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Off Road Go kart PDI Maintenance Instruction Video

Category: Gokart Help

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My Go Kart is Leaking Gas Into the Intake

It’s very rare that this situation will occur, but occasionally we receive phone calls or emails when the owners go kart is having problems running. Most of the time, starting issues on a go kart is caused by problems with the fuel or electric system. In this case, gasoline is leaking into the intake manifold which causes a rich situation and eventually causes the motor to shut off or bog.

The problem with gasoline flowing or dripping into the intake manifold is caused by float bowls in the carburetor being stuck or that the carburetor has a clogged jet. In order to repair this issue, you’ll have to complete a full carburetor clean. To access this process, please review the section below on how to clean a carburetor, and watch our video that will walk you step by step on how to complete this process.

Posted below are instructions on how to clean your carburetor for go karts sold through Variety Powersports:

  1. To clean your carburetor you will need to take the carb off the go kart. Typically there are 2 to 4 screws on the bottom of the carb you will need to remove.
  2. After removal, make sure you have clear access to the float bowl and the carb jets. The jets look like two gold screws with holes in them. Unscrew the carb jets and make sure nothing is clogging them. Your float is usually white and you will need to make sure it moves up and down freely.
  3. Clean the bottom inside of your carburetor and the bottom of the bowl with carb cleaner and this should remove most of the debris.
  4. Reassemble your carburetor, reattach to the go kart, reconnect all hoses and cables and test fire your scooter to verify there are no leaks.

This video below shows you the inner workings of the typical carburetor that is used on most of the go karts we sell at Variety Powersports. Review this video to see what the parts look like and for tips on cleaning and adjusting your carburetor. However, it’s also important to remember to ONLY use premium gasoline; especially after cleaning your carb.

Category: Gokart Help

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Temperature sensor stays on all the time

Most of the go karts sold through Variety Powersports are water cooled, which allows them to run at a desired operating temperature all the time. However, sometimes the temperature sensor will stay on, even though there is not a problem with the coolant or engine temperature. This is usually a sign that there is an issue with the sensor or that the sensor line has come unplugged. To fix this issue, follow the guidelines posted below.
Remove seats: In order to inspect this issue, you need to remove your two seats and then take off the center console. Once that is removed, you will need to be on the passenger side of the unit and find the carb.
Find the sensor plug: Right under the carburetor will be a gold-fitted sensor plug that is plugged into the motor. Follow the wire that comes off that plug and about 12 inches down that wire it will plug into the wiring harness. Make sure that it is plugged into the wiring harness. It is very common that it can become unplugged.
If the sensor is plugged in, it is likely that you have a damaged sensor which will can be ordered through Variety Powersports. Contact Variety Powersports if you experience this issue with your go kart and one of our sales professionals will help you solve the problem.

Category: Gokart Help

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Go Kart Assembly Guide

Most go karts are nearly fully assembled when they are shipped to customers in the United States. However, there are a few small assembly procedures that need to be completed by the customer in many cases. The installation guide posted below is for the Hammerhead GTS150 Go Kart. However, most of the go karts sold through Variety Powersports have nearly identical assembly instructions. Use this as a reference but always follow the manufacturers recommended steps for assembly and proper break in procedures.

  1. Completely unpack the crate: The first step is to remove all objects from inside the crate. This will include the go kart, additional parts, instruction manuals, and any support tools and equipment inside the box.
  2. Organize all contents on the floor: It’s a good idea to keep all components that were inside the crate organized in sections outside the crate. This will help you find parts easily and reduce the potential of misplacing parts.
  3. Prop the go kart with a lift of sturdy and balanced stand
  4. Install suspension: Remove the shock prop rods and replace them with the rear shock. Tighten all bolts. Then, mount the front shocks in the front A-arms. Place the bottom of the front shock into the front A-arm control. Tighten all bolts.
  5. Install all wheels and tighten bolts to recommended torque pressure.
  6. Install steering wheel and place steering wheel cap in the insert when completed.
  7. Install the roll cage.
  8. Install the gas tank, mount fuel and air lines as directed on instruction sheet.
  9. Install reflectors and side fenders.
  10. Mount the seats to the frame and put the straps around the seats
  11. Add recommended gasoline to the fuel tank, fill all fluids and retighten all bolts a final time.

Once you’ve completed the installation process, make sure you triple check all bolts for tightness and that all fuel and air lines are secure. Complete the start-up procedure as recommended by your manufacturer and also complete the break-in process as recommended. If you have any issues during your assembly or have unpacked your crate and are missing any parts, please contact Variety Powersports before proceeding with the assembly.

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Break In and Maintenance

Proper assembly and break in and routine service will ensure a long life for your go kart. In many cases, the go kart will have most of the parts put together for you before it arrives to your home. When you first get your go kart, if it is one that is liquid cooled, make sure that your radiator fluid is filled up to full. Your go kart needs to have a 50/50 mix of recommended radiator fluid with distilled water. So, make sure you mix it properly before you fill it.

Once all fluids have been checked and the go kart if fully assembled, you’ll want to initially start your go kart engine. You should always run your engine for about 10 minutes and let the engine heat up and then refill your radiator unit to ensure the radiator unit is full. As the engine runs, coolant will fill the tubes and inside the motor. Also, when you run your engine, the heat will run out the bubbles that can be in your lines. This is why you will need to add more fluid.

