. GO-KART XYKD260 Repair Manual. 1 Service Notice Position of Identification Number Lubrication diagram Main Features Structure Drawing Standard Torque Rating Troubleshooting Position of Identification Number Vehicle Identification Number Engine Identification Number. Main features Vehicle Dimensions mm KD260-1 KD260-2 KD260-3 Overall Length.2470 2690 2550 Overall Width.1570 1510 1670 Overall Height1535 1460 1440 Wheelbase.1870 1950 2010 Front Track.1345 1270 1485 Rear Track.1250 1250 1263 Ground Clearance200 ENGINE Type.Water cooling, four stroke Engine capacity.260cc Bore.Stroke.70mm.66.8mm. Double quincunx safety belts Restraint System Final Drive shaft drive Road Tire TIRE PRESSUREkPa off-road Tire Front 25 Rear 30 WEIGHTKG KD260-1 KD260-2 KD260-3 Net Weight 355 G.W. Standard Torque Rating XYKD Position Diameter of screw Torque（N.m） （mm） Screw used between Exhaust pipe and Front Cylinder 20-26 Igniter plug 18-20 Screw used between Front wheel hub and front universal 80-100 joint Screw used for Rear wheel hub and Constant-velocity joint 120-140 Universal joint fastening bolt 20-26.
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Lubricating oil and How to do lubrication 1、Engine Position Description of Lubricating Oil Remark Crankcase Only 15W/40SF Full capacity：1.0L Gear case Only 15W/40SF or 85W/140 Full capacity：0.22L Parts of Clutch Li oil ZL-3H（SY 1413） 4.55.0g 2、Vehicle Body The parts, described not limited as following, should be added lubricating oil. If no special requirement, please use the multiple functions lubricating oil. Structure Drawing Pipe cooling liquid kettle Water tubing Temperature Control Switch Brake cable Rear brake oil tube.
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Fuse 15A Relay Flash apparatus Electric parts case rectifier Ignition coil BATTERY Throttle cable Quadric air-intake mechanism Reverse cable Parking brake cable. Speed Sensor cable Main cable Troubleshooting Can not or difficult to start Description Adjustment Reasons Whether oil run in carburetor. Take No oil in oil tank ● ● down vent bolt to check. ● Jam between oil tank and carburetor ●.
Valve socket not good ● No or not enough rings ● Damage of cylinder, piston ● cylinder head gasket works not well ● Valve is damaged Start according right method ● Mixing air time not good ●EEV of carburetor not work ●Air leakage of minus pressure tube No explosion No start with explosion. ● Valve socket not work well ● Plunger ring is damaged No or Lower ● Air leakage from gasket position Mix air time not good ● Check Carburetor jammed. ● Parts of Carburetor jammed Check spark plunger ● Spark plunger polluted/damaged Clean Dirt ●. No sound Unusual sound Egine works unusually（such as idle and low speed） Reasons Description Routine ● Ignition Time OK? CDI parts not good ● Magnetor not good ● Vent screw of carburetor OK? ● Mixed air is rareTake screws down ●.
● Spark plunger not good or polluted CDI parts not good ● ● Ignition coil not good No or less spark ● Ignition coil is broken or in short ● Ignition trigger not good Cut Air Valve OK? Cut Air Valve not good ●. Mixed time right? ● Protruding sprocket wheel and magneto flywheel position not match Spring of valve good？ Spring not good ● ◆ Not move with high speed Reasons Description Routine ● Engine works at high speed or easy to stop?. Open side cover of engine and check clutch strap broken or not ◆ No power in battery Reasons Description Adjustment ● Start engine and check voltage of battery ●Check battery whether out of usage Battery can not charging Normal ●Battery not good Resistance value of coil Stator not good. The charge is not good ( Overcharge ) ● Measure of voltage between rectifier polarities Voltage usual when No voltage when ignition ● black line of main cable ignition switch is “On” switch is “On” is broken Any looseness or default of booster connection-peg connection-peg ●.
Related parts OK? ● Ignition switch not good ● Magneto coil not good ● Trigger not good ● Ignition coil not good ● cable is broken ● Connection of coupling parts not good ● CDI not good 2 Inspections and Adjustment Check &. Brake DISC.
