Crossfire 150 Manual de usuario
1-877-855-0196 or www.tpg-info.com
Tomberlin Product Group
LIMITED WARRANTY
The following warranty only applies to vehicles which after being
unloaded from their original packaging, assembled as described in
this manual, and under normal use, conditions, and service are found
to have defects in manufacturing and workmanship that are not the
operator’s fault.
The limited warranty covers the frame, suspension, steering, brakes,
engine, and engine related components for a period of ninety (90)
days from the date of purchase. This warranty only applies to the
original purchaser of this product.
This warranty does not cover items such as tires, batteries, belts,
brake pads, or any other components that wear under normal use.
This warranty also does not cover items that the seller deems
defective due to improper care, improper assembly, modifications,
abuse, or accidents.
All warranties are voided if the vehicle has been altered in any way,
or meets any of the following criteria:
1. Contains parts deemed “non-original” replacement parts.
2. The vehicle serves as a rental unit.
3. The vehicle is altered, affecting performance, safety, and/or
reliability
4. The vehicle is used in competitions or races.
5. Wheels are bent or broken due to impact.
Do NOT return this unit to the retailer. Many problems that arise are
easily repaired by the consumer or service center. For parts and
service, please contact our customer service representatives at
1-877-855-0196 or www.tpg-info.com.
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The Warranty Registration Card For This Kart
Must Be Filled Out and Returned To The
Manufacturer.
The warranty registration for this vehicle may be filled out by:
returning the warranty registration insert in this manual, registering
online at www.tpg-info.com, or telephone at 1-877-855-0196. Please
have the following information ready when registering your product:
ENGINE NUMBER VIN NUMBER
(Located on the engine casing) (Behind Driver’s seat on frame)
__________________________ _________________________
DATE STORE NUMBER
(See Receipt)
__________________________ _________________________
Table of Contents
Warnings........................................................1
Warning Decals..............................................2
Safety Operation Guidelines..........................3
Unpacking Parts.............................................7
Parts List........................................................8
Brush Guard Padding.....................................9
Filling The Battery........................................10
Charging The Battery....................................12
Assembly.......................................................13
Installing The Battery....................................25
Replacement Batteries..................................25
Before Each Ride..........................................26
Driving..........................................................30
Maintenance..................................................35
Important Information..................................42
Trouble Shooting..........................................46
Wiring Diagram............................................47
California Emissions.....................................48
Kart Specifications........................................50
Notes.............................................................52
Foreword
Congratulations on your purchase of the CrossFire 150 go-kart.
Tomberlin Product Group wishes you many exciting moments with
your new off-road vehicle. The CrossFire 150 combines the joy of
off-road driving with state of the art engineering to provide
customers the best possible product.
This manual contains assembly, operational, safety, warning, and
maintenance information that will help prolong the life of the vehicle
and promote safe driving amongst all users. In reading this manual,
please note the sections that deal with safety while driving and tips
that will help drivers deal with different driving conditions.
Carefully read this entire manual before driving, or allowing others
to operate and/or ride in this go-kart. Failure to thoroughly read and
understand this manual may result in severe injury or death to drivers
and/or passengers.
Tomberlin Product Group wishes all drivers a safe, enjoyable
experience with the CrossFire 150. Carefully read the section dealing
with maintenance and be sure to fill in the chart showing scheduled
maintenance and service.
Servicing and maintaining this vehicle using the provided schedule
will improve longevity and allow for a more joyous experience.
It is important that this manual remain with the go-kart in the event
that it is sold. It provides important information and warnings that
will help keep all off-road enthusiasts safe. If the manual is lost or
damaged, please call 1-877-855-0196 or www.tpg-info.com for a
replacement.
Assumption of Risk
The owner/operator of this go-kart, and all passengers who may ride
assume responsibility for all risks and/or incidents arising from its
use. Failure to follow guidelines and warnings set forth in this
manual may result in serious injury or death.
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WARNING: Read the entire manual before operating
this go-kart. Be sure to carefully read sections dealing with
safety, warnings, and special instructions.
WARNING: This vehicle is intended for OFF-ROAD
USE ONLY. Before operating this vehicle, read all of the
instructions for safe assembly and operation as well as the
instructions governing the engine and other portions of the
vehicle. Pay close attention to all caution and warning labels
on the go-kart.
WARNING: Hearing protection is required while
operating this unit.
WARNING: You must depress the brake pedal before
the engine will start.
