TrailMaster MINI 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 bolts and nuts at lower front A-
arms
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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
Lay out all hardware on a clean work
bench. Take inventory per hardware
list.
11
Locate one of the long cage bars.
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12
Place bar on front pin above head-
light.
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15
Install with washer into front of bar
from the outside.
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13
Place rear of bar onto pin at rear be-
hind seat.
14
Locate 2 long bolts, 4 nuts & 8
chrome cup washers.
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16
It may be necessary to align the hole
in the bar with a screwdriver.
17
Install a second cup washer and the
nut.
NOTE: DO NOT TIGHTEN AT THIS TIME.
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18
Install bolt, washers and nut at rear of
bar.
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22
Place the side bar onto the passen-
ger’s side of the go-kart.
23
Turn the plastic cap with a pair of pli-
ers to align the side bar to the top
bar.
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19
Repeat steps 16-19 for the other top
bar.
20
Locate the passenger side bar.
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21
Locate 4 large bolts, 6 cup washers
and 2 nuts.
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24
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.
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25
Install the top bolt & washer first.
Start the threads but do not tighten.
26
Now, install the bottom bolt and
washer from the front.
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27
Install the second washer and nut on
the bottom bolt.
NOTE: DO NOT TIGHTEN THE HARDWARE.
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28
Repeat steps 20-27 for the driver’s
side bar.
29
Locate the top bar weldment assem-
bly.
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30
Locate 4 large bolts and 4 chrome
cupped washers.
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31
Install the top bar assembly.
32
Start each of the 4 bolts with cupped
washer into the threads of the top bar.
NOTE: DO NOT TIGHTEN HARDWARE .
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34
Locate 2 long bolts and 2 chrome
cupped washers.
35
Install the short bar behind the seats.
Start the bolts with washers into the
threads.
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33
Locate the short rear bar.
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36
Tighten ALL of the bar bolts previ-
ously installed with a 10mm & 12mm
wrenches.
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37
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 46.
38
Locate 4 long bolts and nuts and fuel
hose clamp.
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40
Install the 4 bolts and nuts into the
tank.
41
Tighten with a 10mm & 12mm
wrenches.
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39
Place the fuel tank onto the rear rack
with decal to the rear.
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42
Locate the end of the fuel hose on top
of the engine.
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43
Place the fuel hose clamp onto the
hose and push the hose onto the fuel
filter that’s already attached to the fuel tank.
44
Using pliers, place the fuel hose
clamp on the filter approximately
1/4” from the end of the hose.
.
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45
Turn fuel valve to ‘ON’ position.
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46
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.
47
Discard this bar.
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48
Locate one (1) shock.
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49
Place the top shock eye into the
bracket with the spring up. Reinstall
bolt and washer that was removed in Step 46.
50
Lift up on the rear rack and align bot-
tom shock eyelet with the bracket on
the rear swing arm.
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52
Tighten top and bottom shock bolts
with wrenches.
53
Repeat Steps 48-52 for the driver’s
side rear shock.
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51
Install bottom shock bolt and nut.
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54
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.
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55
Place the battery pad into battery tray
located behind the passenger’s seat.
56
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.
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58
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.
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57
Place gray plastic cover over bat-
tery.
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59
Locate the set bolt on the sprocket
hub and tighten securely.
60
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.
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64
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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62
Place the largest washer and castle
nut onto the axle.
63
Tighten the castle nut securely and
align the holes in the axle with the
nut.
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61
Place the wheel onto the rear axle.
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65
Install rubber hubcap over axle nut.
NOTE: Repeat Steps 60-65 for the driver’s
side rear wheel.
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66
Lift front of go-kart and support with
jack stands.
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67
Locate passenger’s side top spindle
nut and remove cotter pin.
NOTE: Save cotter pin.
68
Locate passenger’s side bottom spin-
dle nut and remove cotter pin.
NOTE: Save cotter pin.
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69
Tighten both nuts securely with a
17mm wrench.
