SPARE PARTS LIST www.gokartsdirect.co.nz
GO KART REGISTRATION
Front Connecting Arms L/H and R/H
Brake pads disc
Short tie rod
Chain drive sprocket
Long tie rod
Chain
Front wheel hub
Chain guard
Dust cap
Left hub chain
Steering wheel
Right hub brake
Steering column
Rear wheel hubs
Steering column with fittings
Axle bearings
Bottom plate
Bearing bracket
Steering Handle assy complete
Rear axle shaft drift
Throttle handle/ Brake handle
Rear axle shaft caged
Throttle cable
Petrol tank
Kill switch wiring
Fuel cap
MODEL NO:
Kill switch on/off
Exhaust
ENGINE NO:
Clutch (Centrifugal)
Air filter
(Imprinted in engine case behind seat)
Clutch spring
Ignition system
FRAME NO:
Carburetor
Front frame
(Located on rear frame near brake)
Shock absorber
Front bumper
COLOUR:
Pull start
Seat
Wheel rim drift go kart
Seat cover vinyl
Wheel rim caged go kart
Seat cover padded
Tyres drift
Seatbelt –Lap
You are now the proud owner of a Drift Go Kart.
Tyres caged
Harness seat belt (3 point)
Remember: This is a motorised vehicle and not a toy.
Drift tyres & rims complete
6.5 hp Engine centrifugal clutch
If instructions are not followed there is a possibility of
Hydraulic brake unit complete
6.5 hp Engine wet clutch
personal injury or equipment damage.
Hydraulic brake pads
NGK sparkplug—BPR5ES
Hydraulic brake bracket
Brake disc plate
( To be recorded at original date of purchase)
PURCHASER: Name & Address
DATE OF PURCHASE:
GO KART ID CODES:
CONGRATULATIONS..
2
15
IMPORTANT—PLEASE READ
CONDITIONS OF USE
SAFETY DISCLAIMER
All our karts are off road leisure go karts and as no safety
standards are available, driving is at your own risk.
Neither the manufacturer, Tonaro SA, sales agents or distributors are
liable for personal or other damage neither to participating or non participating persons. At delivery the owner takes full responsibility for the kart and
use of the kart.
The owner at time of purchase assumes all risks associated with the use of
the go kart and agrees to these terms of use.
Ensure that the person driving is of an age, size and has the necessary skills
and experience to drive the kart safely.
Ensure that the go kart is used in the appropriate environment and conditions present allow safe operating of the go kart to the driver and all non
drivers.
These go karts are not designed for jumping, racing, or performing any abrupt spin out manouevres.
They are not designed for steep or uneven terrain or for use on public roads.
Please use on safe terrain, which you are familiar with.
Failure to adhere to these warnings may result in accidents and serious
injury.
Thank you for Buying a Drift Go Kart
from Tonaro SA.
PLEASE read all instructions and manuals prior to
assembling go karts. PLEASE ensure you watch DVD
provided either on your computer or dvd player.
Please continue reading user manual so you understand
the go kart to ensure many years of safe and fun family
enjoyment.
Troubleshooting chart is located at the back of this manual.
See engine manual for engine maintenance and
inspection.
CAUTION
BEFORE USE: Please ensure you add engine oil to the engine
oil reservoir. These engines are four-stroke. You must also add oil to
the clutch reservoir. (see image below)
Engine oil capacity 600ml: Use Castrol GTX 20W50.The engine oil
reservoir is lower to the ground than the wet clutch reservoir and has
a small dipstick.
Clutch oil capacity 300ml: Recommended oil for clutch:
Castrol 4T 10W-40 These go karts have a wet clutch so require oil to
be added to clutch. The wet clutch unit is closest to the chain guard
and has the larger dipstick.
Drivers under 16 must do so only with the permission of their parents./
guardian. Younger children must be accompanied by an adult at all times.
Please refer to Drift 2 User Manual and Engine Owners Manual
supplied by manufacturer for additional information and troubleshooting.
