FUN KART Owner's/Operator's Manual Clutch and Torque Converter Models WARNING: Read Engine Owner's Manual, Vehicle Operator's Manual and any Supplements Carefully and View "Operations and Safety" Video Before Operating Vehicle. • • • THIS VEHICLE THIS VEHICLE Assembly Operation Maintenance Warranty IS FOR OFF-ROAD IS NOT DESIGNED USE ONLY. FOR USE ON RENTAL TRACKS OR RACING. BEFORE OPERATING THIS VEHICLE, THE OWNER AND EACH OPERATOR MUST UNDER.
TABLE OF CONTENTS SAFETY ............................................................................... Important Rules for Safe Operation 3 ..................................................... 3 Terminology ....................................................................... 7 Qualifications for Fun-Kart Users ....................................................... 7 Consumer Responsibility for Safe Use and Maintenance of Fun-Karts MANGO POWERSPORTS, LIMITED WARRANTY ........................
ChassisandSteering........................................................... Decals................................................................. BrakeService.................................................................... DiscBrake................................................................... Band/Drum Brake.............................................................. ThrottleCable.................................................................... Inspection .................................
SAFETY '_ -[his is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. _Read and follow all instructions in this ,_1_ CAUTION: Indicates a potential hazard which Owner's/Operator's manual, any accompanying supplements, and the Engine Owner's Manual before attempting to operate this Fun-Kart. Make sure to view the Operations and Safety video.
A WARNING: Operator (and any passenger) of this Fun-Kart MUST always wear a properly fitting motorcycle type helmet approved by agencies such as the Department of Transportation (DOT), Safety Helmet Council of America (SHCA), or Snell Memorial Foundation (SNELL). , Most Fun-Kart accident fatalities are due to head injuries. Operator (and any passenger) should also wear face shields or goggles, boots, gloves and other appropriate protective clothing. (See OPERATION-OPERATING INSTRUCTIONS.
,_k WARNING: Excessive Fun-Kart speed is _ potentially dangerous to operator, passengers and others. turning. ,_ • NEVER fill fuel tank while the engine is running or hot. • DO NOT overfill tank. , ALWAYS allow at least 1/2" of expansion space at the top of tank. • • High-speed turning can cause loss of control, possible Fun-Kart turn-over and/or possible operator and/or passenger injury. • Turning on a slope increases the risk of rollover.
_k WARNING: Read and keep all supplied printed material. Supplements to this Operator's Manual contain updated information relative to your specific FunKart model. It is important to keep a!l of these documents for reference. ,_ CAUTION: NEVER operate Fun-Kart while under the influence of alcohol, drugs or medication of any kind. • Such operation is dangerous to yourself and/or others. _11=CAUTION: Brush Bars assembled to this d_l_ CAUTION: ALWAYS stop the engine when the Fun-Kart is not in use.
Terminology Axle Guard - a device, which covers the drive axle on Fun-Karts, so that the possibility of injury resulting from hand, hair, loose clothing or body part contacting the axle is reduced. agencies such as the Department ef Transportation (DOT), Safety Helmet Council of America (SHCA) or Snell Memorial Foundation (SNELL).
Consumer Responsibility for Safe Use and Maintenance of Fun-Karts Fun-Karts shall not be modified from the manufacturer's original design and configuration. 1, 2. Fun-Karts shall not be used to perform racing, stunt riding, jumps, spin-outs, donuts or other maneuvers as they may cause loss of control of the Fun-Kart or may cause uncontrolled operator!passenger or Fun-Kart actions or reactions.
b. Passengers (intwo-seat Fun-Kart) shall remainseatedwitharmsandlegsinsidethe Fun-Kart ata!ltimesduringFun-Kart operations; c. Shallobserveminimum agerestrictions; d. ShallnotridetheFun-Kart if longhair,loose clothes,orjewelryreachbeloworbehindthe seat; _1_ WARNING: d.
