TrailMaster MID XRX User manual

1
Move carton to a clean location with 3
or more feet of room around the unit.
2
Remove outer cardboard from crate.
3
Remove all bolts from metal crate with
9/16” wrenches or socket.
4
Remove metal crating and unpack all
parts.
5
Place parts out on the floor and take
inventory making sure of proper quan-
tities. At this time, if missing or damaged
parts, call or email us.
6
Remove metal side bar from each side
and dispose.
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7
Remove axle straps and discard.
8
Locate white box with battery.
9
See Battery Fill Procedure Instruction
Sheet. Fill battery according to Instruc-
tion Sheet . Let sit.
10
Locate headrests and install into seat-
backs with seatbelt in between head-
rest bars. Push the headrests all the way
down into the seat.
11
Lay out all hardware on a clean work
bench. Take inventory per hardware
list.
12
Locate one of the long cage bars.
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13
Place bar on front pin above head-
light.
14
Place rear of bar onto pin at rear be-
hind seat.
15
Locate 2 long bolts, 4 nuts & 8
chrome cup washers.
16
Install with washer into front of bar
from the outside.
17
It may be necessary to align the hole
in the bar with a screwdriver.
18
Install a second cup washer and the
nut.
NOTE: DO NOT TIGHTEN AT THIS TIME.
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19
Install bolt, washers and nut at rear of
bar.
20
Repeat steps 16-19 for the other top
bar.
21
Locate the passenger side bar.
22
Locate 4 large bolts, 6 cup washers
and 2 nuts.
23
Place the side bar onto the passen-
ger’s side of the go-kart.
24
Turn the plastic cap with a pair of pli-
ers to align the side bar to the top
bar.
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25
It is necessary to tap the plastic cap
all the way onto the bar. Use a plastic
or rubber mallet or a block of wood with a
standard hammer.
26
Install the top bolt & washer first.
Start the threads but do not tighten.
27
Now, install the bottom bolt and
washer from the front.
28
Install the second washer and nut on
the bottom bolt.
NOTE: DO NOT TIGHTEN THE HARDWARE.
29
Repeat steps 21-28 for the driver’s
side bar.
30
Locate the top bar weldment assem-
bly.
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31
Locate 4 large bolts and 4 chrome
cupped washers.
32
Install the top bar assembly.
33
Start each of the 4 bolts with cupped
washer into the threads of the top bar.
NOTE: DO NOT TIGHTEN HARDWARE .
34
Locate the short rear bar.
35
Locate 2 long bolts and 2 chrome
cupped washers.
36
Install the short bar behind the seats.
Start the bolts with washers into the
threads.
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37
Tighten ALL of the bar bolts previ-
ously installed with a 10mm & 12mm
wrenches.
38
Locate the fuel tank.
NOTE: On some models, the fuel tank
is already installed on the engine. Check tank
mounting hardware to insure tight. Proceed
to Step 47.
39
Locate 4 long bolts and nuts and fuel
hose clamp.
40
Place the fuel tank onto the rear rack
with decal to the rear.
41
Install the 4 bolts and nuts into the
tank.
42
Tighten with a 10mm & 12mm
wrenches.
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43
Locate the end of the fuel hose on top
of the engine.
44
Place the fuel hose clamp onto the
hose and push the hose onto the fuel
filter that’s already attached to the fuel tank.
45
Using pliers, place the fuel hose
clamp on the filter approximately
1/4” from the end of the hose.
.
46
Turn fuel valve to ‘ON’ position.
47
Now, it’s time to install the rear
shocks. Remove the metal shipping
bar from the passenger’s side shock mounts.
NOTE: SAVE THE BOLTS & NUTS.
48
Discard this bar.
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49
Locate one (1) shock.
50
Place the top shock eye into the
bracket with the spring up. Reinstall
bolt and washer that was removed in Step 47.
51
Lift up on the rear rack and align bot-
tom shock eyelet with the bracket on
the rear swing arm.
52
Install bottom shock bolt and nut.
53
Tighten top and bottom shock bolts
with wrenches.
54
Repeat Steps 49-53 for the driver’s
side rear shock.
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55
At this time, lift the rear of the go-kart
with the help of an assistant. Place the
kart on a jackstand. Be safe. Use caution.
56
Place the battery pad into battery tray
located behind the passenger’s seat.
57
Install the battery in the cart with the ter-
minals to the rear. First, install the positive
cable (red) to the ‘+” on the battery. Next, install
the negative cable (black or green) to the ’-’ on
the battery. NOTE: Use pliers to hold the nut while
using a Phillips head screwdriver to tighten the
screw.
58
Place gray plastic cover over battery.
59
Place rubber battery strap over bat-
tery hook to the front of the battery
tray first. Then, pull the strap over the battery
and place it on the rear hook of the battery
tray. If necessary, use pliers.
60
Locate the brake caliper on the rear
axle. Tighten the 2 mounting bolts
securely with a 6mm Allen wrench.
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61
Locate the set bolt on the sprocket
hub and tighten securely.
62
Locate the rear passenger’s side
wheel. This is one of the larger
wheels. The tread on top of the tire will point
towards the front of the go-kart & the air valve
stem will be facing towards the outside.
