MAXXAM 150 2R BUGGY KART Service Repair Manual

150 2R ACE-Maxxam-002-02-2007 239 County Road 4435 Brundidge, AL 36081 www.acesportsonline.com P: 1-888-562-9ACE F: 1-888-562-8ACE Buggy Service Manual Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

FOREWORD This service manual has been specially prepared to provide all the necessary information for the proper maintenance and repair of the MAXXAM. The MAXXAM ts the needs of a wide variety of kart users above 16 years old. Those who will be servicing this kart should carefully review this manual before performing any repair or services. All information, illustrations photographs and speci cations contained in this manual are based on the latest product information available at the time of publication. Due to improvements or other changes, there may be some discrepancies in this manual. Therefore, if newest information is requested in the future, please contact the local distributor. The distributor reserves the right to make production changes at any time, without notice and without incurring any obligation to make the same or similar changes to vehicles previously built or sold. A.C.E. SPORTS 239 County Road 4435 Brundidge, AL36010 Phone: 888.562.9ACE Fax:888.562.8ACE Downloaded from www.Manualslib.com manuals search engine

GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES ENGINE LUBRICATION SYSTEM INSPECTION AND SERVICING FUEL SUPPLY SYSTEM INSPECTION AND SERVICING TRANSMISSION CONPONENTS ELECTRICAL STARTING SYSTEM REDUCTION MECHANISM CONTROLLING MECHANISM BELT DRIVEN CVT MECHANISM INSPECTION AND SERVICING CLUTCH DRIVEN BELT PULLEY REAR TRANSMISSION MECHANISM INSPECTION AND SERVICING ELECTRICAL SYSTEM PRIMARY COIL IGNITION SYSTEM INSPECTION AND SERVICING CHASSIS WIRING DIAGRAM INDEX 1 5 9 24 28 33 34 37 39 40 44 46 49 54 56 60 64 70 71 Downloaded from www.Manualslib.com manuals search engine

1 GENERAL INFORMATION MODEL IDENTIFICATION FRAME NUMBER The frame number or VIN is stamped under the seat on the frame cross member and on a sticker behind the seat. ENGINE NUMBER The engine number is located on the lower front left side of the engine case. FUEL AND OIL RECOMMENDATIONS FUEL Gasoline should be 85 to 95 octane or higher. Unleaded gasoline is recommended. ENGINE OIL High-grade 10W-40 motor oil should be used. BREAK-IN PROCEDURE • Vary engine speed for the rst 5 hours. • Never hold engine at full throttle for long periods of time. Downloaded from www.Manualslib.com manuals search engine

2 SPECIFICATIONS DIMENSIONS Overall length 2075mm (87.7 in.) Overall width 1235mm (48.6 in.) Overall height 1400mm (55.1 in.) Wheelbase 1450mm (57 in.) Front Track 1060mm (47.1 in.) Rear Track 1000mm (39.4 in.) Ground Clearance 130mm (5.1 in.) ENGINE Type Forced air-cooled, 4-stroke Engine capacity 150cc Bore x stroke 57.4 x 57.8 Corrected Compression Ration 9.2:1 Carburetor PD25J Output Power 9HP/7500 rpm Maximum Torque [N.m(r/min)-1] 8.0/4000-4500 Starting Electric Ignition CDI Lubrication Force & Splash Transmission Automatic CVT CAPACITIES Load 1 rider or 90kg/198Ibs Fuel tank 7L/1.54Gal Starting 5s Climbing 20-25° CHASSIS Front Brake Hydraulic disc/left foot control Rear Brake Hydraulic disc/left foot control Front Tire 20 x 7.0-8 Rear Tire 22 x 10-10 Suspension-Front Dual A-arm with 1.8” (45mm) of travel Suspension-Rear Spring over shock with 2.4” (60mm) of travel Brake Track 7m@20mph Top Speed 30mph (or limited as customers require) Downloaded from www.Manualslib.com manuals search engine

10 68.95 70 10 68.95 70 Downloaded from www.Manualslib.com manuals search engine

4 LOCATION OF PARTS DRIVE CHAIN DRIVE CHAIN Downloaded from www.Manualslib.com manuals search engine

5 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES PERIODIC CHECK AND SERVICES The maintenance intervals in the following table are based upon average riding conditions. Riding in unusually dusty areas requires more frequent servicing. Items Needing Servicing Initial Service rst week) Monthly Quarterly Yearly Tire pressure/wear I I Brake performance I I Tightness of screws I I Air cleaner C C I Carburetor I A C Spark plug C, A Drive chain I I C, A, L I Replace gearbox oil I R Chassis C, L L Fuel switch/fuel tank C Battery I I Engine oil R Valve clearance of engine A A: Adjust C: Clean I: Inspect, clean or replace if necessary L: Lubricate R: Replace MAINTENANCE AND TUNE-UP PROCEDURES Descriptions of the servicing procedures for each item in the Periodic Maintenance table. SPARK PLUG • Clean up the carbon around the spark plug to prevent it from dripping into the cylinder when being removed. • Remove the spark plug • If the spark plug is too tight to remove, spray rust inhibiter on the spark plug washer and the thread. After soaking for a few minutes, the spark plug should easily unscrew. • Clean up any dirt and carbon accumulation on the spark plug with a steel brush or a blade. • Inspect the spark plug gap, it should be about 0.6 ~ 0.7mm. • When the carbon accumulation and wear of the spark plug are too severe, replace the spark plug with one of the same speci cation. Note: The spark plug should generally be serviced when the engine is cold. Downloaded from www.Manualslib.com manuals search engine

6 TIRE PRESSURE/WEAR Check the tire pressure every time the kart is ridden. The tire pressure is very important for the stability of the ride. Tire Pressure Front 10 psi 68.95kPa/cm 2 0.70kgf/cm 2 Rear 10 psi 68.95kPa/cm 2 0.70kgf/cm 2 BRAKE PERFORMANCE • Always check that there is plenty of brake uid in the brake uid reservoir. • Check that the rear brake pads are in good condition. • Check the brake rotor for abnormal wear. AIR CLEANER If the air cleaner is clogged with dust, performance will be severely decreased, if left unserviced, engine damage can occur. Check and clean in the following appropriate manner. Paper Filter Maintenance • Remove the air cleaner from its housing •T • Replace the element if it is wrinkled or torn Foam Filter Maintenance • Wash in non- ammable cleaning solvent • Install the element back into the air box. Note: Clean after every 20 hours of use, or more often if used in a dusty environment. Caution! Before and during cleaning, inspect the element for tears. A torn element must be replaced. Make sure the element is seated properly and no foreign material can pass by it. THROTTLE CABLE ADJUSTMENT • Conditioning nut, bolt from the adjustment nut goes farther, the greater the degree of throttle opening, the smaller the contrary. The greater the degree of throttle opening, the higher the Idle adjustment nut adjustment nuts Downloaded from www.Manualslib.com manuals search engine

MAXXAM 150 2R BUGGY KART Service Repair Manual

You're Reading a Preview

Recently Viewed