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TrailMaster 150 - User Manual

TrailMaster 150
21 pages
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1
Move carton to a clean location with 3
or more feet of room around the unit.
2
Remove strapping and outer container.
3
Unpack parts and place near where
they are to be installed.
4
Lay out ALL hardware on a clean sur-
face and count.
5
Remove battery box from kart. Read all
precautions, filling instructions and
safety instructions. Make sure to wear safety
glasses and protective gloves.
6
Place the battery in a sink.
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Summary

Vehicle Assembly

Battery Acid Filling and Activation

Remove cell seal, open acid container, fill cells, and vent the battery.

Fuel System Installation

Mount fuel tank, locate and connect vacuum hose, and secure hose clamps.

Main Frame and Cage Assembly

Assemble main bars, top bars, and side bars using bolts and washers.

Side and Top Weldment Installation

Install side bars and top weldment components using appropriate hardware.

Rear Cross Bar and Top Weldment Assembly

Place and align rear cross bar, then install top weldment with bolts.

Final Tightening and Rear Suspension Installation

Tighten all previous hardware and install lower shock bolts and mounts.

Rear Wheel Installation

Mount rear wheels onto axle, install washers, nuts, and cotter pins.

Front Spindle and A-Arm Assembly

Install spindle stud into A-arms and secure with washer and castle nut.

Front Suspension Securing and Pinning

Tighten suspension nuts, align holes, and install cotter pins.

Startup and Operation

Summary

Vehicle Assembly

Battery Acid Filling and Activation

Remove cell seal, open acid container, fill cells, and vent the battery.

Fuel System Installation

Mount fuel tank, locate and connect vacuum hose, and secure hose clamps.

Main Frame and Cage Assembly

Assemble main bars, top bars, and side bars using bolts and washers.

Side and Top Weldment Installation

Install side bars and top weldment components using appropriate hardware.

Rear Cross Bar and Top Weldment Assembly

Place and align rear cross bar, then install top weldment with bolts.

Final Tightening and Rear Suspension Installation

Tighten all previous hardware and install lower shock bolts and mounts.

Rear Wheel Installation

Mount rear wheels onto axle, install washers, nuts, and cotter pins.

Front Spindle and A-Arm Assembly

Install spindle stud into A-arms and secure with washer and castle nut.

Front Suspension Securing and Pinning

Tighten suspension nuts, align holes, and install cotter pins.

Startup and Operation

TrailMaster 150 Specifications

General IconGeneral
BrandTrailMaster
Model150
CategoryUtility Vehicle
LanguageEnglish

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