TrailMaster MINI XRS Manual

TrailMaster MINI XRS
Set up instruction
Version: 2.0
2011/11/28
This set up instruction guides our customer to set up the go kart TrailMaster MINI XRS step
by step to ensure a correct assembly for safe driving.

MINI XRS Set up instruction
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1. Check the components after opening the box.
1.1 One sport steering wheel (pic.1)
Pic.1
1.2.1 one standard parts package, one manual, one flag, four hub coves,
plastic fixing bolt and nut for flag, 5 cable bundles and one steering bolt
cover.
1.2.2 In the standard parts package: 14 bolts M8x45, 2 cotter pins 3X40,
2 cotter pins 2.5X25, 2 castle nuts, 20 R-washers, 6 self-locking nuts M8,
4 M8x35 bolts, 1 M6x30 bolt, 1 M6x12 bolt, 1 M6x16 bolt and 2
self-locking nuts M6 (pic.2)
Pic.2

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1.3 Two bar cages (pic. 3)
Pic.3
1.4 One top cross bar (Pic.4)
Pic.4
1.5 Two side bars for left and right side with tube seats (Pic. 5)
Pic.5

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1.6 One top cross bar with tube seats (Pic.6)
Pic.6
1.7 front wheels left and right; rear wheels left and right (pic.7)
Pic.7
1.8 1 stand exhaust guard and bracket (Pic.8)
Pic.8

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2. Assembly
2.1 Assemble the rear shocks (pic.9): 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 22-29NM torque to fix the shocks attached the frame. (Note: 1NM =
0.74 lb ft)
Pic.9
2.2 Assemble the rear wheels (pic.10): Take off the nut M14x1.5 and Φ
14 washer from the rear axle. Raise up the tail part and set up the rear
wheel onto the rear axle, screw the washer and nut screw tightly with
83-98NM, then open the cotter pin 3X40 for fixing, cover the hub cover.
Pic.10
2.3 Assemble front lower suspension arm (Pic.11): lift the front part of go

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kart onto a table. Take down the nut and washer from the spindle and strut
support, insert the ball head into the mount position of lower suspension
arm (square part of ball head is placed to the square hole of suspension
arm), put on the washer and nut. Screw on the bolt with torque 37-44NM.
At last open the cotter pin 2X20 for fixing.
Pic.11
2.4 Assemble the front wheel (pic.12): Take off the nut M12x1.25 and Φ
12 washer from the rear axle. Raise up the front part and set up the rear
wheel onto the rear axle, screw the washer and nut screw tightly with
55-62NM, cover the hub cover.
Pic.12

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2.5 Assemble the long bar cages (Pic.13): put two sides of long bar cages
onto the connection rods on frame fixing with bolt M8x45, R-washer and
M8 nut. Tighten the bolts.
Pic.13
2.6 Assemble the side bar (pic.14): Put one side of side bar attaching the
long bar cage, connect the side bar and the long bar cage together with
bolt M8x45, R-washer, screw the bolts 3 turns. Connect another side of
side bar onto the connection rod of frame with R-washer, bolt M8x45 and
bolt. Screw on all the bolts tightly.
Pic.14

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2.7 Assemble the cross bar (Pic.15): Connect the cross bar with two long
bar cages with bolt M8X50 and R-washer, do not tightening the bolts at
this step.
Pic.15
2.8 Assemble the roof rack bars (pic.16): fix the rear cross bar with long
bar cage together using bolt M8x50 and R-washer.
Pic.16
2.9 Screw on the bolts from step 2.5 to 2.8 with torque 22-29NM.
2.10 Assemble the yellow flag and flagpole: use the plastic bolt and nut to
fix the flagpole on the rear cargo rack.
2.11 Assemble the steering wheel: Check the front wheel is at the straight
position. Take down the bolts on steering shaft, put the steering wheel
correctly onto the steering shaft (as shown in pic.17). Screw the bolts

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with 11-16NM torque. Cover the steering bolt cover.
Pic.17
2.12 Assemble the stand exhaust guard and bracket (Pic.18): place the
stand exhaust guard on the mounting place of engine, insert the M6x12
bolt from back to front and screw with a M6 self-locking nut. Fix the left
side of stand exhaust guard with M6x12 bolt as shown in Pic.18, fix the
bracket on the cylinder head of engine. Screw tightly all the parts with
M6x16 bolts and M6 self-locking nuts.
Pic.18

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3. Chain Adjustment
In order to package the go-kart better, the chain adjustor is
loosen by packaging for shipment. The customer should adjust
the chain before driving. In this instruction the process of chain
adjustment is detailed introduced:
A. For the new purchased go-kart, the customer should only
tighten the nut of chain adjustor to adjust the rear chain. The
initial adjustment of chain has been carried out before delivery.
The tension of chain adjustment is required between 15-20mm.
B. If after step. 1 tightening the nut of chain adjustor the
chain is still too loose or too tight, another nut at the underpart
of chain adjustor must be adjusted accordingly.

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C. After the go-kart has been driven for a while, the drive
chain on clutch will be loosen and should be readjusted. At first,
four bolts fixing the engine on mount plate have to be loosen
until the engine can be moved. Then, adjust the chain adjusting
bolt at the front side of engine to tighten the chain to an
appropriate tension. At last, after adjusting screw the four bolts
tightly.

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