Brake lighter switch Main lighter Per month Clutch Suspend parts Support parts Screw and bolt Per month Wheel/spoke Trimester Vent hole of crankcase Idle of carburetor The vehicle should carry on the periodic maintenance according to the stipulation time. Before the maintenance the vehicle should be cleaned thoroughly. When exhaust, you must guarantee that there is enough brake fluids in brake pump oil cup. Brake oil pump Parking Brake System Brake Handle When stop vehicle on 20º-25°ground and can not park it. Please check parking brake system for safety: 1 Take down/up adjustment bolt near by brake handle 2 Take down/up adjustment bolt near by brake caliper Attention! Please make sure that length of rear wheel. Leakage or Damage of Vibration Damper Steps on with foot to the vehicle forehead, compress several times, inspect its movement, and whether or not any oil leak, damage, loose or unusual sound; Steps on with foot to the vehicle back position, compress several times, inspect its its movement, and whether or not any oil leak, damage, loose or unusual sound Transmission System Transmission case leakage and capacity.
Full capacity：1.2 Liter Standard capacity：1.1 Liter Put on oil position screw with revolving Try running and confirm no oil leakage Check oil level Driving/Driven Wheel Take off left cover Driven wheel Check driving/driven condition Driving wheel Electronic System Ignition System Check gap, whether Station of Spark Plug any dirt and Carbon. Same to Ignition system, put on Ignition LED. Then start Standard Position engine and make speed up to 7500 to 8000 rpm, system works well if LED reach at standard position. Engine Engine Body Low speed and speed up condition Idle Screw Note: idle speed adjustment shall be made when the engine is warmed up. Lubricating oil quality and quantity Attention! During check oil quantity, you should guarantee the vehicle is in the horizontal position. Let the engine works 2-3 minutes, then stops the engine.
After 2-3 minutes, then check oil quantity. Oil vernier Oil vernier Do not revolve in the vernier when checking it.
Accelerator operation system Oiling position Pedal limit screw status of accelerator pedal Check free pedal travel of the accelerator pedal. Free travel: 3040 mm When the free travel is outside the specified, range, the requirement may be met by adjusting the adjustment nut or checking whether the accelerator pedal stopper is correct or not. Reverse System After days of running, it is possible that reverse or other transmissions are not good because: reverse line is changed in length or shape. Herewith you need to make screw adjustments.
Front adjustment screw Rear adjustment screw 3 Oil System Maintenance information Electricity enrichment valve Floater Room Troubleshooting Cut air valve. ﹒Oil switch is not working ﹒Vent hole of tank cap is jammed Engine Idle is not steady and ﹒Oil line is not working Work abnormally ﹒Floater is not working ﹒Adjustment of idle is not working ﹒No enough oil ﹒Mixed air is rare ﹒Air filter is jammed Mixed air is thick ﹒Air in plug.
Take off plug of electricity enrichment valve Take off carburetor Electricity Enrichment Valve Inspection Check connected line of electricity enrichment value. Resistance value: Screws of support part Support part Stop the engine and after 10 minutes then test resistance. Value should not higher than 10 omegas. Cut Air Valve Inspection Take off cut air valve from Pressure line and vent line Connect pressure line and vacuum pump Connect vent line and vacuum pump Add air by vacuum pump: Minus pressure value：400～600mmHg With pressure no air in vent line and without pressure air in vent line, valve is ok.
Take off spring and vacuum plunger. Take off support pats, spring and ejector pin Spring Plunger Important! Please protect septum of vacuum plunger. Vacuum Plunger Support pats Inspection of Vacuum Plunger Check carburetor valve, ejector pin, no any destroyed and broken Check septum without scar, olden and broken Septum Nozzle Pin. Take off main ejector, pin ejector socket, pin ejector, sub ejector and vent screws.
Main Ejector Main Ejector Socket Important!. To protect ejector and screws.Note down zip number when take down screws. If drives vent-screws strongly, it would be destroyed. Clean ejector with extractive oil. Takes down four screws of oil tank Take oil line and pressure line part from oil switch. Oil Line Oil switch Take off oil tank Oil Switch Pressured line Important! 1 Stops the engine, dismantles the oil line from the carburetor and check whether the oil stream to leave.
After oil switch and line is clean, there should be no oil leakage. Take off radiator lid.
Connect Out-water line and fix it tightly In pouring cooling liquid till it is full. Out-water line Carries on pumping air according to the following main point: 1 starts the vehicle, carries on high speed on the smooth road, at least 200 meters. 2 stops and checks foam whether vanishes, as well as liquid surface water level is whether steady, 3 do the vehicle the system closure, pours into the radiator liquid, until. Temperature Control Switch Disassembly Drain radiator liquid out Dismantles switch wiring. Dismantles the switch Attention!