MANCO LIMITED POWERSPORTS LIMITED WARRANTY WARRANTY Manco PowerSports (hereinafter referred to as "Manco') hereby warrants to the original purchaser that the frame and components of the new Manco vehicle will be free from defects in materials and workmanship. The period of the warranty is thirty (30) days from the date of purchase for the component parts (except as noted below), and for a period of ninety (90) days from the date of purchase for the frame.
COMBINATION LAP AND SHOULDER COMBINATION LAP AND SHOULDER RESTRAINT SYSTEM USE AND MAINTENANCE BELT This vehicle is shipped with a combination lap and shoulder belt restraint system for each occupant location. The combination lap and shoulder belt restraint system must be installed in the kart according to the Assembly Instructions provided with this kart. The proper use of the combination lap and shoulder belt restraint system can reduce the chance of and/or severity of injury in an accident.
5. Adjust the shoulder part of the belt (1A) by pulling down on the free end of the shoulder belt (6). Make sure that all of the webbing has been unwound from the web winder (4) and that the belt is snug across the shoulder and chest with no more than one inch of space between the chest of the occupant and the belt. 6. For a two seat kart, the passenger must be restrained in the same manner as outlined in steps 2, 3, 4, and 5 above.
. 3. The web winder(s) and or webbing may require periodic cleaning to ensure that they wind up the webbing located above the adjuster. That can be accomplished by flushing them out with water and drying. The web winder(s) and webbing must be dried to ensure there is no water that can freeze and render the web winder(s) inoperable. The webbing of the restraint system(s) may require periodic cleaning which can be accomplished by washing with plain water. ]-he webbing must be dried to prevent freezing.
SAFETY FLAG ,_ WARNING: The Safety Flag is added to this kart for off-road visibility ONLY. It is provided, and required, for increased visibility, especially on hilly terrain and is required by law in many states. ASSEMBLY INSTRUCTIONS 1. Attach Safety Flag to the back of the headrest mounting strap using the bolt provided in the parts bag for mounting the Headrest Pad. 2.
PREoRIDE INSPECTION Inspect the Fun-Kart before each riding to make sure it is in proper working order. _1= WARNING: If proper inspection is not performed, serious injury or death can result. • Before riding the FumKart, inspect all operating controls and parts, Allow the engine to cool before adding oil or refueling. Always inspect the Fun-Kart before riding by following the checklist carefully. MKOO1A *Shown with guards removed MK001C Figure 1.
Engine Stopped Inspections 1. (See Figure 1) ITEM INSPECTION PROCEDURE ACTION Engine Oil Level Add oil if required Refer to Engine Owner's Manual. Check for leaks. Tighten filler cap securely. 2. I Fuel Level Add fuel as necessary. Refer to Engine Owner's Manual. DO NOT overfill (no fuel in the filler neck). DO NOT refuel a hot engine. Allow engine to ceol before adding fuel. DO NOT mix oil with gas. Replace cap tightly. m--m 3. . 5, .
ITEM INSPECTION PROCEDURE ACTION BrushBars Make sure all brush bars are in place and securely attached. Replace damaged bars or fasieners and tighten as necessary. Steering Make sure steering turns freely, Lubricate/Adjust as necessary, See MAINTENANCE-CHASSIS. Check for proper "toe-in" of wheels. Lubricate/Adjust as necessary, See MAINTENANCE-CHASSIS. FramelChassis Check for bent or otherwise damaged frame and!or other chassis components. Replace as necessary.
OPERATION Brake (2) _1_ WARNING: Prior to operating the Fun-Kart, review the assembly instructions to make sure the Fun-Kart has been assembled properly. The brake is controlled by the left side foot pedal. Push the pedal to apply the brake. Operating _l_ Controls (See Figure 2) WARNING: DO NOT operate this Fun-Kart unless brake system is working properly. ,_ WARNING: DO NOT attempt to start or operate this Fun-Kart until you are completely familiar with location and use of each operating control.
