionor it
might causedamage tothe
transmission andvoid
warranty.shift onlu when
the footbrake isfully
engaged andthe vehicleis
at acomplete stop.
WARNING
OIL CHECK
AFTER RUNNING YOUR KART EVERY 4
HOURW..YOU NEED TO CHECK YOUR
ENGINE/GEAR BOX OIL FAILURE TO
DO SO CAN CAUSE ENGINE DAMAGE
COOLENT CHECK
AFTER RUNNING YOUR KART EVERY 5
HOURW..YOU NEED TO CHECK YOUR
COOLENT FLUID.FAILURE TO DO SO
CAN CAUSE ENGINE DAMAGE.NEVER
CHECK YOUR COOLENT WHEN ENNGINE
IS RUNNING ALWAYS ALLOW ENGINE
TO COOL DOWN BE FOR CHECKING
5

ARE YOU READY TO DRIVE?
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 confort, convenience,
of 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.
Protective Apparel
For yoursafety,we stronglyrecommend 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.
Aothough completeprotection 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.
Operating this kart without wearing an approved motorcycle helmet, eye protection,
and protective clothing could increase your chances of head and/or eye injury, and the
possibility of death in the event of a severe accident.
Always wear an approved motorcycle helmet that fits properly and wear eye protection
(goggles or face shield), gloves, boots, long-sleeved shirt or jacket and long pants.
6
WARNING

ARE YOU READY TO DRIVE?
IS YOUR VEHICLE 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 skills 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 accus-
,
tomed to the kart s controls, and feel comfortable with its size and weight.
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.
Before each drive, it is important to inspect your kart and make sure any problems you find
are corrected. Apre-drive inspection is a must, not only for safety, but because having a break
down,or even a flat tire, can be a major inconvenience.
If your kart h as 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.
Operating this kart without your seat belt could cause you to be thrown
from the kart, causing serious injury or death.
Operating this 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 serious injury or death.
Never consume alcohol or drugs before or while operating this kart.
Improperly malntaining this kart or failing to correct a problem before driving can
cause a crash in which you can be seriously hurt or killed.
Always perform a pre-drive inspection before every drive and correct any problems.
7
WARNING
WARNING
WARNING
Pre-Drive Inspection
Always carry out the Pre-Drive Inspection detailed on Page 16 before getting in your kart.

Control Speed
Driving at excessivespeed increases the chances of an accident. In choosing an appropriate
speed, you need to consider the capability of your kart, the terrain, visibility and other operating
conditions, plus your own skill and experience.
SAFE DRIVING PRECAUTIONS
Off-Road Use Only
Your kart and its tires are designed and manufactured for off-roaduse only, not for use on
paved surfaces. Driving on paved surfaces can affectthe kart handling and control.You sho-
uld not drive
When driving off-road, also remember to always obey local off-road driving laws and
regulations. Obtain permission to drive on private property. Avoid posted areas and obey
no trespassing signs.
You should never drive your kart on public streets, roads or highways, even if they are not
paved. Drivers of street vehicles mayhave difficultyseeing and avoiding you, which could
leadto a collision.In many states it is illegal to operate karts on public streets,roads and
highways.
Keep Hands and Feet on Controls
When driving your kart, always keep both hands on the steering wheel and both feet
on the foot controls. It is important to maintain your belance and to control the kart.
Removing hands or feet away from the controls can reduce your ability to react and
control the kart.
Operating this karton paved surfaces may seriously affect handling and control of
the kart, andmay cause the vehicle to go out of control.
Never operate the kart on any paved surfaces, including pavements, driveways, car
parks and streets.
Operating this kart on public streets, roads or highways could cause a
collision with another vehicle.
Never operate this kart on any public streets, roads or highways, whether
they are dirt, gravel or paved surfaces.
Removing your handsfrom the steering wheel or feet from the foot controls during
operation can reduceyour ability to control the kart or could cause you to loseyour
balance and fall off the kart.
Always keep both hands on the steering wheeland both feeton the foot controls
of your kartduring operation.
WARNING
WARNING
WARNING
WARNING
Operating this kart at excessive speeds increases your chances of losing
control of the kart, which can result in an accident.
Always drive at a speed that is appropriate for your kart, the terrain, visibility
and other operating conditions, and your experience.
8

