TrailMaster MID XRX User manual

This operation manual is made for Go-kart models:
MID XRX MID XRS TBM80 GK80 GK196
MID GK-1 MID GK-2
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for off-road use only.
USA only:
It does not conform to Federal Motor Vehicle Safety Standards, and in regards to operation
on public streets, roads or highways is illegal.
MINIMUM
RECOMMENDED
OPERATOR AGE: 13+

CONLENTS
,
OWNER S MANUAL Page
PARTS MANUAL
1.FOREWORD 1
2.AFEW WORDSABOUT SAFETY 2
3.IMPORTANT SAFETY INFORMATION 3
4.SAFETY LABELS 5
5.ARE YOU READYTO DRIVE? 6
6.IS YOUR VEHICLEREADY TODRIVE? 9
7.SAFE DRIVING PRECAUTIONS 10
8.REAY TO DVIVE 11
9.P.D.I 13
10.SPECIFICATIONS 14
11.OPERATION 16
12.SERVICE INSTRUCTIONS 22
13.REPAIR 26
14.MAINTENANCE TABLE 28
15.ELETRICITY PRINCIPLE DIAGRAM 29
CRANKCASE ASSY 26
CYLINDER HEADASSY 27
INTAKE EXHAUSTMECHANISM ASSY 28
BRANCE FLYINGWHEEL 29
CENTRIFUGAL ADJUSTMENTASSY 30
STARTING SETS 31
AIR CLEANER ASSY 32
SWITCH ASSY,IGNITION 33
CARBURETOR SYSTEMASSY 35
STEERING SHAFTASSY 37
SUSPENSION ARM ASSY 39
REAR SWINGARM 40
REAR HOUSING 41
CLUTCH ASSY 43
WIRE HARNESS/ELECTRICAL/SEAT/ENGINE 45
WARNING STICKERS ASSY 46

Thank you for purchasing our TrailMaster Go-kart MID. We hope you will enjoy it.
Before you start to operate the TrailMaster Go-kart MID, please read through this
Owner's Manualcarefully asit containsimportant safety and maintenanceinformation.
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
TrailMaster Go-kart MID accordingly. Preventive maintenance is extremely important
to thelongevity ofyour TrailMaster Go-kart MID.
Beginners should seek instructions from your dealer or qualified instructors before
and during initial use of the TrailMaster Go-kart MID. It is also recommended to
practice in a large open area and familiar with operations of this TrailMaster Go-kart
MID.
We hope you will have a pleasant experience with our products and thanks again for
choosing ourTrailMaster Go-kart MID.
1
.
FOREWORD

In order to keep everyone safe, you must take responsibility for the safe operation of your
TrailMaster Go-kart MID.
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 TrailMaster Go-kart MID. You must use your own good judgment.
You will find important safety information in a variety of forms, including:
Safety Labels - On the TrailMaster Go-kart MID.
Safety Messages -Preceeded by a safety alert symbol and one of two signal words:
WARNING, or CAUTION.
These signal words mean:
A FEW WORDS ABOLLT SAFETY
WARNING
2
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 TrailMaster Go-kart MID correctly and safely.
This entire manual is filled with important safety information, please read it carefully.

IMPORTANT SAFETY INFORMATION
3
You TrailMaster Go-kart MID will provide you with many years of service and pleasure.
The Safety Information will provide you to take responsibility for your own safety and
understand the challenges you can meet while driving.
There is much that you can do to protect yourself while operating your TrailMaster Go-
kart MID. You'll find many helpful recommendations throughout this manual. The ollowing
are a few points we consider most important for safety protection.
Follow the Age Recommendation
Adult supervision should be present for all people under the age of 13.
Always Wear a Helmet
Always wear an approved motorcycle helmet. We also recommend that you wear eye
protection, sturdy boots, gloves, and other protective gear.
Your TrailMaster Go-kart MID is designed and manufactured for off-road use only. The
tires are not made for pavement, and the TrailMaster Go-kart MID does not have turn
signals and other features required for use on public roads. If you need to cross a paved or
public road, please get off and walk with your Go-kart across.
Take Time to Learn & Practice
Even if you have driven other Go-karts, take time to become familiar with how this
TrailMaster Go-kart MID works and handles. Practice in a safe area until you build your
skills and get accustomed to this Go-kart's size and weight.
Because many accidents involve inexperienced or untrained drivers, we urge all drivers to
take a training course approved by the Go-kart Safety Institute. Check with your dealer for
more information on training courses.
Drive Off-Road Only

IMPORTANT SAFETY INFORMATION
4
Be Alert for Off-road Hazards
Drive within your limits
Pushing limits is another major cause of TrailMaster Go-kart MID 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.
Don't drink and drive
Do not drive your TrailMaster Go-kart MID after drinking. Even one drink can reduce
your ability to respond to changing conditions, and your reaction 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 TrailMaster Go-kart MID at night
The exhaust from the engine contains a tasteless, odorless and poisonous gas called
carbon monoxide.
Keep away from moving parts of the TrailMaster Go-kart MID
The operator of the TrailMaster Go-kart MID should never place their hands or other parts
of their body near any moving part of the TrailMaster Go-kart MID. Failure to adhere to this
warning will cause physical harm to your body.
Skidding or Sliding
The terrain surface can be a major 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 driving carefully.
The terrain can present a variety of challenges when you drive off-road. Continually judge
the terrain for unexpected turns, drop-offs, rocks, ruts and other hazards. Always keep your
speed low enough to allow time to see and react to hazards.
Dark vision 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 TrailMaster Go-kart MID indoors

