TRAILMASTER UTV CHALLENGER 300 PARTS MANUAL (ENGINE/TRANSMISSION NOT INCLUDED) FamilyGoKarts.com
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1 TRAILMASTER UTV CHALLENGER 300 PARTS MANUAL (ENGINE/TRANSMISSION NOT INCLUDED)
2 FIG.1 FRAME PARTS FRAME PARTS U FRAME COMP.(R.S.B) TOP ROLL BAR.FR TOP ROLL BAR.RR U DOME LIGHT STENTS U FRONT FENDER BRACKET U PROTECTING BAR BOLT M8X55,GB BOLT M8X60,GB G00 R- WASHER BOLT M8X30,GB BOLT M8X16,GB BOLT M6X16,GB WASHER φ6,gb LOCKING NUT M8,GB U PROTECTING BAR CAP 2
3 FIG.2 ACCESSORIES ACCESSORIES G000 CENTER REAR-VIEW MIRROR G000-L SIDE REAR VIEW MIRROR L G000-R SIDE REAR VIEW MIRROR R U AWNING U SIDE NET DOOR U WINDSHIELD G400 CENTER REAR-VIEW MIRROR MOUNT G000 CENTER REAR-VIEW MIRROR O-RING LOCK WASHER φ5,gb BOLT M5X25,GB LOCKING NUT M10*1.25,GB U WINDSHIELD MOUNTING PLATE U WINDSHIELD RUBBER MAT BOLT M8X16,GB BOLT M8X30,GB BOLT M6X30,GB G FUEL TANK RUBBER MOUNT K000 FUEL TANK COLLAR LOCKING NUT M8,GB LOCKING NUT M6,GB U LED DOME LIGHT U DOME LIGHT WIRE 1
4 FIG.3 SEAT AND SEAT BELT SEAT AND SEAT BELT U DRIVER SEAT COMP U PASSENGER SEAT COMP U DRIVER SEAT SLIDER U HEAD-REST SAFETY BELT BOLT M8X16,GB BOLT M8X16,GB LOCKING NUT M8,GB SAFETY BELT SPECIAL BOLT 4
5 FIG. 4 FRONT SUSPENSION AND FRONT SHOCK FRONT SUSPENSION AND FRONT SHOCK G000 CUSHION ASSY.,FR BOLT M10X1.25X40,GB LOCKING NUT M10X1.25,GB U FRONT UPPER SUSPENSION ARM ASSY.L U FRONT LOWER SUSPENSION ARM ASSY.L U FRONT UPPER SUSPENSION ARM ASSY.R U FRONT LOWER SUSPENSION ARM ASSY.R N SUSPENSION ARM CUSHION BUSH G000 SUSPENSION ARM BUSH U FRONT SUSPENSION ARM COLLAR G100 LOWER SUSPENSION ARM DUSH CAP O-RING φ21.2* N000 GREASE NIPPLE BOLT M10X1.25X70,GB BOLT M10X1.25X80,GB5789 4
6 FIG.5 FRONT WHEEL SHAFT FRONT WHEEL SHAFT U FIXER FR.LH.HUB U FIXER FR.RH.HUB U FRONT SUSPENSION ARM ADJUSTMENT PLATE U FRONT SUSPENSION ARM FIXER PLATE,UPPER U FRONT SUSPENSION ARM FIXER PLATE, LOWER BOLT M10X1.25X115,GB LOCK WASHER φ10,gb LOCKING NUT M10X1.25,GB GB COTTER PIN φ2.5 25,GB N REAR SUSPENSION ARM DUST CAP N REAR SUSPENSION ARM BUSH 2 2
