Transcript
TrailMaster Go-Kart 110 XRX PARTS MANUAL
Fig 1
REF. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
CYLINDER
Part No. 104301 104302 104310 104306 104304 104303 104307 104308 102240 104130 104410 104411 102206 102290 116101-003 102250 102222
DESCRIPTION
Q'TY
VALVE,INTAKE
1
VALVE,EXHAUST
1
OIL RETAINER
2
SPRING BASE,OUTER VALVE
2
SPRING,OUTER VALVE
2
SPRING,INNER VALVE
2
VALVE-SPRING RETAINER
2
VALVE COLLET
4
CYLINDER HEAD
1
CAMSHAFT
1
VALVE ROCKER
2
SHAFT,VALVE ROCKER
2
SEAL SPACER,CYLINDER HEAD,R
1
COVER,CYLINDER HEAD,R
1
BOLT M6X20
2
SPARK PLUG
1
BOLT,EXHAUST PIPE
2
Fig 2
REF. No. 1 2 3 4 5 6 7 8
CRANKCASE COVER, R
Part No. 101401 106308 101442 101441 106307 106330 106309 106311
DESCRIPTION CRANKCASE COVER,R ADJUSTMENT NUT M8 O-RING φ18×3 OIL GAGE BOLT M8 TAPPET O-RING φ8×1.8 FLAT WANSHER φ8
Q'TY 1 1 1 1 1 1 1 1
Fig 3
REF. No. 1 2 3 4 5 6 7 8 9 10 11
CRANKCASE COVER, L
Part No. 101301 111200 116101-043 116102-004 101309 101316 101312 116102-020 101313 101307 101301
DESCRIPTION CRANKCASE COVER,L MAGNETO STATOR BOLT M6X16 BOLT M5X16 TENSION DISC INSPECTION PLATE 1 INSPECTION O-RING 27.4×2.4 BOLT M6X16 INSPECTION O-RING 13.8×2.5 INSPECTION PLATE 2 BOLT M6X12
Q'TY 1 1 2 2 1 1 1 1 1 1 4
Fig 4
REF. No. 1 2 3 4 5 6 7 8 9 10 11
CRANKCASE, L
Part No.
DESCRIPTION
Q'TY
104220 104208 104230 104203 104224 104223 101140 105120 105102 116210-002 116210-005
ARM,CHAIN TENSIONING ARM PIN,CHAIN TENSIONING ROD,CHAIN TENSIONING ROD SPRING,CHAIN TENSIONING WASHER,SEAL BOLT SEAL BOLT CRANKCASE ASSY.,L DRIVEN SPROCKET,OIL PUMP SPROCKET SHAFT,OIL PUMP BEARING 6001 BEARING 6203
1 1 1 1 1 1 1 1 1 1 1
Fig 5
REF. No. 1 2 3 4 5 6
CRANKCASE,R
Part No. 101220 101121 101119 108201 116210-005 116210-003
DESCRIPTION CRANKCASE ASSY.,R WASHER, DRAIN PLUG DRAIN PLUG BOLT,SHIFTING POSITION BEARING 6203 BEARING 6201
Q'TY 1 1 1 1 1 1
Fig 6
REF. No. 1 2 3 4 5
PISTON
Part No. 103101 103110 103105 103104 103103
DESCRIPTION PISTON PISTON RING FIRST RING SECOND RING CIRCLIP, PISTON PIN
Q'TY 1 1 1 1 1
Fig 7
REF. No. 1 2 3 4 5 6 7 8 9 10 11 12 13
CRANKCASE ASSY.