Use Kart on Unfamiliar or Rough Terrain ,
Before driving in a new area, always check the terrain thoroughtly, 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 kart and
other off-road vehicles. Always exercise caution and use extra care on rough, slippery
and loose terrain.
Do Not Perform Stunts
You should always operate your kart in a safe and reasonable manner. When driving,
always keep all four wheels on the ground.
Failure to use extra care when operating this kart on unfamiliar terrain
could result in the kart overturning or going out of control.
Go slowly and be extra careful when operating on unfamiliar terrain. Always
be alert to changing terrain conditions when operating the kart.
Failure to use extra care when operating on excessively rough, slippery or
loose terrain could cause loss of traction or vehicle control, which could res
in an accident, including an overturn.
Do not operate on excessively rough, slippery or loose terrain until you have
learned and practiced the skills necessary to control the kart on such errain.
Always be especially cautious on these kinds of terrain.
Attempting wheelies, jumps, and other stunts increases the chance of an
accident, including an overturn.
,
Never attempt stunts, such as wheelies or jumps. Don t try to show off.
9
SAFE DRIVING PRECAUTIONS
WARNING
WARNING
WARNING
Radiator Indicator Lamp
During the driving, you should always keep closecontact with this red indicator lamp.
This indicator lamp will tell you when your engine coolent system is getting too hot.To
keep from causing any damage, you should stop the kart and turn the key off. Check if
there is any leak, At this time do not open the radiator cap,allow your coolent system and
engine to cool down before opening th e radiator cap.
If you find the coolent completely gone,you shoule check if the radiator,hoses or engine
has stch leaks

P.D.I.
A. Install RR. Shocks and tighten the unts.
B. Install Ball Head, Tie Rod, tighten the Castle Nut and insert the cotter Pin.
C. In stall Dust Seals, align the Ball Head Bolt, Knuckle Support to the square hole on the
Lower A-Arm.
D. Install Flange Nut and tighten it (>88.9 foot lbs)
E. Install Front Tires and tighten the nuts.
F. Install Rear Tires, tighten the nuts, insert cotter Pin and put on the Rubber Cover.
G. Raise the C.B.C bar as the picture shows.
H. Install C.B.C bar RR., put on R-Washer.
I. Install Head-Rest.
J. Check all nuts and bolts, wiring, cables, fuel line, switches and tire pressure.
K. Fill battery with Acid and charge, check and fill the engine with the recommended oil.
L. Fill fuel tank with Unleaded Gasoline, and turn on the ignition switch to start the engine.
10

Overall Length 87 in.(2210mm)
Overall Width 53.5 in.(1346mm)
Overall Height 56.6 in.(1438mm)
Wheelbase 66.1 in.(1680mm)
Front Track 45.7in.(1160mm)
Rear Track 42.7 in.(1085mm)
Ground Clearance 8.5 in.(215mm)
DIMENSIONS
ENGINE
CAPACITIES
Type Water-cooled.4-Stroke
Engine capacity 300cc
Bore / Stroke 72.5mm x 66.8mm
Displacement 275.6cm
Corrected compression ratio 10:1
Carburetor VEKS4 & CV30
Output Power 13KW/ 6500RPM
Maximum Torque 22N.m/5000RPM
Starting Electri
Ignition C.D.I
Lubrication Force&Splash
Transmission Automatic(C.V.T system)
Spark Plug DR8EA(NGK)
Plug gap 0.6-0.7mm
Fuel Type Rq90(unleaded)
Lubricate oil SAE 15W -40/SF
Maximum load Do Uble Seats/400lbs
Fuel tank 25 Gal
Engine oil 30 Oz
Starting 5s
oo
Climbing 20 -25
Battery 12V 10Ah
Head Light 12V 35W /35W
Tail Light 12V 21W /5W
Fuse 10A
11
SPECIFICATIONS
DRIVE COMPONENTS
Gear box oil MoS2 & W -2DW-4D