Fig 1. Wet clutch reservoir Add 300ml oil
14
3
WARRANTY
PETROL: We recommend 95 unleaded. Do not overfill petrol tank.
1.
NEVER MIX FUEL and OIL.
2.
Please read manufacturers handbook and all instructions supplied by Tonaro SA before
assembling your go kart. Damage caused by failing to follow correct instructions will not be covered by warranty.
After assembling, please retighten all nuts and bolts and double check all parts are secure and
operating correctly.
If transporting your go kart, turn the fuel valve off to prevent spillage
and engine flooding.
Fig 2. Oil for Engine 600ml
Castrol GTX 20W50
3.
Before starting the engine, ensure correct type and quantity of engine oil and wet clutch oil
has been used.
4.
Oil the chain with chain lube before use and on a regular basis.Follow all maintenance instructions.
5.
6.
7.
Use unleaded 95 fuel only.
Once the engine has been started, allow to warm up for 2-3 minutes before test driving.
Do not allow the engine to operate at low revs as this may overheat and damage the clutch.
This warranty does not cover damage to the clutch through overheating. Over heating may be
caused by incorrect driving habits such as driving too slowly (revs too low), stop and go driving,
driving with the brake engaged and restricting the throttle. Driving in confined or limited areas will
damage the clutch.
8. Test ride and notify us immediately if there is a fault found with the go kart.
9. Do not attempt to do any repairs without contacting us first as this will void warranty.
10. We will replace parts that are damaged or defective.
11. Product warranty does not cover damage due to misuse or abuse.
12. The warranty is voided if the go kart is modified in any way, overloaded, leased or rented. Also
if improperly maintained, serviced or repaired. Any damage due to accidents, or through negligence, used to perform stunts, jumps or any other misuse.
13. Tonaro SA warrants this go kart to be free of manufacturers defect for a period of 60 days
from the original date of purchase.
Fig 3.Oil for Clutch 300ml
14. This warranty does not cover wearing of parts including but not limited to the clutch, tyres, and
Castrol 4T 10W-40
15. This warranty does not cover damage or failure due to inadequate maintenance or neglect by
brake pads.
owner.
16. This warranty does not cover physical damage or failure due to overloading, misuse or reckless operating behaviour.
17. This warranty is available to the original purchaser.
18. If there is a defect in workmanship or material during the warranty period, we will repair or
replace.
19. This warranty does not cover: normal wear and tear, damage caused by abuse or neglect,
WARNING: The exhaust becomes hot during operation and remains hot for a while after stopping the engine. Be careful not to touch
while it is hot. Ensure children are aware of this.
Please supervise to prevent severe burns.
4
overheating or overloading, corrosion, unauthorised modifications or alterations, damage caused
by incorrect fuel, oil or lack of it, consumables including tyres, spark plugs, bearings, brake pads,
clutch assembly, brake or throttle cables, air filter.
If the product requires repair/inspection by an approved/authorised dealer or mechanic, it is the
customer’s responsibility to deliver the product to the place of repair/inspection, and to arrange for
collection. If the repair/fault is not covered by warranty, the customer shall pay for all costs related
to the repair and inspection.
13
TROUBLESHOOTING GUIDE
PROBLEM
PLEASE NOTE:
POSSIBLE CAUSE ACTION/SOLUTION
Engine Stops and won’t 1.Bad coil assembly.
start
2.Air cleaner is dirty and
dusty.
Replace coil cap.
Go Kart moving or
creeping forward, or
wanting to take off
Check for kinks, Ensure the inner
wire cable is moving freely within
the black casing.
1.Throttle cable engaged.
Clean, shake all dust out.
Replace. Never run engine without
air cleaner.
Check the throttle lever is springing back to off position.
These Go Karts are not designed for 4WD Tracks, steep hills, rocky or
very uneven terrain. They are essentially a grass drift go kart. Damage
may occur when used in unsuitable terrain & we hold no liability if the
go kart is not adequately maintained or used inappropriately.
Please do not tow with these karts as clutch may overheat and cause
damage.
Running the karts for long periods of time at low revs can also cause
damage to the clutch.
