GoPowerSports Bolt Go-Kart Kit

Complete Assembly Manual - Edition 1.0

Table of Contents

1. Introduction
2. Safety Information
3. Tools & Requirements
4. Parts Inventory
5. Pre-Assembly Preparation
6. Assembly Stages (1-8)
7. Initial Testing
8. Maintenance Schedule
9. Troubleshooting Guide
10. Support Resources

1. Introduction

Congratulations on your purchase of the GoPowerSports Bolt Go-Kart Kit! This premium bolt-together go-kart has been engineered for both beginning and experienced builders. Your kit features:

• 98cc (3HP) engine standard configuration
• Speeds up to 26mph (stock)
• Complete bolt-together design - no welding required
• Adjustable pedal positions
• Upgradeable to 212cc engine
• Premium frame components

Project Requirements

• Assembly Time: 4-6 hours
• Workspace: 10' x 10' minimum
• Working Surface: Level concrete floor
• Assistance: Some steps require two people
• Skill Level: Beginner to Intermediate

Safety Information

IMPORTANT: Read all safety instructions before beginning assembly

Required Safety Equipment:

• Safety glasses
• Work gloves
• Closed-toe shoes
• Protective clothing

Assembly Safety:

• Keep work area clean and well-lit
• Keep children and pets away from assembly area
• Use proper lifting techniques for heavy components
• Follow all torque specifications
• Double-check all safety-critical connections

Operational Safety:

• Minimum operator age: 13 years
• Maximum weight capacity: 400 lbs
• Always wear DOT-approved helmet
• Never operate under the influence
• Follow all local regulations
• Maintain safe operating speeds

Required Tools

Primary Tools:

• Torque wrench (10-50 ft-lbs range)
• Socket set (metric and standard):
• 13mm (primary size)
• 9/16"
• 13/2"
• 10mm
• 13/16"
• 15/16"
• 1-1/16"
• Allen wrench set:
• 4mm
• 5mm
• 6mm
• Adjustable wrenches (2)
• Phillips screwdriver
• Flathead screwdriver

Specialty Tools:

• Chain break tool (recommended)
• 7/32" drill bit
• Center punch
• Tape measure
• Level
• Thread locking compound

Optional Tools:

• Impact wrench
• Socket extensions
• Universal joint adapter
• Anti-seize compound
• Paint markers
• Digital camera (for documentation)

Parts Inventory

Frame Components:

• Main frame rails (2)
• Front crossbar (1)
• Middle crossbar (1)
• Rear crossbar (1)
• Front axle assembly (1)
• Steering mount tubes (2)
• Seat support tubes (4)
• Armrest bars (2)

Hardware Packages:

• Primary Hardware Kit:
• M8x45mm bolts
• M8 nylon lock nuts
• Washers (flat and split)
• 60mm specialty bolts

• Steering Hardware Kit:

• Tie rod ends
• Steering shaft components
• Steering wheel mounting hardware

• Engine Mounting Kit:

• Engine mount bolts
• Chain
• Master link
• Clutch assembly

Pre-Assembly Preparation

• Inventory Verification
• Unpack all boxes carefully
• Check parts against inventory list
• Photograph any damaged components
• Contact support if parts are missing
• Sort hardware by size and type
• Label bags for organized assembly

• Workspace Setup

• Clear minimum 10' x 10' area
• Ensure proper lighting
• Place rubber mat or cardboard for protection
• Set up parts in assembly order
• Position tools within easy reach
• Prepare cleaning station

• Frame Preparation

• Clean all metal components with acetone/degreaser
• Remove any manufacturing oils
• Check all tubes for debris inside
• Verify all pre-drilled holes are clear
• Remove any burrs from cut edges
• Mark left/right components if needed

• Paint/Powder Coat (Optional)

• Complete dry fit first
• Mark all mating surfaces
• Mask threaded holes
• Sand surfaces if needed
• Apply preferred finish
• Allow proper curing time

Stage 1: Main Frame Assembly

1. Frame Rail Positioning Locate main frame rails:
• Position rails parallel on work surface
• Verify pedal mounting holes are on TOP
• Space rails approximately 20" apart
• Front is end with pedal mounting holes
• Use blocks to raise frame 2" off ground

2. Crossbar Identification Front Crossbar:

• 5 holes in middle
• 4 holes on sides
• 1 hole on top

3. Middle Crossbar:

• 4 holes on top
• Extra hole goes on left side

4. Rear Crossbar:

• 5 holes on top
• Extra hole positioned left

5. Initial Bolt Placement

• Insert M8x45mm bolts in all top holes EXCEPT:
• Skip 4 front holes (cable mounts)
• Skip 2 middle holes (floor pans)
• Use 60mm bolts for rear corners
• Leave all bolts finger-tight
• Verify bolt heads are uniform direction

