TrailMaster GO-KART 300 XRX PARTS MANUAL

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1 TrailMaster GO-KART 300 XRX PARTS MANUAL

2 FIG. 1 LEFT CRANKCASE COMP. LEFT CRANKCASE COMP LEFT CRANKCASE GEARBOX AIR TUBE TUBE CONNECTOR 1 BRAKE SHOE SHAFT (FOR DRUM BRAKE) 1 BRAKE CAM BUSHING (FOR DRUM BRAKE) FRONT SUSPENSION BUSHING SET GEARBOX OIL PLUG 1 BRAKE SHOE SHAFT STICK PLUG (FOR DISC BRAKE) AIR TUBE CLIP COPPER DRAIN WASHER OUTPUT SHAFT SEAL RING (RIGHT) REAR SUSPENSION BUSHING O-RING O-RING (FOR DRUM BRAKE) GB/T BALL BEARING /22-2RS BALL BEARING RNAF NEEDLE BEARING GB/T 5789 M8 16 BOLT M8X16 1 GB/T M NUT M10X1.25 (FOR DRUM BRAKE) 1

3 FIG. 2 RIGHT CRANKCASE COMP. RIGHT CRANKCASE COMP. FRONT SUSPENSION BUSHING SET RIGHT CRANKCASE FILTER OIL TUBE FILTER ELEMENT FILTER SPRING FILTER COVER O-RING 36X3.5 1

4 FIG. 3 PARTS OF PISTON, BRANCE, LEFT AND RIGHT CRANKCASE PARTS OF PISTON, BRANCE, LEFT AND RIGHT CRANKCASE BRANCE PISTON FIRST RING SECOND RING OIL RING ASSY PISTON PIN PISTON PIN CIRCLIP LEFT CRANKCASE COMP RIGHT CRANKCASE COMP WATER PUMP COMP PIN 10X DOUBLE-SCREW LONG BOLT CRANKCASE SEAL RING (LEFT) O-RING 33.5X GB/T16674 M6 70 BOLT M6X GB/T16674 M6 100 BOLT M6X100 5

5 FIG. 4 CYLINDER HEAD COMP. CYLINDER HEAD COMP INTAKE VALVE EXHAUST VALVE LOWER VALVE SPRING SEAT INSIDE VALVE SPRING OUTSIDE VALVE SPRING UPPER VALVE SPRING SEAT VALVE LOCKING CIRCLIP INTAKE ARM SHAFT EXHAUST ARM SHAFT ARM COMP CAM SHAFT CAM SHAFT CLAMP CLAMP OUTSIDE SPACER WATER TEMPERATURE INDUCTOR THERMOSTAT COMP THERMOSTAT COVER COMP SMALL WATER TUBE CIRCLIP SMALL WATER TUBE EXHAUST TUBE DOUBLE-SCREW BOLT 2

6 SMALL WATER CONNECTOR CYLINDER HEAD MECH. COMP EXHAUST TUBE SEAL GASKET OIL PRESSURE INDICATOR COPPER WASHER VALVE STEM OIL SEAL O-RING 9X GB/T BALL BEARING GB/T RS BALL BEARING GB/T5789 M6 12 BOLT M6X GB/T16674 M6 14 BOLT M6X GB/T16674 M6 20 BOLT M6X GB/T859-6 SPRING WASHER 2 (4-32) CAM SHAFT COMP. (INCL.11, 26, 27) 1 (4-33) CYLINDER HEAD COMP (EXCL. 17, 18, 22) 1

7 FIG. 5 CYLINDER / TIMING CHAIN DRIVER / VALVE COVER CYLINDER / TIMING CHAIN DRIVER / VALVE COVER TIMING DRIVEN SPROCKET SPROCKET COVER TIMING CHAIN CHAIN GUIDING PLATE TENSIONING PLATE TENSIONING PLATE SCREW TENSIONING DEVICE COMP INTAKE VALVE COVER EXHAUST VALVE COVER SPROCKET ROOM COVER AIR TUBE TUBE CIRCLIP SPROCKET ROOM COVER BREATHER PLATE BREATHER PIPE CONNECTOR 1