SAFETY LABELS
5
This section presents some of most important information and recommendations to help
you driving your TrailMaster Go-kart MID more safely. Please take some time to read this
section.
TrailMaster Go-kart
MID
The safety labels should be considered as permanent parts of the
becomes. If a safety label becomes hard to read, please contact your dealer for
replacement.
WARNING
3031112
Moving parts
can crush and
cut.
Keep hands
clear.
Do not operate
with guard
removed.
!
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.
WARNING
NORIDING
WARNING
NO LONG
HAIR
ALL HAIR MUSTBE TIED UP AND
SECURED AT OR ABOVE SHOULDER LENGTH.
ALL LOOSE CLOTHING MUST BE SECURED.
ALL NECKLACES AND SCARNES MUST BE
SECURED.
WARNING
303115
THIS GO-KAPT GAN BE HAZARDOUS TO OPERATE
ifdriven carelessly.
INJURLES can resulf If you do not follow these
Instructions:
READ OWNER SMANUALA NDA LLL ABELSB EFORE
YOU OPER ATE THIS GO-KART.
NEVER OPERATE THIS GO-KART WITHOUT PROPER
INSTRUCTIONS.Beglnners require mature supervision.
NEVER OPERATE THIS GO-KART ON PUBLIC ROADS.
It is intended off-road use only.
NEVER OPERATE THIS GO-KART AT EXCESSLVE SPEEDS.
NEVER ATTEMPT WHEELIES,JUMPS,OR OTHER STUNTS..
Under
13
Age
This vehicle is not to be operated by anyone
under13 years of age. A speed reduction kit is
available for this vehicle.
WARNING

ARE YOU READY TO DRIVE?
6
Before each drive, you need to make sure that you and your Go-kart are ready to drive. To help
you be prepared, this section discusses how to evaluate your driving readiness, what items you
should check on your TrailMaster Go-kart MID, and which adjustments would be done for your
comfort, convenience, and safety.
Before you drive this TrailMaster Go-kart MID for this first time, we urge you to:
Read this owner's manual and the labels on your TrailMaster Go-kart MID 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 TrailMaster Go-kart MID.
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 consume any alcohol or drug.
Protective Apparel
For your safety, we strongly recommend that you always wear a D.O.T. approved motorcycle
helmet, eye protection, boots, gloves, long pants, and long-sleeved shirt or jacket whenever you
drive.
Although complete protection is not possible, wearing proper gear can reduce the chance of injury
by an accident.
Helmets and Eyes Protection
The following suggestions will help you choose the proper protective gear.
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.
WARNING

WARNING
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.
ARE YOU READY TO DRIVE?
WARNING
Operating this kart without your seat belt could cause you to be thrown
from the kart, causing serious injury or death.
WARNING
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.
7
Additional Driving Gear
In addition to a helmet and eye protection, we also recommend:
Sturdy off-road motorcycle boots to help protecting your feet, ankles, and lower legs.
Off-road motorcycle gloves to help protecting 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 skill is an on-going process. Even if you have driven other karts before,
please take time to become familiar with how this kart works and handles. Practice driving this
TrailMaster Go-kart MID in a safe area to develop your skills. Do not drive on rough terrain until
you get accustomed 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 it's 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.
IS YOUR VEHICLE READY TO DRIVE?
Before each drive, it is important to inspect your kart and make sure any problems you find are
corrected. Pre-drive inspection is a must, not only for safety, due to a break down or even a flat tire,
can be a major inconvenience.
If your kart has 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.

SAFE DRIVING PRECAUTIONS
WARNING
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 sidwalks, driveways, parks
lots and streets.
WARNING
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.
WARNING
Removing your handsfrom the steering wheel or feet from the foot controls during
operation can reduceyour ability to control the kart or could causeyou to lose your
balance and fall off the kart.
Always keep both hands onthe steering wheel and both feet on the footcontrols
of your kartduring operation.
8
Off-Road Use Only
Your kart and its tires are designed and manufactured for off-road use only, not for use on paved
surfaces. Driving on paved surfaces can affect the TrailMaster Go-kart MID handling and control.
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 may have difficulty seeing and avoiding you, which could lead to a
collision.
Keep Hands and Feet on Controls
When driving your kart, always keep both hands on the steering wheel and both feet on the foot
pedals. It is important to maintain your balance and to control the kart. Removing hands or feet
away from the controls can reduce your ability to react and control the kart.

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.
WARNING
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.
WARNING
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.
READY TO DORIVE?
WARNING
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
Control Speed
Driving at excessive speed 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.
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 react in time if the obstructions like
hidden rocks, bumps, or holes are seen too late.)
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 TrailMaster Go-kart MID in a safe and reasonable manner. When
driving, always keep all four wheels on the ground.