Although the karts can be easily governed for younger children or
inexperienced riders, this should only be a temporary adjustment.
Please ensure all bolts/nuts including pre-assembled parts
are tight and secure before use.
Check on a regular basis, especially during the running in
period as they can vibrate loose.
We recommend lock tight for extra security especially when
go kart is used on uneven terrain.
Fig 4.Ultimate Drifta Go Kart 200cc
Roll Cage
Steering assembly
Seatbelt attachment
Rear frame
Front frame
Mid Frame
Front tie rods
12
Leg & foot protector bars
5
ASSEMBLY INSTRUCTIONS
Please view DVD for detailed instruction.
We have made a list of some handy tips to assist you with
assembling your Go Kart. .
TROUBLESHOOTING GUIDE
PROBLEM
POSSIBLE CAUSE
ACTION/SOLUTION
Engine Stalls
1.Spark Plug fouled/carbon
deposition.
Clean spark plug.
Engine backfires
1.
Firstly, connect the front frame with the middle frame. Bolt securely.
2.
Connect the rear frame and suspension springs to main frame. Connect rear
Running Poorly
frame loosely as later you will need to bolt the seatbelt here.
Hard to Start
We recommend using lock tight as the nuts can become loose over time with
Cuts Off
3.
the vibration. Regularly check and tighten nuts and bolts.
4.
Check pre-assembled nuts and bolts as these have been found to be loose. It is
the buyers responsibility to check these are all secure before using the go karts.
5.
2. Fuel too low.
Install a new spark plug. Recommend: BPR5ES.
3.Make sure kill switch is not
engaged.
Fill fuel tank: min 1/3. Do not overfill. Check fuel switch is on.
4. Check choke to see if it is
open. Too much choke will
flood engine.
If motor is warm you will not need
choke.
5. Fuel line/ hose.
Connect steering column and fully extend to the highest position Tighten collar
clamps using larger allen key provided.
6.
7.
Make sure fuel line has no kink re-
Connect hydraulic brake handle to left steering. Use smaller allen key provided
to tighten handle bracket. (Fig.8) Keep cable on inner side of the outside frame
& between the wishbone below steering. Make sure you remove small black
Chain Falls Off
1.Chain Sprockets not
aligned.
plastic tongue on the brake handle. Use a pair of nose pliers to remove this.
2.Chain too loose.
Release throttle cable & on/off wiring cable on steering. Run through wishbone
3.Excessive chain wear or
stretch.
of steering with brake cable. Run cables along brake side of go kart; keep on
the inner edge of frame. (Fig.5)
8.
9.
Check spark plug is not wet from
the petrol flooding the plug. You
may need to dry the plug out or
replace.
Align Sprockets. Check sprocket on
clutch and bolt holding clutch onto
shaft.
Adjust chain tension. Motor may
need sliding back on adjustable
mount.
Replace chain.
Connect the on/off switch wiring running from steering to the earth on the petrol
tank. (Fig.6)
Difficulty Braking
1.Brake pads worn out.
The air filter needs to be removed before attaching throttle cable to lever on
Making Grinding noise
2.Hydraulic brake fluid low.
Kill switch not working
1.Kill switch wire plug in con- Check connection. Push together.
nector separated at the enRe install or tighten screw holding
gine.
wire end to engine case.
2.Wire end terminal has
come loose from the engine.
Replace brake pads.
motor. Undo both wing nuts to remove unit. Run throttle cable to lever on back
of motor. Remove small screw on bolt. Carefully insert cable wire through hole.
Replace screw & tighten screw to hold cable wire in place. Be careful not to
damage wire inner cable as this needs to move freely. (Fig.7)
10.
Use cable ties to neatly tie to frame. Make sure all cables are free of acute angles & operate freely.
11.
Roll cage assembly:
12.
Unwrap all framing, extra bolts and padding. Place bolts, nuts in a neat pile.
6
11
MAINTENANCE PROCEDURES
1.
Please also refer to and follow manufacturers instructions.
2.