6. Bracket Installation Front Section:

• Install 5-hole triangular brackets (4)
• Position brackets flush against frame
• Verify bracket orientation matches diagram

7. Middle Section:

• Mount 4-hole triangular brackets (2)
• Align holes precisely

8. Rear Section:

• Position corner brackets
• Check for proper angle alignment

9. Front Axle Mounting

• Position spindle tops toward rear
• Verify two mounting holes at bottom
• Install mounting hardware loosely
• Check for proper spacing

Stage 2: Floor Pan and Support Structure

1. Floor Pan Preparation
• Clean all mating surfaces
• Check hole alignment
• Verify pan orientation
• Label front/rear edges

2. Installation Sequence Front Floor Pan:

• Remove front bracket nuts
• Position pan carefully
• Follow under/over pattern
• Use mallet if needed for alignment

3. Middle Floor Pan:

• Align with front pan
• Maintain consistent pattern
• Verify all holes match

4. Rear Floor Pan:

• Complete pan pattern
• Check all seams
• Verify proper overlap

5. Hardware Tightening

• Start from center
• Work outward systematically
• Torque sequence:
• Hand tight first
• Snug with impact
• Final torque 18 ft-lb
• Apply thread locker if permanent

Stage 3: Steering Assembly

1. Spindle Installation Preparation:
   • 1x spindle body
   • 1x nylon wheel spacer
   • 2x nylon split bushings
   • Mounting hardware
• Verify per spindle:

2. Installation Steps:

• Apply grease to mounting surfaces
• Install split bushings into spindle
• Position wheel spacer correctly
• Verify tie rod mounting points face forward
• Torque sequence:
• Hand tight
• Quarter turn with wrench
• Final torque to 18 ft-lb
• Check for free movement

3. Steering Shaft Assembly Components Check:

• 1x main steering shaft
• 2x lock collars
• 1x short lower bracket
• 1x tall lower bracket
• Mounting hardware

4. Assembly Order:

• Install bottom lock collar
• Mount short bracket (front position)
• Position tall bracket (rear position)
• Install top lock collar
• Verify shaft rotation is smooth
• Check for binding points

5. Tie Rod Installation Preparation:

• Lay out tie rod ends
• Note left and right threads
• Verify proper length adjustment range

6. Installation Steps:

• Thread rod ends equally
• Install in this order:
• Bolt
• Split washer
• Tie rod end
• Second split washer
• Nylon lock nut
• Leave slightly loose for alignment

7. Wheel Alignment Process Initial Setup:

• Position wheels straight
• Center steering shaft
• Mark center position

8. Adjustment Steps:

• Adjust tie rods equally
• Check toe-in (1/8" recommended)
• Verify steering range
• Lock jam nuts firmly
• Double-check all connections

Stage 4: Engine Mounting

1. Engine Preparation Pre-Installation Checks:
• Fill with 10W30 oil
• Check all mounting points
• Verify clutch assembly
• Test pull-start operation

2. Clutch Installation:

• Mount clutch cover bolts first
• Install output shaft spacer
• Align clutch with keyway
• Torque clutch bolt (specific torque)
• Attach clutch guard

3. Engine Mounting Process Position Setup:

• Place engine on mount plate
• Align mounting holes
• Install mounting hardware:
• Split washers on top
• Flat washers below
• Leave loose for chain adjustment

4. Drive Chain Installation Preparation:

• Measure required length
• Mark chain at break point
• Verify master link orientation

5. Installation Steps:

• Break chain to length
• Route around sprockets
• Install master link:
• Clip faces away from clutch
• Verify clip orientation
• Check link security

6. Drive System Alignment Critical Checks:

• Sprocket alignment
• Chain tension (1/2" deflection)
• Engine position
• Clutch clearance

7. Final Steps:

• Torque engine mounts
• Secure chain guard
• Check for binding
• Verify smooth operation

Stage 5: Brake System Installation

1. Brake Component Preparation Parts Check:
• Brake band assembly
• Cable and housing
• Mounting hardware
• Return springs
• Adjustment components

2. Mechanical Installation Mounting Steps:

• Position brake band
• Install mounting bracket
• Route cable properly
• Attach return springs
• Set initial adjustment

3. Cable Routing

• Follow frame contours
• Avoid sharp bends
• Secure with cable ties
• Allow for suspension movement
• Protect from heat sources

 

Stage 6: Control Systems & Electrical

1. Pedal Assembly Installation Position Selection:
   • Forward position (39" leg room)
   • Rear position (33" leg room)
• Determine driver size
• Choose mounting position:

2. Installation Steps:

• Mount pedal brackets
• Install pedal stops
• Position return springs
• Set cable attachment points
• Verify smooth operation

3. Kill Switch Installation Wiring Process:

• Route primary wire along frame
• Strip wire ends properly:
• 1/2" strip length
• Clean copper exposure
• No stray strands
• Make connections:
• Wrap stripped end clockwise
• Secure under mounting bolt
• Apply electrical tape
• Test connection stability