Part No. 101200 101100 103200 107100 107200 109300 108100 101101 109313-003 109313-002 116108-011 109308 109304
DESCRIPTION CRANKCASE PART,R CRANKCASE PART,L ROD,CRANK CONNECTING MIANSHAFT COUNTERSHAFT STARTING SHAFT TRANSMISSION DRUM CRANKCASE SEAL,L SNAP RING φ12 SHAFT GASKET PINφ10×14 SEAT,STARTING SPRING STARTING SPRING
Q'TY 1 1 1 1 1 1 1 1 1 1 2 1 1
Fig 8
REF. No. 1 2 3 4 5 6 7
Part No. 101205 101114 116101-013 116101-012 116101-011 116101-002 102221
DESCRIPTION PIPE CLAMP,VENTILATION PIPE CLAMP,OVER-FLOW BOLT M6X65 BOLT M6X60 BOLT M6X50 BOLT M6X14 IRON WASHER φ6
Q'TY 1 1 4 2 1 1 1
Fig 9
REF. No. 1 2 3 4
Part No. 108210 108130 108101 116108-007
DESCRIPTION SHAFT,SHIFTING GEAR GUIDE PLATE SPRING,GUIDE PLATE PINφ8×12
Q'TY 1 1 1 2
Fig 10
REF. No. 1 2 3 4 5 6 7 8 9 10
Part No. 101130 106002 106020 106101 106001 116105-009 105110 105103 105104 116105-008
DESCRIPTION GEAR OIL FILTER DRIVING GEAR SLEEVE DRIVEN GEAR ASSY. CLUTCH COLLAR DRIVING GEAR BOLT M6X22 OIL PUMP SHAFT SLEEVE,OIL PUMP SPROCKET SEAL,OIL PUMP BOLT M6X16
Q'TY 1 1 1 1 1 1 1 1 2 2
Fig 11
REF. No. 1 2 3 4 5 6 7
Part No. 106200 106102 106112 106111 106109 106108 106104
DESCRIPTION CLUTCH BODY RETAINING WASHER BUTTERFLY WASHER ROUND NUT SEAL, END CAP END CAP, CLUTCH SNAP RING φ17
Q'TY 1 1 1 1 1 1 1
Fig 12
REF. No. 1 2 3 4 5 6 7
Part No. 116106-001 106105 106106 101403 101401 106130 108230
DESCRIPTION BOLT M5X12 TUBE,OIL FLOW TUBE SPRING,OIL FLOW SEAL SPACER,CRANKCASE COVER,R CRANKCASE COVER,R CAM DISC SHIFTING LEVER
Q'TY 4 2 1 1 1 1 1
Fig 13
REF. No. 1 2 3 4 5 6
Part No. 103100 103102 103103 116108-007 101103 101104
DESCRIPTION PISTON PISTON PIN CIRCLIP, PISTON PIN PINφ8×12 STUD A STUD B
Q'TY 1 1 1 2 2 2
Fig 14
REF. No. 1 2 3 4 5 6 7
Part No. 104150 102104 102100 102217-004 102108 102107 102105
DESCRIPTION TIMING CHAIN SEAL φ11.5×φ14.7×1.5 CYLINDER BODY BOLT M6X23 SEAL SPACER, CYLINDER BODY BUSHING SEAL φ9×φ11.7×1.5
Q'TY 1 1 1 1 1 1 1
Fig 15
REF. No. 1 2 3 4 5 6 7 8 9
Part No. 104101 102103 102106 102230 104206 104207 104204 116108-011 10205
DESCRIPTION DRIVEN SPROCKET,TIMING SEAL φ14.5×φ18.5×2.4 BUSHING φ11.5 SEAL SPACER, CYLINDER HEAD CHAIN GUIDE ROLLER SHAFT WANSHER φ8, ROLLER,CHAIN TENSIONING PINφ8×14 ROLLER,CHAIN GUIDING
Q'TY 1 1 1 1 1 1 1 2 1
Fig 16
REF. No. 1 2 3 4 5 6 7 8 9 10
Part No. 102202 102200 102223 102224 102217-004 102218 102201 102219 102221 104102
DESCRIPTION SEAL SPACER,CYLINDER HEAD COVER CYLINDER HEAD PART BOLT M6X110,CYLINDER HEAD,L WASHER φ6,CYLINDER HEAD,L BOLT M6X23 ACORN NUT M6 CYLINDER HEAD COVER COPPER WASHER φ6 IRON WASHER φ6 TIMING BOLT M5X12
Q'TY 1 1 1 1 1 4 1 1 3 3
Fig 17
REF. No. 1 2 3 4
Part No. 102207 102208 102203 102204
DESCRIPTION VALVE COVER O-RING, VALVE COVER COVER,CYLINDER HEAD,L SEAL SPACER,CYLINDER HEAD,L
Q'TY 2 2 1 1
Fig 18
REF. No. 1 2 3 4 5 6
Part No. 101105 101106 101124 116106-002 104202 104201
DESCRIPTION SEAL PAN O-RING φ107×2,SEAL PIN O-RING φ5.8×1.9,SEAL PIN BOLT BOLT M6X16 GUIDE PLATE,CHAIN TENSIONING PLATE,CHAIN
Q'TY 1 1 2 2 1 1
Fig 19
REF. No.