Proper tips for the Break-In Period: You’ll need to take it easy on your unit for about 30 consecutive minutes. Just do easy riding and resist the urge to apply full throttle or ride the go kart rough. The gaskets need to heat seal and if you “hammer down” on your unit when you first get it, you’re engine will have an enormous amount of pressure build up and you can blow a gasket, which may void any warranties.

After running your go kart for about 30 minutes, you should retighten all bolts and nuts. A good idea is to purchase some blue Loctite and apply on all major bolts, especially suspension parts that hold engine components together. This will help to protect the bolts from coming loose at the wrong time. It’s also recommended to tighten every bolt after your first three rides.

Maintenance Tips: You will want to change your oil about once every 10 hours of riding. The unit will hold 2.25 quarts of oil. We recommend running 4-Stroke 10w40 oil. After about an hour of riding, you’ll want to check your chain and make sure that it is tight. Usually within the first hour of riding, the chain will loosen and you’ll need to tighten it sometimes. The chain adjusters are located on the axle; adjust these until the chain is tight. Check this every so often after you finish riding to ensure the chain is tight. A loose chain can jump the sprocket, break teeth on the sprocket, and if it breaks then it can snap to your engine and bust your case.

As long as you stay on top of replacing motor oil, checking coolant fluid and adjusting your chain, the go kart should work fantastic for many years. Obviously, make sure to replace your battery and tires as needed. If you need any assistance or have questions about go kart accessories and replacement parts, contact our sales team at Variety Powersports.

Category: Gokart Help

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Full Throttle Bogs Down Go Kart

One of the most frustrating situations for a go kart owner is when they hit the gas to full throttle and the engine bogs down. Believe it or not, this is a very common problem, especially when people travel to higher altitudes. If you live at higher altitudes, you’ll have to change the jets inside the carburetor. It’s best to contact a local go kart mechanic for advice on fuel set ups at higher altitudes.

When living at sea level or below 3,000 feet, the issue is usually caused by an issue with the air/fuel mixture. In this case, when you apply full throttle, too much fuel enters the combustion chamber and the spark simply can’t burn the fuel. This is a simple fix. Listed below are the steps you need to complete to make this adjustment to the carburetor.

Remove the carb: The most common way to take the carburetor off the go kart is to remove 2 bolts off the top of the carb and take the top off carefully because it is spring loaded.

Remove the top and the spring, then remove the slide in the carburetor.

Adjust the bleed needle: Put the needle through the slide. Make sure you don’t lose the clip that secures the needle. There will be a c-clip on the needle; move this down one notch. This is adjusting the fuel/air mixture. As you move the c-clip down, it leans the motor out, moving the c-clip up will richen the motor with more fuel.

Once you are finished, reassemble everything and test the go kart to see if this fixed the bogging issue. If the problem is worse, you’ll have to adjust the bleed needle in the other direction, however, this is very uncommon. If it does not clean up, contact a local mechanic for professional help or call our team at Variety Powersorts for technical support.

Category: Gokart Help

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My Unit Won’t Start

A common problem we receive here at Variety Powersports is when customers have issues starting their go kart. Whether it’s fuel or electronic related, many of the typical starting issues are easy to solve. Listed below are a few of our most common solutions that you can check at home if you’re having difficulty staring your go kart.

    1. Check power and fuel: When a go kart engine won’t start, it is usually because of a lack of electricity or fuel restrictions. The first thing you’ll want to do is check your battery and make sure it has a 100 percent charge. The next quick step is to check your gas to make sure you have flow to the engine. If after this step you determine that there is power in the battery and fuel flowing through the lines, you’ll need to inspect a few specific parts.
      • Remove your spark plug and put the plug back into the ignition coil, hold the coil with your handle, and put the plug onto a ground or the engine, then have someone try and start it. If the spark plug doesn’t fire, change your plug. If after this step the spark plug still does not spark, then you have a faulty ignition coil.
      • Next, you will need to make sure you have gas going to the carb. Take the gas hose off the carb and make sure gas flows from the lines. You might have to try and start the engine to see gasoline flowing if you have a suction-type petcock. If gas is getting to the carb, then try to start your unit for about 30 seconds. Once you are done with that, take the spark plug out and see if it is wet. If so, then the issue is not fuel-related. If it is not wet, then you need to do a carburetor clean and rebuild. See the section about carb maintenance here on Variety Powersports for further instructions.
    2. Check kill switch: If you’ve completed the above steps to verify that there is battery life and fuel flowing, the next step you’ll want to inspect is the kill switch or an issue with the ignition switch. Sometimes the ignition switch on a go kart can go bad, especially if it’s exposed to outdoor elements for extended period of time. In order to complete this, you’ll need to take it apart and check for power flowing to the switch with a battery tester. If you do not feel comfortable with this type of service, contact a local mechanic to check this for you or call our service department for assistance.
  1. Check ground wire connections: Finally, if you’ve verified that fuel and electricity is flowing and your kill switch has not failed or is stuck on, you should check your ground wire connections. To complete this, find your battery’s negative terminal. There should be a wire that attaches to the frame. Make sure that wire is not frayed or cut. If it is, repair it and reattach.

Most of the time, finding the reason why your go kart won’t start is rather simple. However, if you’ve completed all of these steps and still can’t diagnose the precise issue, you’ll want to contact Variety Powersports for further recommendations.

Category: Gokart Help

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