7 FIG.6 FRONT WHEEL SYSTEM FRONT WHEEL SYSTEM U002 FR.WHEEL ASSY.L. 22* U002 FR.WHEEL ASSY.R. 22* U002 TIRE RR.22X U002 RIM, FRONT WHEEL G000 TIRE NIPPLE BOLT M6X16,GB G000 BRAKE DISC,RR YF DUST SEAL 42*25* RS BEARING RS RS BEARING RS G100 TIRE BOLT M GH00 FRONT WHEEL HUB G500 TIRE NUT M WASHER φ10,gb CASTLE NUT M14X1.5, GB GB COTTER PIN φ3 30,GB G002 HUB COVER 2
8 FIG.7 THROTTLE AND BRAKE PEDAL THROTTLE AND BRAKE PEDAL U BRAKE PEDAL COMP U THROTTLE PEDAL COMP WASHER φ15,gb CIRCLIP φ N BRAKE PEDAL RETURN SPRING U THROTTLE PEDAL RETURN SPRING U THTORRLE CABLE COMP BOLT M5X40,GB NUT M5,GB WASHER φ5,gb BOLT M6X20,GB NUT M6,GB U BRAKE PEDAL/THROTTLE PEDAL MOUNTING PLATE BOLT M8X16,GB G000 RUBBER,THROTTLE PEDAL STOP 1
9 FIG.8 PARKING BRAKE AND SHIFTING BOX PARKING BRAKE AND SHIFTING BOX G000 PARKING BRAKE LEVER ASSY BOLT M8X16,GB NUT M8,GB U PARKING BRAKE CABLE COMP G000 PARKING BRAKE CABLE SPRING U SHIFTER HOISE ASSY U REVERSE CABLE COMP G000 REVERSE CABLE BRACKET BOLT M6X12,GB G000 SHIFTER DISK BOLT M6X25,GB5783 1
10 FIG. 9 STEERING SHAFT ASSY. STEERING SHAFT ASSY G000 STEERING BOLT COVER G000 STEERING WHEEL BOLT M6X12,GB G000 STEERING SHAFT G000 BUSH STEERING SHAFT GH00 TILT STEERING HOUSING G000 UPPER SUSPENSION ARM BUSH, G000 UPPER SUSPENSION ARM COLLAR, BOLT M8X105,GB LOCKING NUT M8,GB G000 STEERING GEAR ADJUSTING BOLT G000 DUST COVER BALL JOINT U STEERING LINKAGE KNUCKLE BOLT M8X30,GB LOCK WASHER φ8,gb93 2
11 FIG.10 STEERING GEAR ASSY. STEERING GEAR ASSY U002 STEERING GEAR ASSY U002 TIE ROD (L=275MM) U002 ROD END BOLT M8X100,GB LOCKING NUT M8,GB CASTLE NUT M10X1.25, GB LOCK WASHER φ10,gb GB COTTER PIN φ2.5 25,GB U STEERING GEAR MOUNTING PLATE WASHER φ8,gb LOCK WASHER φ8,gb93 2
12 FIG.11 UPPER REAR SWING ARM ASSY. UPPER REAR SWING ARM ASSY U REAR SWING ARM ASSY. UPPER BOLT M10X1.25X223,GB LOCKING NUT M10*1.25,GB G700 SWING ARM DOG BONE G000 CON'ROD BUSH G000 CON'ROD SPACER BOLT M8X16,GB LOCK WASHER φ8,gb BOLT M12X1.25X60,GB LOCKING NUT M12X1.25,GB G000 TOW BALL LOCK WASHER φ16,gb BOLT M16X2.0X25,GB5783 1
13 FIG.12 ENGINE MOUNT ASSY. ENGINE MOUNT ASSY LOCKING NUT M12X1.25,GB G100 ENGINE MOUNT LINK WASHER G000 ENGINE MOUNT LINK CUSHION G100 ENGINE MOUNT LINK SPACER G000 ENGINE MOUNT LINK COLLAR NUT M14X1.5,GB U ENGINE MOUNT BOLT PLATE BOLT M10X1.25X45,GB G101 ENGINE MOUNT BOLT PLATE COLLAR LOCKING NUT M10*1.25,GB G000 ENGINE MOUNT PLATE BOLT M8X16,GB OUTPUT SPROCKET SPROCKET LOCATING PLATE GB/T16674-M6x12 BOLT M6 12, GB/T