Brake Track <7m@20miles/h
Top speed 75miles/h(or limited as customers require)
CHASSIS
TIRE PRESSURE
WEIGHT
Front,Rear brake Hydraulic disc,left foot control
Front tire 20 x 7-8
Rear tire 22 x 10-10
Front Suspension Independent Dual A-Arm
Rear Suspension Full Independet Rear Suspension/ Oil Damped Shock
Restraint System Dual 4-point Harness
Final Drive CV- Shafts
Front 7-9psi
Rear 8-9psi
Net Weight 280Kg
Gross Weight 320Kg
12

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 operatormust know
how to stop this machine before starting and driving it.
a. Throttle
The right foot pedal is the throttle that controls the kart speed. As the engine speed incre-
ases above idle, the clutch automatically engine and moves the vehicle forward.
(See Fig. 1)
Each time prior to starting the engine, check the throttle assembly to ensure
that when the 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 through lubrication,
adjustment or replacement of worn parts, contact your dealer for assistance.
b. Brake
The brake is the left foot pedal (See Fig.1). Applying pressure to the pedal slows or
stops the kart.
c. Start engine
Insert the key into key-switch,
turn the key clockwise, release the
key when the engine starts. The
engine willwarm upwithin 5 minutes
and the choke will close autom-
atically allowing operation at
,
normal RPM(Warning: Don t crank
the starter for more than 5 seconds
at one time).
d. Engine stop button
Important-stop button teat.
Before driving this vehicle, test the Engine
Stop Button to ensure that it is operating properly. With the engine running, push and
hold the Engine Stop Button for two seconds for the engine to shut down.
13
Figure 1
BRAK PEDAL
REVERSE LEVER
THROTTLE PEDAL
ENGINE STOP BUTTON
SMITCH UNT WINKER
HORN BUTTON
POWER OUTER
LIGHT SWITCH
METER
GNITION START SNITCH
PARKING BRAKE
WARNING

OPERATION
B. Pre-Drive Inspection
Perform this pre-driveinspection everyday before driving the vehicle. If not
performed, serious damage to the vehicle or personal injury may result.
Check the engine oil level is between the bottom of the dipstick and the 0 mark, Check
for leaks. Add oil if required.
Check the Fuel Level. Add fuel as necessary and do not overfill. Check for leaks. Ensure
the fuel filler cap is securely fastened.
Check the Brakes. Depress the left brake pedal several times, and check for adequate brake
pedal free play. Make sure there is no brake fluid leakage.
Check the tires. Check their condition for damage or excessive wear and pressure.
Check the Throttle Chain. Check for smooth operation.Ensure the throttle snaps back
to idle when released and moves smoothly without sticking.
Check the Engine Stop Button. While the engine is running press and hold the engine stop
button for 2 seconds. Make sure the engine stops.
Check all Nuts, Bolts, and Fasteners. Check the wheels to see that all axle nuts and lug nuts
are tightened properly. Check and tighten as necessary all other nuts, bolts and fasteners.
Check the C.B.C.Bar. Ensure all C.B.C bars are in place before operating the kart.
Check the Lights. Check the headlights, brake light and tail light are all working.
Check the Steering. Check that the steering wheel moves freely in both directions but
without any unusual looseness.
Check all Cable Housings. Check these for wear and the fitting for any looseness.
Check the underbody and exhaust system. Remove all dirt, vegetation and mud and check
for any damage due to impact with rocks or unever terrain.
Check the Air Cleaner Housing Drain Tube. Checkthe deposits in thedrain tube.If necessary,
check the tube and air cleaner housing.
Check Leaks and Loose Parts. Walk around your kart and look for anything that appears
unusual, such as a leak or loose cable.
Check the Parking Brake. Make sure the kart does not move forward or backward when
the parking barke is applied.
Chech the Radiator.Make sure there is no leak of radiator or hoses before you start the
engine.Check the water level.
Check the radiator to see if the level of the coolent is full.Refill the coolent as needed or
your engine would burn up and cost you in repairs.Never open the radiator cap when
engine is running.Allow the engine to cool down,and the refill the coolent.
a.
b.
c.
d.
e.
f.
g.
i.
i.
j.
k.
l.
m.
n.
o.
p.
q.
14
WARNING

STEERING WHEEL
HORN NUITS
TANK COMP.FUEL
REAR CAPGO PACK
Figure 2
SEAT BELT
MIRROR
FLAG POLE BRACKER
FUEL TANK CAP
OPERATION
Component Iocations
15