When 80°C, the fan can automatically open; if failed, it needs the prompt inspection. 5 Engine Rear Wheel Screw Disassembly Dismantles Earth Line from the battery Lift back vehicle with Left and Right support parts, and make sure rear Wheel takes off. Take off spark plug cap Take off Temperature Control Sensor Take off lines of carburetion Water Line Take off auto-restarted plug Take off transmission line Take off earth line Take off line between engine and battery Power Line Erath Line Take down screws of bumper Take down screws between air filter, support part and Vehicle body. Take down screws between engine and rear suspend part Rear Suspend Screw Take down front suspend part of engine Front Suspend Take down suspend part under engine Take off engine with muffle, air filter and carburetion ATTENTION! The engine is heavy, so multi-people coordination is import to disassemble, in order to avoid offends somebody or the damage engine. 6 Front Wheels and Steering System. Disassenmbly Front wheel rim screws Support front part of vehicle and make front wheel take off.
Take apart four screws of front wheelLeft wheel for example. Take down the cotter pin locked screws of the front wheel hub. Take down two screws and take off front brake pump assembly. Take off assembly of front wheel hub and brake disc.
Front Wheel Rim Important! It is connected by bearing You should use special tools. Take apart U/D support part and front bone. It is connected by wimble please knock assembly carefully.
Front Bone It is same to RIGHT WHEEL. Take down three screws and take apart steering support nips. Fix part of S.S. U/D Support Part Take down screws between steering assembly and gimbal Steering assembly.
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Steering Wheel Steering Wheel Take down six screws and gather respective assembly Installation Screw Do it as opposite procedure compared with DISASSEMBLY. Screw 7 Seat System Disassembly. Safety Belt Man Handle Disassembly safety bolt on seat right. Disassembly safety bolt on seat back. Bolt Disassembly safety bolt on vehicle body. Bolt Take off seat. Handle counter-clock wise rotation, may carry on to the seat adjustment, back or front.
Man handle Slide Rail Disassembly setting screws of safety belt on left side of seat Take off safety belt Screw It is same to take off left seat and safety belt. 8 Rear Drive Line System. Disassembly Rea wheel rim screw To support behind the entire vehicle, and make the trailing wheel to take off. Dismantles 4 front wheels fixing g screws. (Left side Wheel ) Take down the cotter pin of the front wheel hub locking screws. Front wheel screw. Dismantles 2 setting screws, and take down the brake to pump.
Parking Brake Screw Dismantle locking screws, take down the trailing wheel. Rear brake pump Dismantle two setting screws and take down brake pump. Screw Dismantle two setting screws and take down rear brake pump.
Parking Brake Dismantle four setting screws of rear bone Screw. Universal Joint It is same on right side. Take off seat. Take down two setting screws of tranquilization part. Fixed part Rubber sheath Take off fixed part and rubber sheath.
Disassembly setting screws on left and right tranquilization part. Screw Take of tranquilization part. 9 Electric System Repair Information Battery Troubleshooting Charge System Repair Information IMPORTANT! ． Various cables must carry on the connection by the same color one. The different color line cable must be same with one kind of color.
The colored throat is closed to the connect part. When doing the connection, you must pay attention to the color of the line cables. Specification Item Standard Value Capacity 14AH Voltage （in full） At least 12.5V Battery Charge current Standard 1.4A Charge time Standard 13 hours Model Semiconductor switch type Rectifier of Voltage Control voltage 14.0-15.0V Resistance value of Charge Coil 0.1-1.0Ω （20℃） Troubleshooting No Power(Ignition trigger is “OFF”) Voltage is lower －The battery is at the electric discharge condition. Carries on the warm start and make sure that other electricity components are at the off-position. (For instance lights, speaker). The engine control in Idle speed the condition, the digital multitester twists to the DC voltage files and then connect in parallel fashion to the storage battery beginnings and ends.
Stihl fs 120 carburetor. The storage battery must be in fills the electricity in the situation, gradually speeds up the engine speed, biggest charging voltage should be 14 to 15V. －CDI and Igniter trigger Black and White －Bad connection between lines －CDI and Magneto Stator Black and Red －CDI is not good. ．Sub Ignitions line －CDI and Trigger Green/White，Blue/Yellow － －Spark plug is not good CDI and Grounding line Green ．Ignition Switch is not good －Trigger is not good ．CDI is not good.