8 CYLINDER CYLINDER HEAD SPACER COMP PUMP DISCHARGE ELBOW SPARKING PLUG CYLINDER HEAD SCREW PLUG PIN 10X PIN 14X SPROCKET SPACER CYLINDER HEAD COPPER SPACER O-RING 14.5X O-RING 57.5X O-RING 94X O-RING 15.5X TENSIONING DEVICE SPACER CYLINDER PAPER SPACER GB/T16674 M6 16 BOLT M6X GB/T16674 M6 20 BOLT M6X GB/T16674 M6 120 BOLT M6X GB/T5786 M BOLT M10X1.25X25 1

9 FIG. 6 RIGHT COVER / MAGNETOR / ENGINE OIL PUMP / PUMP / ELECTRIC START DRIVING RIGHT COVER / MAGNETOR / ENGINE OIL PUMP / PUMP / ELECTRIC START DRIVING RIGHT COVER OIL GAUGE PEEP DOOR SCREW PLUG PUMP DRIVE SHAFT PUMP GEAR ELECTRIC START INTERMEDIATE GEAR COMP in FREE-WHEELING CLUTCH INNER RING in FREE-WHEELING CLUTCH OUTER RING COMP INTERMEDIATE GEAR SHAFT in MAGNETOR FLYING WHEEL in MAGNETOR STATOR 1

10 ENGINE OIL PUMP COMP CRANKCASE RIGHT SIDE NUT M16X PIN 10X COVER PLATE CRANKCASE RIGHT SIDE SPACER PUMP GEAR SPACER ELECTRIC START INTERMEDIATE SHAFT SPACER RIGHT COVER CAMSHAFT OIL SEAL O-RING 18X O-RING 14X RIGHT COVER PAPER SPACER ENGINE OIL PUMP PAPER SPACER GB/T 70.1 M5 12 SCREW M GB/T 70.1 M5 25 SCREW M GB/T 70.1 M8 18 SCREW M GB/T70.2 M6 25 SCREW M GB/T16674 M6 16 BOLT M GB/T16674 M6 40 BOLT M GB/T SNAP RING FOR SHAFT GB/T SNAP RING FOR SHAFT GB/T WOODRUFF KEY GB/T119 B3 22 PIN B3X22 1

11 FIG. 7 V-BELT DRIVING V-BELT DRIVING DRIVE COMP V BELT CLUTCH, DRIVEN PULLEY COMP CAMSHAFT LEFT SIDE BOLT M14X CAMSHAFT LEFT SIDE SPACER 1

12 FIG. 8 GEARBOX DRIVING GEARBOX DRIVING GEARBOX COVER INPUT SHAFT GEARBOX INTERMEDIATE GEAR SHAFT INTERMEDIATE GEAR SHAFT LARGE GEAR OUTPUT SHAFT OUTPUT GEAR PIN 10X GEARBOX INTERMEDIATE GEAR SHAFT SPACER OUTPUT SHAFT LEFT SIDE SPACER INPUT SHAFT LEFT SIDE OIL SEAL GEARBOX COVER PAPER SPACER GB/T BALL BEARING GB/T BALL BEARING RNAF NEEDLE BEARING GB/T16674 M8 40 BOLT M8X GB/T SNAP RING FOR SHAFT 25 1

13 FIG. 9 JINGLANG TYPE-RUYI LEFT COVER COMP. ( B) JINGLANG TYPE-RUYI LEFT COVER COMP. ( B) B LEFT COVER B FRONT COVER NET COVER COMP B LEFT COVER FRONT COVER COMP B RUYI TYPE COVER NAME PLATE B OUTTAKE COVER PLATE ST SCREW ST3.8X GB/T818 M6 20 SCREW M6X M5 16 SCREW M5X GB/T845 ST SCREW ST4.8X GB/T819.1 M5 10 SCREW M5X10 2

14 FIG. 10 INTAKE PIPE, CARBURETOR INTAKE PIPE, CARBURETOR CARBURETOR COMP INTAKE PIPE COMP INTAKE PIPE INSULATION SPACER O-RING 35X GB/T16674 M6 25 BOLT M6X GB/T M6 NUT M6 2