Part No.
1
108240
2 3 4 5
107230 116101-001 109240 109210
6
109250
7 8
113200 113206
DESCRIPTION OIL SEALφ11.6×φ24×10, SELECTOR SHAFT OIL SEALφ29×φ17×5,COUNTERSHAFT BOLT M6X12 DRIVING CHAIN DRIVING SPROKET OIL SEAL φ30×φ18.9×5, DRIVING SPROKET GEAR INDICATOR SWITCH PLATE
Q'TY 1 1 1 1 1 1 1 1
Fig 20
REF. No. 1 2 3 4 5 6 7 8 9 10
Part No. 116101-011 112000 116108-007 111100 101304 116102-013 116101-007 116101-006 101300 103208
DESCRIPTION BOLT M6X50 STARTER MOTOR PINφ8×12 ROTOR SEAL SPACER,CRANKCASE COVER,L BOLT M6X65 BOLT M6X32 BOLT M6X28 CRANKCASE COVER,L NUT M10
Q'TY 4 1 2 1 1 1 1 1 1 1
Fig 21
REF. No. 1 2 3 4
Part No. 118001 118002 118003 118004
DESCRIPTION PLATE,IDLER GEAR IDLER GEAR SHAFT,IDLER GEAR SHAFT SLEEVE,ODLER GEAR
Q'TY 1 1 1 1
Fig 22
REF. No. 1 2 3 4 5
Part No. 121001 121002 121003 121004 121005
DESCRIPTION GB5783 M6X25 CARBURETOR TUBE #67 PAPER WASHER,CARBURETOR TUBE BAKELITE MAT,CARBURETOR TUBE O-RING,BAKELITE MAT
Q'TY 4 1 1 1 1
Fig 23
REF. No. 1 2
Part No. 121006 121007
DESCRIPTION GB5787 M6X252 REAR COVER,L
Q'TY 2 1
Fig 24
REF. No. 1 2 3 4 5 6 7 8 9
FRAME GROUP
Part No. 8.070.054 6.060.300 8.070.055 8.080.078 57100-110G 6.000.189 GB5787 M8X50 8.070.056 8.010.047
DESCRIPTION C.B.C.BARCAGE.(R.S.B) C.B.C.CUSTOM CROSS BARTOP.FR(R.S.B) C.B.C.CUSTOM J-BAR.LSIDE(R.S.B) C.B.C.CUSTOM CROSS BARTOP.RR(R.S.B) FRAME COMP.(R.S.B) FOAM RADDING-1 BOLT M8x1.25x50 C.B.C.CUSTOM J-BAR.RSIDE(R.S.B) R- WASHER
Q'TY 2 1 1 1 1 2 14 1 20
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 51 52 53
GB93 φ6 6.100.319 GB6177 M6 GB6187 M8 7.020.045 GB6170 M8 GB5789 M8X16 6.000.136 7.010.017 6.000.135 60120-110G 60110-110G 6.000.319 7.110.018 7.010.006 6.000.320 7.020.111 6.131.172 6.130.172 6.132.172 6.133.172 6.001.074 GB5789 M6X16 GB5789 M6X14 4.100.034 40001-110G GB5789-M8X30 GB5789 6.000.235 GB6187 M10X1.25 GB6170 M10*1.5 58110-110G 9.700.518 9.500.130 7.010.003 52310-110G 9.708.145 6.300.111 GB97 61700500000010005
SPRING WASHER φ6 FOAM RADDING-4 NUT M6 NUT M8 RUBBER FOOLPLAIE NUT M8 BOLT M8x1.25x16 HORN.L TUBE SEAT 25 HORN.H THROTTLE CABLE COMP. CHOKE CABLE COMP. FOAM RADDING-2 TUBE SEAT 28 STEERINGSHAFT BUSH BIKINI TOP FOAM PADDING-3 FRONT FENDER BRACKET,L FRONT FENDER BRACKET,R REAR FENDER BRACKET.L REAR FENDER BRACKET,R FENDER BLOT M6X16 BLOT M6X14 HANGLE,GEAR LEVER GEAR LEVER BOLT M8X30 BOLT M10X1.25X40 KNUCKLE BEARING,R NUT M10X1.25 NUT M10X1.5 REVERSE ROD ROUND PINφ5X18 COTTER PINφ1.5X30 BUSHING,PLASTIC REVERSE ARM FLANGE BOLT M8x1.25x145 REFLECTOR FLAT WASHERφ5 NUT M5
