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Decals
_1_ WARNING: Safety decals must be replaced if
they become unreadable or detached from the
Fun-Kart.
If decals are unreadable or missing, warningof
potential hazards or safety requirements may be
lacking. This could result in the operator and/or
passenger not taking the proper safety
precautions.
When the WARNING decals become illegibleand/or
detached, the old decal must be removed, the area
cleaned with a liquid dish washing detergent, rinsed
and thoroughly dried, and the new decal installed.
NOTE: See OPERATOR'S MANUAL SUPPLEMENT
for part numbers and contact the nearest dealer to
order replacements.
Brake Service
Disc Brake
_IL WARNING: DO NOT operate this Fun-Kart if
the brake system will properly not stop the Fun-
Kart. See OPERATION-BRAKE TEST.
A
WARNING: DO NOT perform maintenance of
brake rotor, pads or calipers until the parts have
had sufficient time to cool.
BRAKE INSPECTION (See Figure t7)
Inspect the brake caliper(s) before each use of the
Fun-Kart Always clean and service before each
season and when removed from storage. The routine
maintenance presented below is required to keep the
brake system in good working order.
1. Inspect the entire braking system to ensure all
connections are secure and all pivot points move
freely.
2. Check brake pedal travel. Brake linkage should
move freely and snap back to rear position when
released. Free play should be less than 1/2 inch
of pedal travel.
3. Check that the caliper assembly (1) slides freely
in the mounting bracket (2) and caliper actuator
lever (3) moves freely. Clean and lubricate as
required.
4. Check brake pads for wear and replace if brake
pad material is 1/16" or less.
5. Check brake rotor (4) surface condition. Brake
rotor surface should be free of pits, deep grooves,
dirt, corrosion, oil and grease. Worn, warped,
grooved or pitted rotors must be replaced.
BRAKE ADJUSTMENT (See Figure 17)
The brake caliper(s) should be adjusted if brake
pedal free play is in excess of 1/2 inch, brake does
not stop the Fun-Kart or the parking brake does not
hold the Fun-Kart when applied. If any of these
conditions exist on the Fun-Kart, the brake caliper(s)
must be serviced immediately.
To
1.
2_
3.
4.
5.
6.
adjust the brake caliper(s):
Make sure the brake pedal (5) and the caliper
actuator lever (3) are in the rear position.
Remove guard covering the brake caliper(s).
Loosen the jam nut (6) and rotate the adjuster
screw (7) clockwise until it is snug.
Back out the adjuster screw counterclockwise 1/4
turn.
While holding the adjuster screw in this position,
securely tighten the jam nut.
Check that the brake pedal arm is against the
rear stop (8). If not, the brake rod can be
shortened by removing the hex head bolt (9) that
holds the brake rod on the brake pedal,
reassemble the bolt in the rear hole (10) of the
brake rod and tighten the nut securely.
WARNING:The guard(s) must be in place to
protect the rider(s) from the rotating parts of the
Fun-Kart. DO NOT operate the Fun-Kart without
the guards securely in place.
,
8.
Replace the guard.
Perform BRAKE TEST as described in the
OPERATION-OPERATING INSTRUCTIONS
before operating the Fun-Kart. Re-adjust brake as
necessary and repeat BRAKE TEST until the
brake willhold and stop the Fun-Kart properly.
37
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