15 FIG. 11 ELECTRIC PARTS ELECTRIC PARTS STARTOR COMP IGNITOR IGNITION COIL RECTIFIER COMP. REGULATE 1

16 FIG. 12 WATER TANK, WATER TUBE AND CIRCLIP WATER TANK, WATER TUBE AND CIRCLIP WATER TANK COMP SUSPENSION BUSHING SET (WITH RUBBER BUSH INSTALLED IN WATER 2 TANK) FAN TEMPERATURE SWITCH FAN COMP WATER TUBE A WATER TUBE B WATER TUBE C WATER TUBE D WATER TANK COVER AFFUSION SEAT CIRCLIP CIRCLIP CIRCLIP GB/T16674 M6 14 BOLT M6X GB/T859-6 SPRING WASHER GB/T WASHER 3

17 FIG. 13 FRAME GROUP FRAME GROUP C.B.C.CROSS BAR,(B.R.S.) C.B.C.BAR CAGE(B.R.S.) C.B.C.CROSS BAR,RR(B.R.S.) C.B.C.BAR,L./R.SIDE(B.R.S.) FRAME COMP.(B.R.S.) R-WASHER N SOCKET BOLT M8*1.25*50 6

18 N SOCKET BOLT M8*1.25* WASHER φ TOW BALL LOCK WASHER φ BOLT M16* BOLT-WASHER M12*1.25* LOCKING FLANGE NUT M RUBER FOOT FLATE HEADLIGHT UNIT BOLT-WASHER M8*1.25* WINKER LIGHT ASSY.L.FR./R.RR WINKER LIGHT ASSY.R.FR./L.RR BANJO BOLT M10* BRAKE HOSE ASSY.L. 34" BRAKE HOSE ASSY.R. 43" BRAKE HOSE ASSY.RR. 80" G THROTTLE CABLE COMP BOLT M6* G PARKING BRAKE CABLE COMP TUBE SEAT φ TUBE SEAT φ HEADLIGHT BULB 35W/35W/12V FENDER,FR FRONT FENDER BRACKET,L BOLT M6* LOCKING FLANGE NUT M HEADLIGHT RUBBER MOUNT BOLT-WASHER M6* HORN,H HORN,L BOLT M5* REAR MIRROR MOUNT REAR VIEW MIRROR SPRING REAR MIRROR ASSY FRONT FENDER BRACKET,R FOAM PADDING FOAM PADDING A POSITION LIGHT BULB 3W 12V FRONT REFLECTOR WINKER BULB 10W 12V LOCKING FLANGE NUT M BOLT M6*12 2

19 SWAY BAR BRACE SWAY BAR BRACE BUSHING AWNING WIND GUIDE SCREW M6* RUBBER PIECE BOLT M6* DECORATION PLATE I DECORATION PLATE II PROTECTING PLATE BOLT M8* BOLT M6*20 4

20 FIG. 14 STEERING SHAFT ASSY. 27 STEERING SHAFT ASSY STEERING BOLT COVER SCREW M6* SPINDLE WHEEL STEERING WHEEL STEERING SHAFT NEEDLE NK SPECIAL WAHER φ20 1

21 CIRCLIP φ BOLT M8* LOCK WASHER φ STEERING KNUCKLE STEERING GEAR BOLT-WASHER M8*1.25* ROUND NUT M16* STEERING GEAR45 DEGREE ANGLE NUT M BALL JIONT DUST COVER TIE ROD ROD END FLAT WASHER φ LOCK WSAHER φ CASTLE NUT φ COTTER PIN φ2* STEERING KNUCKLE DUST COVER STEERING GEAR BRACKET LOCKING FLANGE NUT M THRORRLE PEDAL BOLT M8*1.25* THROTTLE PEDAL RETURN SPING,L BOLT-WASHER M8*1.25* NUT M THROTTLE PEDAL COMP PAN SCREW M5* FLAT WASHER φ NYLON LOCK NUT M BRAKE PEDAL COMP PIN φ6* SPINDLE PIN COTTER PIN φ2* BRAKE LAMP SWITCH ASSY PAN SCREW M3* PEDAL BUSH BRAKE PEDAL RETURN SPRING,R BRAKE PEDAL BOLT M8*1.25* MASTER CYLINDER BOLT-WASHER M8*1.25* THROTTLE PEDAL PAD BRAKE PEDAL PAD STEERING WHEEL LOCK MASTER CYLINDER BRACKET BOLT M6*19 2

22 FIG. 15 FRONT SUSPENSION ASSY. FRONT SUSPENSION ASSY. REF NO. PART NO. DESCRIPTION QTY SS STRUT AND SPINDLE SUPPORT,R.WITH BRACKET-BLACK BOLT-WASHER M8*1.25*105 2