8 2 12 8 4 2 2 1 6 1 1 1 2 2 1 1 2 1 1 1 1 4 12 8 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1
Fig 25
REF. No. 1 2 3 4 5 6 7
STEERING SHAFT ASSY
Part No. 7.010.056 GB6187 M6 7.020.057 2.000.056 GB5783 M6X16 40100-80G 8.000.002
DESCRIPTION STEERING BOLT COVER LOCKING NUT M6 STEERING WHEEL STEERING-SHAFT BOLT M6 x16 STEERING ASSY. TIE ROD ASSY
Q'TY 1 9 1 1 3 1 2
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
6.000.180 8.010.135 6.000.181 GB6187 M8 GB6170 M8 GB6170 M8(L) GB818 M5X14 7.020.059 GB97 φ5 4.010.001 8.010.075 7.010.007 8.010.079 8.010.131A-50A GB5787 M6X20 9.820.010 8.020.130 9.500.008 8.010.123 4.000.044 7.010.003 8.040.011 8.040.010 9.500.218 7.020.043 7.020.044 GB70 M8X12 9.500.007 8.020.209 9.500.130 6.000.000 6.000.305 6.000.306 7.020.076 GB6170 M6 6.000.010 9.700.004 9.300.010 6.000.028 7.020.016 GB5789 M6X25 9.700.628
STEERING BALL JOINT TIE ROD ROD END NUT M8 NUT M8 NUT M8(L) BOLT M5 x14 STEERING BALL JOINT DUST COVER FLAT WASHER φ5 CONNECTING DEVICE GEAR AXLE STEERING GEAR BUSH CONNECTING PIPE STEERING GEAR BOLT M6 x20 LOCKING NYLON NUT M10*1.25 STEERING GEAR BRACKET(R.S.B) ROLL PIN φ3 x 20 PEDAL BOLT BRAKE PEDAL COMP. PEDAL BUSH BRAKE PEDAL RETURN SPRING,R THROTTLE PEDAL RETURN SPRING,L THROTTLE PEDAL COMP BRAKE PEDAL PAD THROTTLE PEDAL PAD BLOT M8X12 ROLL PIN φ3 x 16 STOPPING PLATE COTTER PINφ1.5x 30 HYDRAULIC BRAKE ASSEMBLY MASTER CYLIND ER CYIINDER ROD DUST COVER NUT M6 BRAKE HOSE ASSY BOLT M10X24 WASHER φ10 RR. CALIPER ASSY. RR. BRAKE PAD SET BOLT M6X25 LOCKING ROLL PIN
2 2 2 2 2 2 2 2 2 1 1 2 1 1 4 1 2 1 1 1 4 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 4 1 2 2 1
50 51 52 53 54 55 56 57
8.020.224 GB5782 M8X65 7.010.022 GB5783 M8X18 GB6170 M8 GB70 M8X12 GB93 φ8 GB97 φ8
CYIINDER ROD BRACKET BOLT M8X65 RUBBER FOOT PEDAL STOP BOLT M8X18 NUT M8 BOLT M8X12 SPRING WASHER φ8 WASHER φ8
1 1 1 1 1 2 2 1
Fig 26
REF. No. 1 2 3 4 5 6 7 8 9 10 11 12 13
SUSPENSION ARM ASSY
Part No. GB5789 M8 x 105 7.010.003 8.010.015 4.000.047 GB6187 M8 GB5787 M10 x 40 6.100.325 9.708.145 7.020.061 4.000.041 2.000.055 6202-2RS 6.000.309
DESCRIPTION FLANGE BOLOT M8 x 1.25 x 105 UPPER SUSPENSION ARM BUSH UPPER SUSPENSION ARM COLLAR UPPER SUSPENSION ARM LOCKING FLANGE UNT.M8 FLANGE BOLT M10 x 40x1.25 CUSHION ASS Y.FR FLANGE BOLT M8x1.25x145 BALL HEAD DUST SEAL LOWER SUSPENSION ARM ASS Y SPINDLE AND STRUT SUPPORT,R BEARING 6202 FRONT WHEEL ASS Y.L.
