GSMOON KD260-2 User manual

1

GO-KART [XYKD260] Repair Manual

2

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

3

Main features

Vehicle Dimensions [mm] KD260-1 KD260-2 KD260-3

Overall Length………………………….………………………………………………..2470 2690 2550

Overall Width……………………………………………..……………………………..1570 1510 1670

Overall Height……………………………………………………………………………1535 1460 1440

Wheelbase………………………………………………………………………………..1870 1950 2010

Front Track……………………………………………………………………………….1345 1270 1485

Rear Track……………………………………………………………………………….1250 1250 1263

Ground Clearance…………………………………………………………………………200 220 200

ENGINE

Type…………………………………………………………………….……………..Water cooling, four stroke

Engine capacity……………………………………………………………………….260cc

Bore *Stroke………………………………………………………………………….70mm*66.8mm

Displacement………………………………………………………………………….257cm³

Corrected compression ratio…………………………………………………………9：1

Max output power…………………………………………………………………..11kw/7000rpm

Max Torque…………………………………………………………………………..17Nm/5000N.m/r/min

Starting………………………………………………………………………………..Electric Start

Ignition………………………………………………………………………………..C.D.I

Lubrication…………………………..………………………………………………..pressure splash

Transmission…………………………..………………………………………………. Automatic C.V.T System

Spark plug…………………………..……………………………………………….DPR5EA-9（NGK）

Plug gap…………………………..……………………………………………….0.6-0.8mm

Fuel type…………………………..……………………………………………….RQ90 (leadless)

Lubricate oil…………………………..……………………………………………….SAE15W-40/SF

Capacities

Maximum load…………………………..……………………………………………….Two seats/200Kg

Fuel tank…………………………..……………………………………………………...9.5L

Engine oil…………………………..……………………………………………………..1180mL

Starting Time…………………………..……………………………………………………..<10s

Climbing…………………………..……………………………………………………..20º-25°

Battery…………………………..……………………………………………………..12V 14Ah

Head Light…………………………..……………………………………………………..12V 35W

Tail Light…………………………..……………………………………………………..12V 21W/5W

Fuse…………………………..……………………………………………………..10A

Brake Track…………………………..……………………………………………………..7m at 30KM/h

Top speed…………………………..…………………………………..75KM/h (Or as customer requirement)

CHASSIS

Front/Rear brake ………………………………Hydraulic disc brake/ Left leg control

Front tire ……………………………………………… AT21X8-10

Rear tire ………………………………………………AT22X11-10

Front Suspension ………………………………………… Independent dual-A arm

Rear Suspension …………………………………Independent swing arm/ Double hydraulic shock

4

Restraint System ……………………………………… Double quincunx safety belts

Final Drive ………………………………………………… shaft drive

TIRE PRESSURE[kPa] off-road Tire Road Tire

Front …………………………………………………… 25 200

Rear …………………………………………………… 30 225

WEIGHT[KG] KD260-1 KD260-2 KD260-3

Net Weight …………………………………355 346 365

G.W. …………………………………… 380 370 380

5

Standard Torque Rating

SER

NUM Position

XYKD

Diameter of screw

（mm）

Torque（N.m）

1 Screw used between Exhaust pipe and Front Cylinder 8 20-26

2 Igniter plug 10 18-20

3 Screw used between Front wheel hub and front universal

joint

14 80-100

4 Screw used for Rear wheel hub and Constant-velocity joint 18 120-140

5 Universal joint fastening bolt 8 20-26

6 Bolt of protective parts of steering mechanism 8 30-40

7 Screws between handle ball and gimbal 10 50-60

8 Screws of wheel and wheel rim[Front and rear] 10 50-60

9 Screws of support parts[Front wheel] and vehicle body 10 50-60

10 Connection of brake pump parking brake and front gimbals,

elevation

8 20-26

11 Screws of handle adjusting line 10 30-40

12 Screws exhaust pipe and engine rear support part 8 20-26

13 Screw used on Front Vibration Damper 10 30-40

14 Screw used on Rear Vibration Damper 12 50-60

15 Connecting screws between rear support part and vehicle

body

16 110-130

16 Screws of rear support parts of engine 10 30-40

17 Screws of front support parts of engine 10 30-40

18 Screws of back brake disc and back wheel rim 8 30-40

19 Screws of front brake disc and front wheel rim 6 20-26

6

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） 4.5~5.0g

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.

In order to prevent the unusual sound and improve the durability, lubricating oil also should be used in

other transmission parts.