23 UPPER SUSPENSION ARM COLLAR UPPER SUSPENSION ARM BUSH UPPER SUSPENSION ARM LOCKING FLANGE NUT M CASTLE NUT M BALL HEAD DUST SEAL BALL HEAD SPACER SS STRUT AND SPINDLE SUPPORT,L.WITH BRACKET-BLACK BOLT M8* LOWER SUSPENSION ARM COLLAR BOLT STRAP M6* FR.WHEEL ASSY.,R. 20* FR.BRAKE CALIPER PAD SET FRONT BRAKE CALIPER,L BRAKE DISC DUST SEAL 47* Z BEARING 6204-Z CAP LUG NUT M10*1.25* WHEEL HUB Z BEARIG 6202-Z CAP LUG NUT M TIRE,FR.20* B RIM,FR LOCKING FLANGE NUT M CASTLE NUT M COTTER PIN φ2* HUB COVER BOLT-WASHER M10*1.25* FRONT BRAKE CALIPER,R CUSHION ASSY.,FR.L= BOLT-WASHER M10*1.25* LOWER SUSPENSION ARM DUSH CAP LOWER SUSPENSION ARM BUSH O-RING φ21.2* LOWER SUSPENSION ARM ASSY B FR.WHEEL ASSY.,L. 20* ACORN M COTTER PIN φ3.2*26 2

24 FIG. 16 FULL SHIFTING ASSY. FULL SHIFTING ASSY. REF NO. PART NO. DESCRIPTION QT Y GK ENGINE MOUNT BRACKET I GK ENGINE MOUNT BRACKET II GK REVERSE CABLE FIXED PLATE GK SHIFTER DISK BOLT M10x1.25x k000 FRONT ENGINE MOUNT BRACKET NUT M12x k000 BUSHING ENGINE BRACKET ENGINE BRACKET BOLT k000 BUSHING ENGINE BRACKET 2 2

25 k000 SPACER ENGINE BRACKET ENGINE MOUNTING BOLT M10x1.25x WASHER-CHAIN ADJUSTER 2 (φ12xφ35x6) CAP WASHER-CHAIN ADJUSTER BOTTOM CAP WASHER-CHAIN 1 ADJUSTER BUSHING CHAIN ADJUSTER BOLT M12x CAA CHAIN ADJUSTER ASSY LOCKING FLANGE NUT M10x BOLT M10x COLLAR ENGINE MOUNT BOLT PLATE LOCKING FLANGE NUT M 8x GK REVERSE CABLE PARING BRAKE ASSY BOLT-WASHER M8X20X WASHER BOLT M GK SHIFTER HOISE ASSY NUT M6X GK ENGINE FIXED PLATE. RR 1

26 FIG. 17 REAR CARGO RACK / SEAT / BELT REAR CARGO RACK / SEAT / BELT TAIL LIGHT BULB 21W/5W 12V TAIL LIGHT LOCK NYLON NUT M REAR CARGO RACK (B.R.S.) REAR SIDE REFLECTOR LUG NUT TUBE COVER LICENSE LIGHT ASSY SCREW ST3.5* LOCKING FLANGE NUT M8 6

27 FUEL TANK CAP COMP FUEL TANK COMP.(B.R.S.) BOLT-WASHER M8*1.25* TANK COMP. COLLAR RUBBER MOUNT FLAT WASHER φ FUEL AUTO COCK ASSY.NO/OFF VALVE GAS FILTER TUBE COMP.FUEL # TUBE COMP.FUEL # TUBE COMP.VACUUM SAFETY BELT HEAD-REST SEAT COMP.L SPECIAL BOLT M7/16"* BELT WASHER φ NUT BELT M7/A6" BOLT STRAP M8*1.25* BOLT M8*1.25* SEAT RAIL SET VACUUM TUBE FUEL TUBE SEAT COMP.R R-WASHER BOLT M8*1.25* SCREW 6* TOOL KIT TOOLS AUXILIARY SPERKER BOLT M6* FLAT WASHER φ NUT M MAIN SPEAKER 1

28 FIG. 18 AIR CLEANER/RADIAROR/BATTERY/MUFFLER ASSY. 34 AIR CLEANER/RADIAROR/BATTERY/MUFFLER ASSY G AIR CLEANER ASSY TUBE COMP.WATER 1# TUBE COMP.WATER 2# TUBE CLAMP TUBE COMP.WATER 3# 1