Q'TY 2 8 2 2 4 4 2 2 4 2 1 2 1
14 15 16 17 18 19 20 21 22 23 24 25
6201-2RS GB9457 M12*1.25 7.020.039 GB9457 M10*1.25 6.100.310 6.100.311 2.000.057 GB6187 M10 6.100.321 8.010.084 9.500.230 7.190.018
BEARING 6201 GB9457 NUT M12*1.25 HUB COVER FR GB9457 NUT M10*1.25 RIM,FR TIRE,FR 16X6-8 SPINDLE AND STRUT SUPPORT,L LOCKING FLANGE M10X1.25 FRONT WHEEL ASSY.R. FRONT WHEEL COLLARφ15*φ19*24.5 COTTER PIN φ2.5X30 AIR VALVE
2 2 2 4 2 2 1 4 1 2 6 2
Fig 27
REAR SWING ARM
REF. No. 1
Part No. 52100-110G
DESCRIPTION REAR SWING ARM
Q'TY 1
4 5 6 7 8
GB5789 M10X40 6.000.325 GB6187 M10 7.020.077 GB6170 M10
FLANGE LOCKING BOLT M10X1.25X40 250CUSHION ASSY. FR. LOCKING NUT M10X1.25 BUSHING, SWING ARM ISOLATOR 10*30*30/35 NUT M10X1.25
4 2 6 2 2
16 17 18 19 20
7.010.028 6.000.085 7.020.020 7.020.023 GB5789 M10X68
BATTERY COVER BATTERY 12V 6.5AH LOWER BATTERY CUSHION BATTERY STRAP FLANGE LOCKING M10X1.25X68
1 1 1 1 2
Fig 28
REF. No. 1 2 3 4 5 6 7
REAR HOUSING
Part No. 7.020.039 GB9457 M16*1.5 GB96 φ16 6.000.315 GB5789 M8X16 6.000.196 6005-2RS
DESCRIPTION HUB COVER,RR CASTLE NUT M16*1.5 WASHER Φ16 REAR WHEEL ASSY R. FLANGE BOLT M8 x16 AXLE COVER BEARING,6005
Q'TY 2 2 2 1 6 2 2
8 9 10 11 12 13 14 15 16 17 18 24 25 26
GB70 M8X20 8.010.201 8.010.202 9.110.025 5400600050L000 8.010.199 6.000.316 9.500.330 420-58 420-10 6.100.333 7.020.078 7.090.001 7.190.018
FLANGE BOLT M8x20 DISC BRAKE,RR REAR AXLE HUB BOLT M10x1.25x25 REAR SPROCKET REAR AXLE REAR WHEEL ASS Y.L COTTER PIN 3x40 DRIVE CHAIN MASTER LINK RIM,RR REAR TIRE 16x7-8 WASHER Φ45X35.5X2 AIR VALVE
8 1 1 1 1 1 1 2 1 1 2 2 2 2
Fig 29
CLUTCH ASSY.