Please refer to engine manual for engine maintenance and inspection.
3.
After use, clean/ wash the go kart and regularly use WD40 or CRC.
4.
This will enable you to examine your kart for any potential problems
or adjustments that need to be made.
13.
Place back frame on. Bolt
on loosely as this is where one point of the safety
harness will be attached at the end of assembly.
14.
Position left and right front upright bars and connecting bar between the two
onto front frame.
15.
Line up holes and place bolts, washer, attach bolts loosely.
16.
Add remaining frame and connect to back frame. Bolt and tighten all bolts.
17.
Double check all bolts on the roll cage are tight and attached to main frame.
18.
Wrap padding around roll cage and cable tie in place. Cover with sun cover.
19.
Place seat on and attach harness seat belt to main frame.
20.
Ensure tyre pressure is at 18 – 20 psi in all tyres. Do not let down. This may
5.
Clean air filter regularly from dust.
6.
Keep chain lubed. Spray with chain oil regularly.
7.
Lubricate wheel bearings and moving parts regularly.
8.
To drain oil, there is a sump bolt at the back and under the motor.
9.
Do not allow the engine to operate at low revs for long periods as this
Recommended Oil: Castrol 4T 10W-40(part synthetic based). If insufficient oil
may over heat and damage the clutch.
is added the clutch will be damaged.
10.
Ensure wet clutch contains sufficient oil or else damage will occur.
11.
We recommend NGK sparkplugs BPR5ES or BPR6ES
12.
Please take care of your go kart.
result in the rims digging in to the ground when cornering, and the kart rolling.
21.
Fill engine with approximately 600ml oil 20W50 or 10W40. Fill from behind the
seat
22.
Fill Wet Clutch with correct type and amount of oil .Oil Capacity 300ml.
23.
Fill with 95 unleaded petrol.
24.
To Start – Ensure Fuel lever on.
25.
Set choke to on position. Once started move choke into run (front) position .
When starting go kart for the first time it may be necessary to pull the starter
handle 4-5 times. Do not allow pull start to snap back, Return it gently to
prevent damage to the starter.
26.
After engine is started, let it warm up for 2-3 minutes before riding.
27.
Please take the time to ensure the go kart has been assembled correctly, and
all controls are operating correctly.
Please view DVD prior to assembling and using your go kart. This will ensure
you have assembled your go kart correctly and added correct amount of oil to
the engine and wet clutch unit.
10
7
SAFETY RECOMMENDATIONS
PLEASE FOLLOW THESE INSTRUCTIONS
Fig 6. On/off switch wiring connected
to earth below petrol tank
Fig 5. Brake & throttle cables on
steering assembly.
Fig 7. Position of Throttle cable on
motor. Remove air filter to attach.
Fig.8 Hydraulic brake clamp attachment to
steering wheel. Use allen key to tighten.
1.
Spend time and explain carefully to young children and inexperienced riders how to operate go karts.
2.
Drivers under 16 years of age must only operate the go karts with
the permission of their parents/guardian.
3.
Younger children should be accompanied by an adult at all times.
This applies to participating and non-participating persons.
4.
Children under 16 years of age must always be closely and actively
supervised.
5.
Never permit anyone to operate the go kart without proper instructions.
6.
Ensure seatbelts and safety helmets are ALWAYS worn.
7.
Explain clearly use of the throttle and brake handle, and the kill
switch.
8.
Always make a pre-operation inspection before you start the engine.
This is essential and may prevent an accident or equipment damage. It
is advised to place the rear of the kart on blocks so the wheels spin
freely to enable you to check controls adequately.
9.
Once the engine has been started, go over all controls and ensure
they are operating effectively and make adjustments accordingly. Allow
engine to warm up for up to 2 or 3 minutes before riding to help prevent
spark plug fouling up.
10.
Check brake and throttle cables are adjusted correctly and there
are no kinks.
11.
Ensure ALL bolts and nuts are tight and secure. Check regularly.
12.
Check tyre pressure regularly. Recommended tyre pressure is1820 psi.
8
9