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GO-KART [XYKD260] Repair Manual

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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

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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

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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

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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

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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） 4.5~5.0g

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

gimbal

Rear wheel rim axle

Rear swing arm axle

Sub seat slide rail

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Structure Drawing

Pipe of

cooling liquid

kettle

Water tubing

Temperature

Control

Switch

Rear brake oil

tube

Brake cable

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Fuse 15A

Flash apparatus

Relay

CDI

BATTERY

Ignition coil

rectifier

Electric parts

case

Quadric air-intake

mechanism

Throttle cable

Reverse cableParking

brake cable

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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 according right 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

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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