The brake pedal is latched by pushing down the brake pedal and raising the latch so its notch (a) fits on the pedal bushing (b). The return action of the brake pedal will keep the brake applied. the clutch bearing in two or three hours of operation. Slipping can occur by riding at slow speeds with high engine RPM such as trying to climb hills, pulling through soft soil or high grass or with brake applied, The pedal Is unlatched by pushing the brake pedal and allowing the latch to fall away.
Operating Instructions Before operating the Fun-Kart, be sure to read and follow all the WARNINGS, CAUTIONS and instructions on the preceding pages. Use a tire pressure gauge during the. removal or addition of air as necessary to achieve proper tire pressures. Testing Pre-Ride Inspection Perform Dai}y Pre-Ride inspection as previously described in this manual BEFORE each use, Perform the following tests before operating this FunKart.
BRAKETEST _!1_WARNING: DO NOT operate this Fun-Kart unless the brake is working properly. • BEFORE Fun-Kart operation, ensure the effectiveness of the brake system. Perform this test BEFORE each operation. 1. Sit in the Fun-Kart. Make sure there is a clear path ahead and depress the brake pedal, 2. Start the engine. a) On Fun-Karts without an electric starter, have an assistant start the engine, b) On Fun-Karts with an electric starter, use the ignition switch to start the engine. 3.
MKOO4A Figure 4. Seats with Seat Slides & Fixed Seats Passenger Restraint System and Handhold (See Figure 5) _ WARNING: A passenger is only permitted in specially designated DOUBLE SEAT KARTS. This Fun-Kart is equipped with an operator/passenger restraint system. It is to be used by the operator and passenger at all times to control their motion in the Fun-Kart. The passenger restraint system must be tightened securely prior to Fun-Kart operation.
MK005B MK065A Figure 5. Passenger Restraint System and Handhold Operation STARTING 1. Make sure properly functioning parking brake is engaged or operator is properly seated in the Fun-Kart with the brake applied. _k WARNING: Avoid touching the engine, muffler or drive components as those areas could cause burns on contact. 2. Prime the engine or set the engine choke according to Engine Owner's Manual. 3. Make sure throttle is in idle position. See OPERATION - OPERATING CONTROLS.
STOPPING _ WARNING: DO NOT operate Fun-Kart if the engine stop switch is not functional. Release the throttle to return the engine speed to idle. Apply the brake pedal to stop the Fun-Kart's motion. RUNNING Operate the Fun-Kart in a large, level, open space in order to learn to start, steer and stop properly. Operate the Fun-Kart at low speed until you are comfortable and confident operating it. Avoid sharp turns, high speed and rough ground at all times.
Therefore, when turning, the inside wheel may lose traction slightly. The new rider must learn to shift weight and control the throttle to allow the rear tires to negotiate the turn. 1. Practice turning at slow, constant speeds in a large level open area. 2. Turn the steering wheel in the direction of the turn. 3. Lean your body to the inside of the turn in order to maximize front tire traction. 4. Use the throttle to maintain power throughout the turn.
MAINTENANCE Tool List o 10 mm combination wrench for battery cable bolts. e 3/8" combination wrench for installing seat pads and covers. 9/16" combination wrench for custom bar installation. Just as your automobile needs professional, mechanical maintenance from time to time, so does this FumKart Replacement of the spark plug and other repairs and adjustments are made necessary by normal use. Professional air cooled engine service is easily obtained.
_ WARNING: All Iocknuts must have full thread engagement. For any Iocknut to function properly, threads must extend completely through and at least three threads beyond the Iocknut. Two types of Iocknuts are used on this Fun-Kart: 1, Prevailing-Torque-type !ocknuts (1) have a locking feature which deforms the thread in the nut. This type of nut must be turned with a wrench after being started (1 or 2 turns) by hand.
LUBRICATION INSPECTION Use proper lubricants. Remove guards covering drive components. Install new guards if damaged. [CO__MP_ONENT !LUBRICANT RollerChains / Spray-on graphite based chain lubricant I_ Bearing / Automotive SAE 30 weight 1. It may be necessary to remove guards covering drive components. 2. Apply proper type spray-on chain lubricant thoroughly inside and outside plates and rollers of chain, Move Fun-Kart as needed to access entire chain. 2.