14 FIG. 13 ENGINE, MUFFLER, SECONDARY AIR INTAKE ENGINE, MUFFLER, SECONDARY AIR INTAKE G ENGINE ASSY U MUFFLER COMP.EX.STAINLESS STEEL U MUFFLER RUBBER EX.PIPE GASKET LOCK WASHER φ8,gb LOCKING NUT M8,GB WASHER φ8,gb BOLT M8X30,GB K000 PIPE,SECONDARY AIR INTAKE G000 PIPE GASKET,SECONDARY AIR INTAKE G000 PIPE, BREATHING MANIFOLDS U SECOND AIR INTAKE, CHECK VALVE G000 SECOND AIR INTAKE,PIPE BOLT M6X20,GB LOCKING NUT M6,GB U OIL PIPE,φ3.5*φ
15 FIG. 14 CARBURETOR AND AIR FILTER CARBURETOR AND AIR FILTER O-RING INSULATING MAT QN01030 JOINT CARBURETOR Y28V1L0300G000 CARBURETTOR ASSY BOLT M6X25,GB LOCK WASHER φ6,gb LOCKING NUT M6,GB K000 HOSE CLAMP, G AIR CLEANER ASSY G000 FILTER ELEMENT G000 AIR CLEANER JOINT G000 AIR CLEANER CASE G000 AIR CLEANER MOUNT PLATE,RR GH00 AIR CLEANER FIXED PLATE,RR BOLT M6X16,GB K000 ELECTRIC CHOKE 1
16 FIG. 15 LOWER REAR SWING ARM AND REAR SHOCK LOWER REAR SWING ARM AND REAR SHOCK U CUSHION ASSY. RR BOLT M10X1.25X40,GB LOCKING NUT M10*1.25,GB GH01 RR, LOWER SWING ARM COMP G000 CUSHION BUSHINGΦ12*Φ30*30/ BOLT M12X1.25X60,GB LOCKING NUT M12X1.25,GB G000 SWING ARM BUSH G100 SWING ARM COLLAR.Φ12*Φ18* G001 CHAIN DISC GUARD BOLT M6X12,GB NUT M6,GB6177 4
17 FIG. 16 REAR WHEEL AND HUB REAR WHEEL AND HUB U UTV REAR WHEEL RIGHT U UTV REAR WHEEL LEFT G UTV REAR TIRE U UTV REAR RIM G000 AIR NIPPLE U UTV REAR HUB G100 TIRE BOLT M G500 TIRE NUT M WASHER φ16,gb CASTLE NUT M16X1.5, GB GB COTTER PIN φ4 40,GB G002 HUB COVER 2
18 FIG. 17 REAR AXLE COMP. REAR AXLE COMP G0A0 REAR AXLE G000 RR. BRAKE DISC BOLT M8X25,GB LOCKING NUT M8,GB BOLT M8X30,GB G000 REAR SPROCKET (39T-530) G000 DRIVE CHAIN (52-530H) G000 CHAIN MASTER LINK (530H) YF DUST SEAL 50X RS BEARING RS G100 RR. AXLE BEARING HOUSING COMP G100 BEARING BASE YF DUST SEAL 42X BOLT M8X40,GB5787 6
19 FIG. 18 BRAKE SYSTEM - 1 BRAKE SYSTEM U BRAKE ASSY N BRAKE MASTER CYLINDER G000 FRONT BRAKE CALIPER R G000 FRONT BRAKE CALIPER L G000 FRONT BRAKE CALIPER PAD SET G000 BRAKE CALIPER ASSY.RR G000 REAR BRAKE CALIPER PAD SET U HOSE ASSY.L.BRAKE U HOSE ASSY.R.BRAKE U HOSE ASSY.RR.BRAKE U BRAKE SPINDLE PIN NUT M8,GB U BRAKE LAMP SWITCH 1