P.D.I.
10
A. Install rear shocks and tighten the nuts.
B. Install rod end, tie rod, tighten the castle nut and insert the cotter pin.
C. Install ball head 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 custom bar cage as in picture.
H. Install C.B.C rear custom bar cage, 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.
Fill fuel tank with unleaded gasoline, and turn on the ignition switch to start the engine.

11
SPECIFICATIONS
DIMENSIONS
Overall Length 58.5 in.(1700mm)
Overall Width 36 in.(1100mm)
Overall Height 43 in.(1300mm)
Wheelbase 41.7 in.(1230mm)
Front Track 32 in.(930mm)
Rear Track 28 in.(850mm)
Ground Clearance 3.5 in.(70mm)
ENGINE
Type Single, Forced air-cooled, 4-Stroke
Engine capacity 168cc
Bore x Stroke 2.67in x 2.1in
Displacement 196ml
Corrected compression ratio 8:1
Carburetor RX
Output Power 6.3 HP at 3600RPM
Maximum Torque 9.6 lb ft at 2500RPM
Starting Electric / Pull start backup
Ignition C.D.I
Lubrication Force & Splash
Transmission Automatic (C.V.T system)
Spark Plug F7RTC
Plug gap 0.7-0.8mm
Fuel Type Rq 90
Lubricate oil SAE 10W/30
CAPACITIES
Maximum load Double Seats / 400lbs
Fuel tank 0.95gal
Engine oil 3Oz
Starting <5s
Battery 12V 9Ah
Fuse 10A
Brake Track <7m@10miles/h
Topspeed 25 mph (or limited as customers require)

12
CHASSIS
Rear brake Disc brake
Front tire 16 x 6-8
Rear tire 16 x 7-8
Front Suspension Independent Dual A-Arm
Rear Suspension Swing Arm / Double Oil Damped Shock
Restraint System Dual 4-point Harness
TIRE PRESSURE
Front 7~9psi
Rear 7~9psi
WEIGHT
Net Weight 150Kg
PACKING DIMENSIONS
Dimensions 66.9in x 43.3in x 25.9in
N.W 330lbs
G.W 385lbs
Loading quantity 54pcs / 1 x 40ft HQ
SPECIFICATIONS

OPERATION
NOTICE
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.
13
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 operator must 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 increases
above idle, the clutch is engaged automatically and moves the vehicle forward. To disengage the
clutch at any time, allow the throttle to return to the idle position. (See Fig. 1)
b. Brake
The brake is the left foot pedal (See Fig.1). Applying pressure to the pedal draws the brake caliper
around the brake disc at the rear wheel and slows stop the kart.
c. Start Engine
Insert the key into key-switch, turn
the key clockwise, release the key
when the engine starts. The engine will
warm within 5 minutes and the engine
choke will close automatically and run
at normal RPM (Warning: Do not crank
starter more than 5 seconds at one time).
Remark: the TrailMaster Go-kart
MID basic version XRS has also
variant model without electric start
function. Only pull start.
BRAK PEDALBRAK PEDAL THROTTLE PEDAL
IGNITION START SWITCH
ENGINE STOP BUTTON
LIGHT SWITCH
HORN BUTTON
Figure 1 front panel
d. Engine stop button
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 until the engine has
been shut down.

B. Pre-Drive Inspection
a) Check the engine oil level is between the bottom of the dipstick and the 0 mark.
b) Check for leaks. Add oil if required.
c) Check the Fuel Level. Add fuel as necessary and do not overfill.
d) Check for leaks. Ensure the fuel filler cap is securely fastened.
e) 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.
f) Check the tires. Check their condition for damage or excessive wear and pressure. The
pressure on the front and rear tires is 7-9 psi respectively.
g) Check the drive chain. Check its condition and tension. Lubricate if necessary.
h) Check the throttle cable; check its smooth operation. Ensure the throttle can return back to
idle and move smoothly without sticking by releasing the throttle pedal.
i) 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.
j) Check all nuts, bolts, and fasteners.
k) 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.
l) Check the Brush Guard. Ensure all C.B.C bars are in place before operating the kart.
m) Check the Lights. Check the headlights, brake light and tail light are all working.
n) Check the steering system. Check that the steering wheel moves freely in both directions but
without any unusual looseness.
o) Check all Cable Housings. Check these for wear and the fitting for any looseness.
p)
Check the underbody and exhaust system. Remove all dirt, vegetation and mud and check any
damage due to impact with rocks or uneven terrain.
q) Check the air cleaner housing drain tube. Check the deposits in the drain tube. If necessary,
check the tube and air cleaner housing.
r) Check leaks and loose parts. Walk around your kart and look for anything that appears
unusual, such as a leak or loose cable.
s) Check the parking brake. Make sure the kart does not move forward or backward when the
parking brake is applied.
OPERATION
WARNING
Perform this pre-driveinspection everyday before driving the vehicle.If not
performed, serious damage to the vehicle or personal injury may result.
14

OPERATION
STEERING WHEEL
HORN NUITS
TANK COMP.FUEL
FUEL TANK CAP
15
Figure 2 Component locations