63
Place the wheel onto the rear axle.
64
Place the largest washer and castle
nut onto the axle.
65
Tighten the castle nut securely and
align the holes in the axle with the
nut.
66
Install the cotter pin into the axle nut.
Bend one end of the cotter pin over
the end of the axle. Clip off other end with
cutters.
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67
Install rubber hubcap over axle nut.
NOTE: Repeat Steps 62-67 for the driver’s
side rear wheel.
68
Remove bolts from the passenger’s
side rear fender mounts with a 10mm
wrench.
69
Install rear passenger fender.
NOTE: Rear fender mounting brack-
ets have the shorter reach arm.
70
Tighten the bolts securely using a
10mm wrench.
NOTE: Repeat Steps 68-70 for the driver’s
side rear fender.
71
Lift front of go-kart and support with
jack stands.
72
Remove fender mount bolts on pas-
senger side located behind the front
shock with a 10mm wrench.
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73
Locate passenger’s side front fender.
This fender has the longer mounting
arm.
74
Install the front fender with bolts and
lock washers. Tighten securely with a
10mm wrench.
75
Tighten the 3 fender bolts and nuts
that are already installed with two
(2) 10mm wrenches.
76
Repeat Steps 73-75 on driver’s side
fender.
77
Locate passenger’s side top spindle
nut and remove cotter pin.
NOTE: Save cotter pin.
78
Locate passenger’s side bottom spin-
dle nut and remove cotter pin.
NOTE: Save cotter pin.
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79
Tighten both nuts securely with a
17mm wrench.
80
Make sure the hole in the spindle
lines up with the castle nut.
81
Reinstall cotter pins. Bend and cut off
excess. Repeat Steps 77-81 on the
driver’s side spindle.
82
Locate outer steering joints and tight-
en the nut securely using a 12mm
socket on the nut and a 12mm wrench on the
top.
83
Locate the front passenger’s side
wheel and place it on the passenger’s
side front axle. The tread on top should point
forward with the air valve stem to the outside.
84
Locate 2 castle nuts, 2 washers and 2
cotter pins.
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85
Place the washer and castle nut onto
the axle and tighten securely with a
19mm socket.
86
Install cotter pin and bend. Cut off
excess cotter pin. Repeat Steps 84-86
on the driver’s side.
87
Check tire pressure in all 4 tires. Set
to 10 PSI. You will need a low pres-
sure gauge to check the tire pressure.
88
Make sure that the brake fluid is be-
tween the ‘MIN’ & ‘MAX’ levels on the
brake master cylinder reservoir.
89
Add brake fluid, if necessary, to the
‘MAX’ level. Use DOT2 or DOT3
brake fluid.
90
Locate the brake rod jam nut at the
master cylinder and tighten securely
with a 10mm wrench.
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91
Locate throttle cable mount and
make sure nuts are snug with two (2)
10mm wrenches. Tighten gently.
92
Locate the parking brake and tighten
the bolt and nut securely with two (2)
10mm wrenches.
93
Locate the throttle stop and tighten
the jam nut securely.
NOTE: Lowering this bolt will restrict the top
speed of the go-kart.
94
Locate the steering box clamps and
tighten all four (4) bolts and nuts se-
curely with 8mm & 10mm wrenches.
NOTE: Plastic connector should be next to the
metal clamp.
95
Locate the three (3) small bolts and
nuts.
96
Locate the steering wheel.
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97
Install the steering wheel with the center
spoke facing down & the front wheels
straight forward.
NOTE: If the steering wheel does not line up cor-
rectly with the front wheels, continue mounting the
steering wheel as close as possible.
98
Tighten bolts securely with two (2)
10mm wrenches.
99
Install the plastic steering wheel cap
by snapping it into place.
100
If the steering wheel is not
straight when the front wheels are
pointing straight, locate the plastic gearcase
on the steering box.
101
Remove plastic cap from the bot-
tom of the plastic case with a
screwdriver.
102
Make sure the front wheels are
straight ahead and determine
which way the steering wheel needs to be
turned to align correctly.
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103
Remove steering shaft nut with
17mm socket.
104
Pull steering wheel and shaft out
of the gear. You may need to
bump the steering wheel gently.
105
Hold the gear in place with your
finger.
106
Turn the steering wheel straight
and push the shaft back down into
the gear.
107
Reinstall the nut securely. Rein-
stall the plastic cap by simply
pushing it into place.
108
Now, it’s time to align the steer-
ing. Turn the steering wheel to
straight ahead.
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109
Stand approximately 10 feet in
front of the go-kart and look at the
front passenger wheel in relationship to the
rear passenger wheel.
110
The front wheel should be in a
straight line with the rear wheel
or parallel.
NOTE: The front of the go-kart is wider than
the rear.
111
The measuring tape in the pic-
tures is for sight reference ONLY!
112
Adjust the passenger tie rod ac-
cordingly to align the wheel.
113
Hold the rod with a 10mm wrench
and loosen the outer jam nut
(standard thread).
114
Now, loosen the inner nut
(backwards thread).
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