4. Throttle Cable Setup Routing:

• Install cable housing clamps
• Route along frame rail
• Maintain gentle bends
• Secure with zip ties

5. Adjustment:

• Set idle position
• Verify full throttle reach
• Check return spring tension
• Set cable free play (1/8")

Stage 7: Seat Installation & Final Body Components

1. Seat Mounting Preparation:
• Position seat on frame
• Mark mounting holes
• Drill with 7/32" bit
• Clean drilling debris

2. Installation:

• Install mounting hardware
• Add washers as needed
• Torque to specifications
• Check for stability

3. Safety Padding Installation Components:

• Roll cage padding
• Steering wheel cover
• Frame protection points

4. Application:

• Clean surfaces
• Apply adhesive if required
• Secure with zip ties
• Trim excess material

5. Body Panel Installation Sequence:

• Side panels
• Front nose
• Rear panel
• Check all fasteners
• Verify panel alignment

Stage 8: Final Assembly & Testing

1. Pre-Start Checklist Mechanical Checks:
• All bolts torqued
• Chain tension correct
• Wheel alignment verified
• Brake adjustment proper
• Steering movement free

2. Safety Systems:

• Kill switch operation
• Brake light function
• All safety labels in place
• Guards and shields secure

3. Initial Start Procedure Preparation:

• Add fresh fuel
• Check oil level
• Clear area
• Support rear wheels

4. Testing Sequence:

• Activate kill switch
• Check choke position
• Start engine
• Allow warm-up
• Test all controls

5. Break-In Period Guidelines First Hour:

• Vary engine speed
• Avoid full throttle
• Monitor temperature
• Check for loose parts

6. Next Five Hours:

• Gradually increase speed
• Check adjustments
• Monitor chain tension
• Verify brake operation

Maintenance Schedule

• Before Each Ride
• Tire pressure check
• Brake function test
• Chain tension verification
• Control operation check
• Fuel level check

• Weekly Maintenance

• Clean air filter
• Lubricate chain
• Check all fasteners
• Inspect wear points
• Clean entire unit

• Monthly Service

• Change engine oil
• Grease bearings
• Adjust chain tension
• Check tire wear
• Inspect frame integrity

• Annual Maintenance

• Replace fuel lines
• Change air filter
• Check valve clearance
• Replace spark plug
• Inspect all bearings

Troubleshooting Guide

• Engine Issues Won't Start:
• Check fuel level/quality
• Verify kill switch position
• Examine spark plug condition
• Confirm choke setting
• Check air filter cleanliness

• Poor Performance:

• Clean carburetor
• Check valve clearance
• Verify timing
• Inspect fuel filter
• Test compression

• Drive System Problems Chain Issues:

• Proper tension (1/2" play)
• Sprocket alignment
• Master link security
• Lubrication state
• Wear inspection

• Clutch Problems:

• Engagement speed
• Wear patterns
• Spring tension
• Bearing condition
• Proper clearance

• Steering/Handling Issues Steering Binding:

• Spindle lubrication
• Tie rod alignment
• Bearing condition
• Frame alignment
• Tire pressure

• Handling Problems:

• Wheel alignment
• Tire condition
• Frame integrity
• Bearing play
• Suspension settings

• Brake System Troubleshooting Poor Braking:

• Cable adjustment
• Pad condition
• Drum surface
• Return spring tension
• Linkage wear

Support Resources:

1. Community Resources Online Groups:

• Facebook: "Bolt Kart Builders"
• Video Tutorial
• Email: sales@gopowersports.com

Specifications

• Technical Data Dimensions:
• Length: 72 inches
• Width: 42 inches
• Height: 48 inches
• Weight: 165 lbs

• Performance:

• Top Speed (Stock): 26 mph
• Turning Radius: 12 feet
• Brake Distance: 25 feet

• Torque Specifications Critical Fasteners:

• Engine mount: 25 ft-lbs
• Wheel nuts: 55 ft-lbs
• Steering components: 18 ft-lbs
• Frame bolts: 18 ft-lbs
• Brake hardware: 15 ft-lbs

• Fluid Capacities

• Engine oil: 16 oz
• Fuel tank: 0.95 gallon
• Gear oil: 4 oz
• Grease points: As needed

Contact Information

GoPowerSports Support:

• Phone: 866-846-5278
• Email: sales@gopowersports.com
• Website: www.gopowersports.com
• Hours: Mon-Fri 9AM-5PM CST

Maintenance Log

[Include blank maintenance log sheets for:

• Oil changes
• Chain adjustments
• Brake service
• General maintenance
• Modification records]

This concludes the complete assembly and maintenance manual for your GoPowerSports Bolt Go-Kart Kit. Keep this manual for future reference and maintenance scheduling.