Connection part

between Steering gear

parts and handle ball

Steering wheel nylon bushing

Brake pedal

Accelerator pedal

Accelerator cable

Parking brake cable Front lower swing arm

Front Wheel Support Part

Front wheel axle

Main seat slide rail

Constant speed

g

imbal

Rear wheel rim axle

Rear swing arm axle

Sub seat slide rail

7

Structure Drawing

Pipe of

cooling liquid

kettle

Water tubing

Temperature

Control

Switch

Rear brake oil

tube

Brake cable

8

Fuse 15A

Flash apparatus

Rela

y

CDI

BATTERY

I

g

nition coil

rectifie

r

Electric parts

case

Quadric air-intake

mechanism

Throttle cable

Reverse cable

Parking

brake cable

9

Troubleshooting

Can not or difficult to start

Main cable Speed Sensor cable

Description Adjustment Reasons

Whether oil run in carburetor. Take

down vent bolt to check.

Take off spark plug to check

sparkle or not

Yes

● ● No oil in oil tank

● Jam between oil tank and carburetor

● Oil tank hole jammed

● Oil filter jammed

● Oil cleaning net jammed

● Pressure oil switch not work

● Spark plug not work

● CDI parts not work

● Spark plug not clean

● Trigger not work

● Spark plug coil broken or short-circuit

● Ignition coil broken or short circuit

● Igniter switch not work

● Magneto coil not work

● Valve gap not enough

No

Yes No or not enough

Pressure Value

10

Description Routine

Power is not strong, not speed up

● Damage of cylinder, piston rings

● cylinder head gasket works not well

● Valve is damaged

● Mixing air time not good

●EEV of carburetor not work

● Valve socket not good

●Air leakage of minus pressure tube

●Ignition time not good

●Vent bolt of carburetion not work

● 化油器过满溢出

OK No or not enough

Start accordin

g

ri

g

ht method

No explosion No start with explosion

Take off spark plug again

火花塞是干的火花塞湿

●Too many oil in carburetor

●EEV of carburetor not work

●Value of throttle is unusual.

Dry Wet

◆

Reasons

Check Ignition

time [Ignition led]

● Battery connection badness

● Air filter jammed

● Vent hole of oil tank cover jammed

● CDI parts not work

● Trigger not work

Yes No

● Valve gap not good

● Shape of valve changed

Yes No

Check Valve Gap

Check Compress pressure Value in Plunger

Yes

●

● oil tube jammed

● minus Pressure line not connected well

● Carburetor jammed

No

Let engine work

at high speed

11

Description Routine

◆

● Plunger ring is damaged

● Air leakage from gasket position

Yes No or Lower

● Parts of Carburetor jammed

No Yes

● Spark plunger polluted/damaged

● Temperature of spark plunger wrong

Clean Dirt

● Valve socket not work well

● Mix air time not good

Check spark plunger

Check Carburetor jammed.

Engine is too hot or not

● Oil is not replaced

● Mix air rare

● Quality of oil bad

No Yes

Speed up or work at high

speed

Check oil quantity

level and quality

OK

●

● Too many oil

● Oil is not enough No

● Plunger or Cylinder damaged

● Too many carbon powers in firebox

● Ignition time wrong

● Mix air rare

● Ignition time wrong

● Quality of oil is bad

● Too many carbon powers in firebox

● Cooling liquid not enough

Reasons

12

Description Routine

Egine works unusually（such as idle and low speed）

No sound Unusual

sound

Ignition Time OK?

Yes

●

● CDI parts not good

● Magnetor not good

No

● Mixed air is rare[Take screws down]

● Mixed air is thick[Take screws up]

Yes No

● Carburetor is loosed

● Airproof parts not good

No Yes

● “O” gasket not good

● Air leakage in vacuum parts

Vent screw of

carburetor OK?

Air leakage in

carburetor gasket?

Sparks OK?

Reasons

13

Description Routine

Engine works unusually [High speed]

OK No or less spark ● Ignition coil not good

● Ignition coil is broken or in short

● CDI parts not good

● Spark plunger not good or polluted

● Ignition trigger not good

● Air tube jammed or damaged

Yes

● Cut Air Valve not good

● Vacuum line jammed or damaged

No

◆

Cut Air Valve OK?

Ignition time OK?

Yes

●

● CDI parts not good

● Magnetor not good

No

● Adjustment not good

● Value socket damaged

Yes No

● Oil line or oil filter jammed

● Vent hole is jammed

OK Unusual

● Not enough oil in oil tank

● minus Pressure line switch not work

Handspike gap OK?

Check oil automatic

screw function?

● Clean carburetor socket

No Yes

Carburetor socket jammed?

Reasons

14

Description Routine

Not move with high speed

● Protruding sprocket wheel and magneto

flywheel position not match

Yes No

Mixed time right?

● Spring not good Yes No

Spring of valve good？

◆

Engine works at high

speed or easy to stop?

