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CARTER GOCARTS SERVICE TIPS

PREVENTIVE MAINTENANCE

STORAGE - In the event your vehicle is not to be operated for a period in excess of 30 days and at the end of each riding season prepare for storage as follows:

1. Drain fuel tank and remove all fuel remaining in the tank by using a suction device or by soaking up with a clean rag or towel. Remove all fuel remaining in the carburetor by allowing engine to run out of fuel. Do not perform any fuel removal procedure while smoking or near an open flame. Dispose of any rags or towels properly.

WARNING - Do not drain fuel while engine is hot. Be sure to move vehicle outside before draining fuel.

2. Lubricate engine cylinder by removing the spark plug and pouring one ounce of clean lubricating oil through the spark plug hole into the cylinder. Crank the engine slowly to spread oil and replace spark plug.

3. Do not save or store gasoline over winter. Using old gasoline which has deteriorated from storage will cause hard starting and affect engine performance.

4. Monthly charging of the battery (if applicable) is recommended in the off-season.

WARNING - Battery may generate explosive gases after filled with acid and during charging or use. Keep sparks, flame, cigarettes, or anything flammable away. Ventilate when charging or using battery in an enclosed space, and ensure that the battery vent path is always open.

5. When the vehicle is removed from storage re-read the owner's manual, perform any assembly required, and perform a pre-ride inspection. See Pre-Ride Inspection section of this manual.

GENERAL - Just as your automobile needs professional, mechanical maintenance from time to time, so does this vehicle. Replacement of the spark plug and ignition points is made necessary by normal use. Professional air cooled engine service is easily obtained. Check your phone book yellow pages under "Engines-Gasoline."

SERVICE INSTRUCTIONS

ENGINE LUBRICATION - You must change the oil in the crankcase after the first two hours of operating your new engine, and after each 25 hours of use thereafter. That will insure proper lubrication in internal parts and prevent costly repairs due to excessive wear. Refer to Engine Maintenance Instructions.

KART LUBRICATION - Every two or three hours of use lubricate the following items with several drops of oil; steering bearing points, brake rod pivot points, pedal pivot points, steering spindles, and steering rod ends. Use the same grade of lubricating oil that is used in the engine crankcase.

CHAIN LUBRICATION - For the best chain life, it should be lubricated with a graphite type lubricant such as the spray-on type which evaporates leaving the graphite on the chain. Using oil or grease on the chain in dusty or sandy riding conditions may cause dirt particles to stick to the chain resulting in rapid wear from abrasion.

TORQUE CONVERTER LUBRICATION - Although the Torque Converter has been designed for many hours of use, periodic cleaning and lubrication is necessary for optimum life and performance. Extremely dust, dry climates would require more frequent maintenance checks.

Here are the steps to take to maintain the Torque Converter:

Examine the sheaves surfaces of both the front and rear unit. Clean all dust, dirt and belt residue from surfaces. This must be done with an evaporative solvent. The belt and belt surfaces must be free of dirt and grease.

Remove the cover from the front drive unit. Clean all dust and dirt from internal parts, and re-lubricate with a dry lubricant such as molybdenum disulfide. Reassemble unit and be sure cover is securely replaced.

CENTRIFUGAL CLUTCH LUBRICATION - There are two main elements that can shorten the life of a clutch - poor lubrication and dirt/sand. The clutch contains an oil-impregnated bronze bushing (part '3' on illustration). It is press fitted inside on the sprocket and surrounds a steel sleeve onto which a snap ring clips. The small snap ring at the end of the sprocket holds the clutch together, and for this reason the snap ring should not be removed.

With the engine off, apply oil (SAE 30 motor oil) to the snap ring area. (See illustration 2 for details.) To make it easier for the oil to work its way into the bushing area, try to manually roll the kart along while applying the oil. If you lift the rear end and support it on the frame you can rotate the rear wheels to work the oil into the bushing. Never apply grease to this bushing, because it clogs the pores and retards proper lubrication. For best results, oil every two hours of running time. (4 or 5 drops).

Dirt and sand are abrasive and can act like sandpaper to prematurely wear the bushing, the sprocket, the chain, and other parts of your vehicle. Since these vehicles are driven on all kinds of terrain, it's often hard to keep the moving parts dirt free. A clean vehicle can prolong the life of the clutch's bushing and sprocket as well as the chain and other bearings on the vehicle. Try wiping or brushing away as much dirt as possible from these areas after each use of your kart.

If you find that the drum and sprocket assembly wobbles on the steel sleeve, this is an indication of a worn bushing. You should get a new clutch or replacement bushing. A worn bushing can lead to a thrown chain. Replacing the bushing early when you first see the excessive wear will prevent the sleeve from becoming worn and damaged.

FRONT WHEEL REPLACEMENT - Care must be used when replacing wheels. DO NOT OVER-TIGHTEN AXLE NUTS. It is only necessary to tighten the nuts so that the wheel turns freely on the axle with minimum end play. If the wheel does not turn freely the nut is too tight.

REAR WHEEL REPLACEMENT - Loosen the large locknut in the center of the wheel to remove the rear wheel.

CHAIN ADJUSTMENT - After the first two hours of operation, check the chain adjustment and readjust it if it has more than 3/8" flex. Loosen the engine clamp nuts and slide the engine and jack shaft assembly rearward to tighten the chain. Allow about 3/8" flex for proper adjustment. Tighten the nuts securely. On models equipped with a centrifugal clutch, the engine may need to be moved forward to tighten the chain.