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70
Make sure the hole in the spindle
lines up with the castle nut.
71
Reinstall cotter pins. Bend and cut off
excess. Repeat Steps 67-71 on the
driver’s side spindle.
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72
Locate outer steering joints and tight-
en the nut securely using a 12mm
socket on the nut and a 12mm wrench on the
top.
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73
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.
74
Locate 2 castle nuts, 2 washers and 2
cotter pins.
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75
Install cotter pin and bend. Cut off
excess cotter pin. Repeat Steps 72-75
on the driver’s side.
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76
Check tire pressure in all 4 tires. Set
to 10 PSI. You will need a low pres-
sure gauge to check the tire pressure.
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77
Locate the throttle stop and tighten
the jam nut securely.
NOTE: Lowering this bolt will restrict the top
speed of the go-kart.
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78
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.
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79
Locate the three (3) small bolts and
nuts.
80
Locate the steering wheel.
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81
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.
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82
Tighten bolts securely with two (2)
10mm wrenches.
83
Install the plastic steering wheel cap
by snapping it into place.
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84
If the steering wheel is not straight
when the front wheels are pointing
straight, locate the plastic gearcase on the
steering box.
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86
Make sure the front wheels are
straight ahead and determine which
way the steering wheel needs to be turned to
align correctly.
85
Remove plastic cap from the bot-
tom of the plastic case with a screw-
driver.
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87
Remove steering shaft nut with
17mm socket.
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88
Pull steering wheel and shaft out of
the gear. You may need to bump the
steering wheel gently.
89
Hold the gear in place with your
finger.
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90
Turn the steering wheel straight and
push the shaft back down into the
gear.
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91
Reinstall the nut securely. Reinstall
the plastic cap by simply pushing it
into place.
92
Now, it’s time to align the steering.
Turn the steering wheel to straight
ahead.
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93
Stand approximately 10 feet in front
of the go-kart and look at the front
passenger wheel in relationship to the rear
passenger wheel.
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96
Adjust the passenger tie rod ac-
cordingly to align the wheel.
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94
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.
95
The measuring tape in the pictures
is for sight reference ONLY!
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97
Hold the rod with a 10mm wrench
and loosen the outer jam nut
(standard thread).
98
Now, loosen the inner nut
(backwards thread).
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99
Now, adjust the wheel in or out by
turning the rod.
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100
Hold the rod with a wrench and
tighten the jam nuts securely.
101
Repeat Steps 92-100 for the driv-
er’s side.
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102
For final front end alignment pro-
cedure, the front wheels should
turn toward each other approximately 1/4” to
1/2”.
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103
Measure across the front wheels
that the front of the tires and at the
rear of the tires and adjust accordingly ac-
cording to the procedures in Steps 92-100.
104
Locate the foam padding and
place it on the top outside bars of
the go-kart.
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105
Remove air filter nut and cover.
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106
Tighten inner air filter nut secure-
ly with fingers. Reinstall cover
and nut.
107
Locate the shift cam. Tighten both
cables with a 12mm wrench.
NOTE: This is ONLY on the Mini XRX-R
108
Cut and remove all strings on can-
opy top and pad covers and dis-
pose.
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109
You’re almost done! Just a few
pre-drive items to inspect, and
you will be ready to ride your new go-kart.
110
Locate oil dipstick on front of en-
gine behind the driver’s seat.
With the go-kart sitting on level ground, the
oil level should be to the top of the threads. If
not, fill with 10W30 oil.
111
Fill fuel tank 3/4 full with premi-
um high octane fuel.
NOTE: Follow all gasoline handling pre-
cautions and fuel can.
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112
It is highly recommended to use
a fuel additive or fuel stabilizer
such as Seafoam or Stabil. Follow manufactur-
er's instructions on the bottle.
113
If there is no passenger in the go-
kart, keep the seat belt buckled to
keep it from dragging the ground or from
being run over by the rear tire.
114
Make sure the fuel valve is on.
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