Engine works at

high speed

●

● Ignition coil wrong connection

● Spark plug bad connection

No high speed or easy to

stop

reverse gear OK

Check reverse operation system

●Length of reverse cable is not suitable

reverse position wrong

● Connection of battery not good

● Oil line not good

No Yes

Any unusual sound of engine

gear case

●Differential gear damaged

●reverse gear damaged

●Connector sheath of reverse gear damaged

●Differential damaged

Reasons

15

Description Adjustment

No power in battery

◆

Open side cover of engine and check

clutch strap broken or not

Start engine and check

voltage of battery

Battery can not charging

●

●Check battery whether out of usage

●Battery not good

Normal

● Connection of line is not good

Normal

● Stator not good

● Yellow line is broken

Unusual

Resistance value

of coil

Yes ● Blue/yellow or Green line is broken

No

Voltage between Blue/yellow and Green

li

Yes

● Booster not good

● connection-peg not good

No

Whether any looseness of booster and connection-peg？

● Magneto not good

Reasons

16

Description Adjustment

The charge is not good ( Overcharge )

No spark

● Measure of voltage between

rectifier polarities

Voltage is usual when

ignition switch is “On” No voltage when ignition

switch is “On” ● black line of main cable

is broken

Any looseness or default of booster connection-peg

No Yes ● connection-peg not

good

● booster not good

Use a new spark plunger then check

i

No or less sparks

●

Sparks OK

No

Any looseness between lid of spark and

between high-voltage lines

● Lid of spark is loosen

Yes

● previous Spark Plunger broken

Connection of CDI parts

OK?

Yes No ● Connecter is not good

Check statement and features of connecter of CDI and measure

the resistance

Reasons

17

Item

2 Inspections and Adjustment

Check & Repair method Transmission System Brake System

Electronic System Wheel System Engine

Cushion System Others

Check & Repair method

Maintenance period List

Maintained time ITEM

Requirements

Km ( remark )

1000Km 4000Km 8000Km 12000Km remark

Oil System I I I

Carburetion System I I I

Carburetor I I I I

Core of air filter often R

Spark plug I R I

Lubricating oil in engine First time1000Km; then per 2000 Km

Clean net of lubricating oil Per year R C C C

Gap of valve I I I I

Battery I I I

Brake system I I I I

OK No

Yes No

arts OK?

● Ignition switch not good

● Magneto coil not good

● Trigger not good

● Ignition coil not good

●cable is broken

● Connection of coupling

p

arts not good

● CDI not good

18

Brake DISC. I I I

Brake lighter switch I I I

Main lighter Per month I I I I

Clutch I

Suspend parts I I I

Support parts I I I

Screw and bolt Per month I I

Wheel/spoke Trimester I I I

Vent hole of crankcase C C C

Idle of carburetor I I I I

The vehicle should carry on the periodic maintenance according to the stipulation time.

Before the maintenance the vehicle should be cleaned thoroughly.

Definition of Letters：

I: to check, clean, adjust lubricate or change apart.

C：cleaning

R：use a new part

A：make an adjustment

L：Lubricating

Note: When the odometer reading surpasses the maximum features listed in the table,

the maintenance should be done repeatedly according to the table.

Brake System

Adjustment

Check pedal free travel:

20~30 mm

If it is beyond of this distance, please take down/up

adjustment screw.

When air enters the brake cylinder piston or the brake oil pipe, resulting in

brake failure, it is necessary to discharge the air in the brake in the following

manner: first step on the brake pedal with foot, loosen the exhaust screw

of the brake cylinder, open the brake cylinder oil cup, screw up the exhaust

screw until there is no brake liquid and air outflowing, release the accelerator

pedal and repeat the procedures until there is no air out-flowing.

Vent bolt

20~30mm

Adjustment Bolt

19

Parking Brake System

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

Parking Brake system is complexes; adjust parts in a whole system to

Make PB system work well.

Wheel System

Wheel

Check tire with air pressure gauge.

Standard information：

Spec. of Tire Pressure Value

（off-road）

Pressure Value

（Road）

Front AT21X8-10 28kPa 200kPa

Rear AT22X11-10 35kPa 225kPa

Check mental hexad flange screws of front wheel and axle.

tight them as per required torque.

Cushion System

Brake oil pump

Attention!

When exhaust, you must guarantee that there is

enough brake fluids in brake pump oil cup.

Adjustment bolt of brake

Attention! Please make sure that length of rear wheel

brake line is out about

3

-

5mm

.

Attention! Please make sure that tire is cold before checking.

Metal hexad flange screws

Front/rear axe screws

Brake Handle

Ad

j

ustment bolt

20

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

Stop the engine and take down oil position screw. If oil level reach at standard position it is OK;

otherwise pour in oil.

OIL TYPE：85W-140 or 15W/35S

Put on oil position screw after checking airproof gasket

Replacement of lubricating oil

Take down oil position screw

Take down vent bolt and put oil out

Put on vent bolt with revolving

Pour oil according to standard value：

Attention! Make sure that ground is plainness.

Oil position screws Air proof

gasket

Attention! Make sure that no damage in airproof gasket

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GSMOON KD260-2 User manual

GSMOON KD260-2 User manual

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