REF. No. 1
Part No. 52200-110G
Q'TY 1
GB6187 M10 GB5789 M10X240 5210100110G000 GB5789 M10X55 10110-110G GB6187 M8 GB5789 M8X115 7.010.029 GB818
DESCRIPTION ENGINE MOUNTING PLATE-METALLIC BUSHING, SWING ARM ISOLATOR 10*30*30/35 NUT M10X1.25 FLANGE BOLT M10 x1.25x240 COLLAR,HANGING BRACKET FLANGE BOLT M10 x1.25x55 BUSHING-CHAIN ADJUSTER NUT M8 FLANGE BOLT M8x115 ELECTRIC ASSY. COVER PAN SCREW M6x60
2
7.020.077
3 4 5 6 7 8 9 10 11 13 25 26 27 28 29 33
GB6177 GB6170 M12 8.010.042 8.010.041 7.020.001 8.020.045 GB6187 M12
NUT M6 NUT M12X1.25 WASHER-CHAIN ADJUSTER(φ12Xφ35X6) BUSHING-CHAIN ADJUSTER CAP WASHER-CHAIN ADJUSTER BOTTOM CAP WASHER-CHAIN ADJUSTER NUT M12X1.25
2 1 2 1 1 1 1
4 3 1 1 2 1 2 2 1 2
Fig 30 WIRE HARNESS, ELECTRICAL/SEAT/ENGINE
REF. No. 1 5 6
Part No. 6.000.328 7.010.076 6.000.164
DESCRIPTION SAFETY BELT SWITCH PANEL COVER ENGINE STOP BUTTON
Q'TY 1 1 1
7 8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 37 38 39 44 45 46 47 48 49 50 51 52 53 54 60
6.000.133 6.000.165 8002500110G000 6.000.329 6.000.330 6.000.331 9.910.841 GB6177 M8 Engine-110 7.060.022 6.000.200 GB2823 ST4.2X13 GB5787 GB5789 GB6187 50110-110G 50130-110G GB70 GB6187 6.000.166 7.020.029 6.000.056 8.040.009 7.020.030 PZ19000110G000 49010-110G 49100-110G GB6187 7.020.005 8.010.034 GB5787 47100-110G 47001-110G GB5789 40010-110G 60010-110G 930006000000 617706000100 80022-110G
HORN BUTTON POWER ON SWITCH WIRE HARNESS HEAD-REST SEAT COMP.R SEAT COMP.L BOLT STRAP M8X1.25X45 FLANGE NUT M8 ENGINE COMP. LOCKING WASHER ELETRIC STARTER BUTTON BOLT ST4.2X13 BOLT STRAP M8X1.25X40 bolt M6X16 NUT M6 FUEL TANK COMP FUEL FILLER CAP COMP bolt M8*16 110 Gas tank nut FUEL COCK ASS'Y FUEL TUBE, #2 FILTER FUEL TUBE CLIP FUEL TUBE, #1 PZ19 CARBURETOR AIR CLEANER CLIP AIR CLEANER NUT M8 BUSHING, RUBBER TANK COLLAR BOLTM8x40 MUFFLER COMP. BUSHING,MUFFLER BOLT M6x30 SHIFTER SHIFTER MOUNTING ROD A WASHER 6 JAM NUT M6 DIGITAL DISPLAY, GEAR
1 1 1 2 1 1 2 2 1 3 1 4 2 4 4 1 1 4 4 1 1 1 4 2 1 1 1 1 1 1 1 1 1 1 1 1 0 2 1
Fig 31
REF. No. 1 2 3 4 5 6
WARNING STICKERS ASSY.
Part No. 14-1201-00 14-1202-00 14-1203-00 14-1204-00 14-1205-00 14-1206-80
DESCRIPTION LABEL SEAT BELT LABEL NO CLIMBING LABEL WARNING OPERATION LABEL CHAIN GUARD LABEL NO LONG HAIR LABEL AGE
Q'TY 1 1 1 1 1 1
Fig 32
REF. No. 1 2 3 4 5 6 7 8 9 10 11
Electric ASSY.
Part No. 8002400110G000 8001600110G000 8001800110G000 8001700110G000 GB5789 M6*16 GB6187 M6 GB5789 M6*20 GB5787M6*20 8002200110G000 8120000080GA00 8110000050GB01
DESCRIPTION Regulator C.D.I Ignition Coil Starting relay BOLT M6*16 NUT M6 BOLT M6*20 BOLT M6*20 Shifting Indicator On/off switch LED light
Q'TY 1 1 1 1 3 5 2 2 1 1 2