20 FIG. 18 BRAKE SYSTEM - 2 BRAKE SYSTEM F BANJO BOLT M HOSE WASHER φ10,brake BOLT M8X25,GB K000 HOSE CLIP BOLT M6X16,GB N000 SPINDLE BRACKET PIN φ GB COTTER PIN φ2.5 25,GB BOLT M8X100,GB BOLT M8X16,GB LOCK WASHER φ8,gb WASHER φ8,gb97 1
21 FIG. 19 GAS TANK COMP. GAS TANK COMP U FUEL TANK BOLT M8X16,GB U FUEL TANK RUBBER WASHER φ8,gb G000 FUEL TANK CAP BOLT M6X16,GB U GAUGE,OIL LEVEL U OIL PIPE Φ4.5*Φ8.5* G000 PETROL FILTER U OIL PIPE Φ4.5*Φ8.5* U OIL PIPE Φ4.5*Φ8.5* U OIL PIPE Φ4.5*Φ8.5* A TUBE CIRCLIP φ U OIL PUMP BOLT M6X16,GB5789 2
22 FIG. 20 COOLING SYSTEM COOLING SYSTEM U RADIATOR ASSY U RADIATOR U WATER FILLER U RADIATOR COVER U FAN ASSY U HEAT SENSITIVE SWICH(75 ) U RADIATOR INLET HOSE U RADIATOR OUTLET HOSE U ENGINE INLET HOSE U WATER PIPE (IRON ) TUBE CLAMP φ U WATER HOSE Φ6*Φ10* U WATER HOSE Φ6*Φ10* A TUBE CIRCLIP φ FR-S COOLING POT HOLDER U COOLING POT BOLT M6X30,GB G FUEL TANK RUBBER MOUNT K000 FUEL TANK COLLAR NUT M8,GB BOLT M6X16,GB5789 1
23 FIG. 21 ELECTRICAL COMP. - 1 ELECTRICAL COMP U MAIN ELECTRICAL WIRING U VICE ELECTRICAL WIRING U BATTERY CABLE G000 VOLTAGE REGULATOR CDI IGNITION COIL G000 STARTING RELAY N SUPPLEMENTARY RELAY G000 RESISTANCE COMBINATION SWITCH COMBINATION SWITCH G000 FLASHER G000 CIGAR LIGHTE G000 CIGAR LIGHTE COVER G000 IGNITION SWITCH U000 ENGINE STOP SWITCH BOLT M6X12,GB BOLT M6X25,GB BOLT M5X20,GB LOCK WASHER φ5,gb WASHER φ5,gb NUT M6,GB6187 4
24 FIG. 21 ELECTRICAL COMP. - 2 ELECTRICAL COMP HEAD LIGHT TURN LIGHT TAIL LIGHT,L TAIL LIGHT,R TURN LIGHT BRACKET U TURN LIGHT MOUNTING PLATE U TURN LIGHT MOUNTING PLATE BOLT ST4.2*16,GB BOLT ST4.2*13,GB NUT M6,GB G000 BATTERY G000 BATTERY COVER G000 BATTERY BAND U000 SPEEDOMETER ASSY U000 SPEED TRANSDUCER U000 SPEED TRANSDUCER CABLE NUT M5,GB K000 MAGNETIC CYLINDER 1
25 FIG. 22 PLASTIC BODY PARTS PLASTIC BODY PARTS FRONT FENDER INSTRUMENT SEAT AIR WINDOW UTV HOOD FRONT GUARD LEFT GUARD RIGHT GUARD FOOTREST PEDAL SEAT BASEBOARD LEFT WHEEL ARCH RIGHT WHEEL ARCH BACK GUARD BOARD POTHOOK TRUNK REAR FENDER SNAP 58 *: Part # in red are parts only in the Challenger 300UTV-X.
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