ADJUSTMENT 4. Be sure clutch (2) and drive wheel sprockets (3) are aligned. CLUTCH 5. Securely tighten the four engine bolts. KARTS (See Figure 9) 1. Remove guards covering drive components. 6. Recheck chain tension. Refer to INSPECTION. 2. Loosen, but do not remove, the four engine mounting bolts (1). 7. Replace guards covering drive components, Install new guards if damaged. 3. Slide engine as necessary to obtain 1/4" to 3/8" chain flex. © MKO08 Figure 9.
CHAIN REPLACEMENT (See Figure 10) INSTALLATION REMOVAL 1. Install new chain. 1. Remove guards covering drive components. 2. Slide the pin portion of the master link (3) in to each end of chain to be connected. 2. Rotate drive wheel to place master link (3) in accessible position between two sprockets. 3. Slide the retaining clip (1) of the master link (3) until the reliefs are centered over the link pins, Remove clip and remove side plate (2). 4. Slide master link out and remove the chain. 3.
If the clutch starts "slipping" see your dealer for maintenance. Clutch (SeeFigure11) Oiltheclutchbearing after each ride, using 30W motor oil. © MKO09 Figure 11.
Torque Converter (See Figure 12) NOTE: it is recommended that torque converter maintenance beyond inspection and belt replacement be performed by your dealer. The following information is provided as a guide to help determine when professional maintenance is required. Inspect the torque converter clutch pulley (1), driven pulley (3) and drive belt (2) on a regular basis. Check for dirt and frayed belts plus any other potential problem that might be obvious from a visual inspection.
Chassis and Steering LUBRICATION (See Figure 13) Every two or three hours of use lubricate the following items with several drops of automotive SAE 30 weight motor oil where shown: steering bearing points, pivot points of tie rod ends, spindles (if not equipped with grease fittings), brake rod pivot points, pedal pivot points. Weekly, grease the steering spindles and brake linkage assembly (if equipped with grease fittings) as shown. Use multi-purpose grease and a standard grease gun.
FRONTWHEELALIGNMENT(SeeFigure14) ThisFun-Kart is equipped withthreaded tierodsso thefrontwheelalignment maybeadjusted. Thefront wheelsshouldbe"toed-in" from1/8"to 1/4."Before measuring thealignment, makesurethesteering armisverticalandcentered. Thewheelsshouldbe pointed directlyforward, notturned.If thewheelsare turnedtooneside,thewheelsrequirealignment. To checkthealignment, measure distance A andBto thecenterlineofthetires.IfdistanceB isnot1/8"to 1/4"lessthandistance A,thewheelsrequire alignment.
WHEELREPLACEMENT TheFun-Kart maybeequipped withspindle and/or lugmounted wheels,Usethefollowing procedure for wheelreplacement. 2. Jack up the Fun-Kart to raise the wheel off the ground. 3. Remove spindle nut and replace wheel. 4. Install spindle nut finger tight. 5, Lower the Fun-Karl to the ground. WARNING: Never place any part of your body under the vehicle while it is on a jack or jack stands.
LUG MOUNTED WHEELS (See Figure 16) 1. With the Fun-Kart on the ground, loosen all lug nuts (1). 2. Jack up the Fun-Kart to raise the wheel off the ground. 3. Remove lug nuts and replace wheel. 4. Install lug nuts (cone side towards wheel) finger tight. 5. Lower Fun-Kart to the ground. 6. Tighten tug nuts in a criss-cross pattern to 80 ft Ib of torque. 7. After two hours of operation, check wheel lug nut torque.
Decals _1_ WARNING: Safety decals must be replaced if they become unreadable or detached from the Fun-Kart. If decals are unreadable or missing, warning of potential hazards or safety requirements may be lacking. This could result in the operator and/or passenger not taking the proper safety precautions. When the WARNING decals become illegibleand/or detached, the old decal must be removed, the area cleaned with a liquid dish washing detergent, rinsed and thoroughly dried, and the new decal installed.