29 TUBE COMP.WATER 4# BOLT M8*30* RADIATOR COMP.COLLAR RUBBER MOUNT NUT M COLLANT TANK BATTERY COVER BATTERY (YTX12-BS) BATTERY BAND BATTERY LOWER G MUFFLER COMP.EX MUFFLER JOINT NUT M EX.PIPE GASKET BOLT-WASHER M10*1.25* NUT M G RADIATOR COMP TUBE CLAMP NUT M G FAN COMP BOLT M6* G 300cc ENGINE TUBE COMP WATER 5# TUBE COMP WATER 6# TUBE COMP WATER 7# TUBE COMP WATER 1# TUBE COMP WATER 2# RADIATOR.COMP BOLT M6* G BOOT.SIDE CASE G CLAMP.BOOT HEAT SENSITIVE SWICH N FAN COMP N RADIATOR COMP COVER N COLLANT TANK CAP RUBBER STOPPER 4 (18-54) CC MUFFLER CLAMP WATER TEMPERATURE INDUCTOR 1

30 FIG. 19 REAR SUSPENSION ASSY. REAR SUSPENSION ASSY RR.HUB COVER COTTER PIN φ4* CASTLE NUT M LUG NUT CAP M B RIM RR. 2

31 REAR WHEEL HUB TIRE BOLT M10*1.25* BEARING COLLAR BOLT-WASHER M12*1.25* LOCKING FLANGE NUT M BOLT-WASHER M12*1.25* SWING ARM CUSHION BUSH BALANCE LEVER LINK ROD LOCKING FLANGE NUT M10* BALANCE LEVER BOLT-WASHER M8*20* SS RR.BRAKE DISC BRAKE DISC.W/SPEEDO MAGNET HOLE BOLT M10*1.5* RR.BRAKE PAD SET G CALIPER HYDRAULICAL BRAKE, RR ALLEN HEAD BOLE M8*1.25* C CV/SHAFT JOINT CUSHION ASSY., RR. L= SWING ARM COMP. R SWING ARM COMP.L DUST SEAL φ62*44* B REAR WHEEL ASSY.,R B REAR WHEEL ASSY.,L TIRE,RR.22* BOLT-WASHER M6* FENDER, RR REAR FENDER BRACKET,R REAR FENDER BRACKET,L BOLT-WASHER M8*1.25* CHAIN O-RING DRIVE HOUSING COMP.PP AXLE BRG BEARING E G AXLE REAR SPROCKET BOLT-WASHER BOLT-WASHER PROTECTOR,DISK BRACKET SENSOR AWICO SCREW M3*5 1

32 CIRCLIP RUBBER BUSH RUBBER BUSH CIRCLIP TIRE NIPPLE REAR AXLE CIRCLIP SCREN M3* BOLT M6* BRACKET LOCKING FLANGE NUT M6 2

33 FIG. 20 WIRE HARNESS / ELECTRIC PARTS WIRE HARNESS / ELECTRIC PARTS BOLT M6* NUT M REGULATE RECTIFIER COMP PAN SCREW M6* WASHER φ LOCKING NYLON NUT M SWITCH PANEL COVER BOLT COVER 4

34 HORN SWITCH POWER OUTLET COVER POWER OUTLET WINKER SWITCH UNIT DIMMER SWITCH UNIT ENGINE STOP BUTTON IGNITION START SWITCH RELAY COMP.AUDIBLE PILOT&WINKER TEMPERATURE BUZZER HORN RECTIFIER SOCKET COMP PAN SCREW M6* WIRE HARNESS ELECTRIC ASSY.COVER K C.D.I.UNIT COMP STARTING RELAY K IGNITION COIL COMP LOCK NYLON NUT M PAN SCREW M5* RESISTOR COMP.10W PAN SCREW M4* LOCK NYLON NUT M SPEEDOMETER WITH HI/LO 1

35 FIG. 21 WARNING STICKERS WARNING STICKERS LABEL. PARKING BRAKE LABEL.REVERSE LEVER LABEL.GEAR CASE LABEL.NO LONG HAIR LABEL.WARNING LABEL.NO CLIMBING LABEL.WARNING LABEL.SEAT BELT LABEL.RADIATOR LABEL.WARNING 1

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