MK013a MK013b Figure 17.
BRAKEPADREPLACEMENT (SeeFigure18) _1_ WARNING: Do not perform maintenance of high temperature grease and replace the actuator pin into the brake housing spherical end first. 9. brake rotor, pads or calipers until the parts have had sufficient time to cool. Remove guard covering the brake caliper(s). 1, 2. Remove right rear wheel and axle spacers. (See Wheel Replacement,) 3. Remove brake rod from brake lever and slide brake caliper off Fun-Kart frame. 4.
Band/Drum _ Brake 1, WARNING: DO NOT operate this Fun-Kart if the brake system wig not properly stop the FunKart. See OPERATION-BRAKE TEST. _i_ WARNING: DO NOT perform maintenance of brake rotor, pads or calipers until the parts have had sufficient time to cool. _ WARNING: Replace the Iocknuts with the same type each time they are removed. _IL WARNING: DO NOT overtighten fasteners. Pedal must move freely. BRAKE INSPECTION Inspect the brake system before each use of the FunKart.
BAND REPLACEMENT (See Figure 20) 1. Remove the guard covering the brake band. 2, Remove cotter pin (1) and clevis pin (2) from the brake rod (3) and band (4), 3. Remove cotter pin (6) and nut (5) from the other end of the brake band anchor point, 4. Remove brake band by slipping it off the brake drum and pulling it off the axle. 5. Install the new band by reversing the order above. _1_ WARNING:The guard(s) must be in place to protect the rider(s) from the rotating parts of the Fun-Kart.
Throttle Cable 4. Screw the rear jam nut (1) against the frame. 5. Tighten the front jam nut (2) securely. Inspection The throttle cable hQusing may need to be adjusted periodically because the cable stretches, When fully depressing the throttle pedal no longer activates full engine speed, adjust the throttle cable housing. Throttle Cable Housing Figure 21) Adjustment (See 1. Fully loosen the jam nuts (1) and (2) and mount the throttle cable housing to the frame.
Battery (See Figure 22) 1. Disconnect battery cables. 2. Remove the wing nuts (1) and lift off the battery clamp bar (2). 3. Disconnect vent hose (3) and remove battery (4) _rom Fun-Kart. 4. Fill Battery with battery acid. . NOTE: Fill to upper level indicated on battery. _ _b_ WARNING: The battery may generate explosive gases after filled with acid and during charging or use. Keep flammable materials away from the battery.
Light Bulbs Head/Tail Light Fuse To replace the head or tail light bulb, remove the screws and lens from the housing. To remove the bulb, push bulb in and rotate counterclockwise. Clean any dirt or corrosion from the housing, If both the head light and tail light are n_)tworking check and replace the fuse if necessary. Locate the inline type fuse holder on the wiring harness between the engine and the seat. Push both halves of the fuse holder toward each other and twist to access the fuse.
STORAGE In the event the Fun-Kart won't be operated for a period in excess of 30 days or at the end of each riding season prepare it for storage by following the storage instructionsin your Engine Operator's Manual. Removal from storage: After Fun-Kart has been in storage, re-read Operator's Manual, Engine Operator's Manual and perform assembly/maintenance as necessary. Perform PreRide Inspection. NOTE: Do not save or store gasoline over the winter.
PERIODIC MAINTENANCE SCHEDULE The maintenance intervals shown in the following schedule are based upon average riding conditions, Karts subjected to severe use, ridden in wet or unusually dusty areas require more frequent servicing. See Engine Owner's Manual for additional requirements, Check Each Ride 1. Engine Oil Level 2. Test Brakes 3. Lubricate Clutch Bearing (if equipped) 4. Inspect brake and throttle systems 5. Check engine stop switch function 6. Check all fasteners 7.
MKOigA \ \ MK019B Figure 23.