WARNING: To avoid serious burns or injury, always
use caution when working with gasoline. The engine should
only be refueled while it is not running and outdoors in a well
ventilated area. Avoid spilling gasoline anywhere. If gasoline
comes in contact with skin or clothing, immediately wash it off
with soap and water and change clothes. Do NOT smoke near
or expose the gasoline to an open flame. Follow all gasoline
producer directions and be sure to tighten the fuel cap after
fueling.
WARNING: The maximum combined weight for
driver and passenger is 400 pounds.
12
8. All persons under 18 years of age must have parental supervision
at all times while operating or riding as a passenger in the
CrossFire 150.
9. Do NOT operate this vehicle while under the influence of
alcohol, drugs, or any substance that may impair one’s ability.
Operating the vehicle under these circumstances may cause harm
to yourself and/or others.
10. Do NOT attempt to use this vehicle if you have no prior
experience driving. If you have no prior driving experience,
please take the time to practice and learn basic driving techniques
before operation.
11. Before each use, ALWAYS inspect the kart using the guidelines
in this manual.
12. ALWAYS check the fuel level before starting the CrossFire 150.
Do NOT fill the gas tank while the motor is running or still hot.
While filling the tank, avoid enclosed places and open flames.
13. Tire pressure should be checked before each use. Improper tire
pressure may cause unstable conditions while operating the
CrossFire 150. Tires should be inflated between 10-12 psi.
14. The CrossFire 150 should NEVER be started unless the throttle is
in idle position. The driver MUST be seated before attempting to
start the vehicle. Do NOT attempt to start the vehicle unless all
riders are seated with their safety harness fastened. Always keep
your foot on the brake while attempting to start the vehicle.
15. Engine components become extremely hot. Do not touch the
engine while the vehicle is running or while attempting to start
the vehicle.
Safety Operation Guidelines
1. This manual is NOT intended to serve as a service manual for the
CrossFire 150. This manual provides instructions for assembly,
maintenance, and general operation.
2. The CrossFire 150 should only be assembled by persons with
the necessary skills to properly read, understand, and follow
mechanical instructions.
3. When working on areas of the go-kart away from the engine,
remove the spark plug to prevent the engine from starting. If
working on or near the engine, avoid the muffler and other hot
areas around the engine.
4. Use extreme caution when working on an engine that has been in
use. Engine components will be extremely hot.
5. Do NOT attempt to modify or change any of the original
equipment on the CrossFire 150. The removal of any parts or
components could render the vehicle unsafe or in violation of state
laws.
6. Before each use, check all hardware on the vehicle to ensure that
it is safe to use. Check all connections, cables, bolts, locknuts,
and other parts prior to use.
7. It is not possible to obtain a license for this vehicle. This vehicle
is only to be used on private property or areas where local laws
permit. To prevent accidents, avoid areas where other recreational
vehicles are operating. Do not use the CrossFire 150 on any
location without proper permission.
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16. The brush guard surrounding the driver and passenger is not
intended to serve as rollover protection. Before each use, be sure
that tubes are securely in place by checking for loose bolts.
17. Although headlights are functional, they are not intended
for driving at night. This vehicle is designed for operation during
daylight hours.
18. Due to the poisonous nature of carbon monoxide, this vehicle
should NEVER be started or operated indoors. Carbon monoxide
is an odorless, tasteless gas found in engine exhaust fumes.
19. Do NOT race this vehicle. The CrossFire 150 is not designed
for racing or use on rental tracks.
20. This vehicle is designed to hold ONE driver and ONE
passenger. No person should ride on this vehicle unless properly
seated with the safety harness securely fastened.
21. If driving without a passenger, fasten the passenger safety harness
to prevent it from getting caught in moving parts.
22. Do NOT operate this vehicle unless wearing proper clothing.
Proper clothing includes but is not limited to: helmets approved
by the proper agencies, face guards/goggles, closed toe shoes,
and other protective clothing.
23. The recommended minimum age for drivers and passengers in
this vehicle is 16 years. Ability to operate this vehicle safely
depends on the drivers/passengers age, experience, size,
understanding, and mental and physical capabilities.
25. ALWAYS slow down for turns. Excessive speed in turns may
cause the vehicle to flip or roll. In some cases, excessive speed
can lead to the driver losing control. Use Caution when operating
on or around hills or obstacles.
26. Failure to slow down while turning may cause injury to the driver
and passenger.
27. This vehicle does not operate the same on all driving surfaces.
Operate ONLY on familiar terrain. If operating in the rain, the
CrossFire 150 will require additional space to brake.
28. Slow speeds are necessary when operating the vehicle on wet,
slick, rough, or steep terrains. WARNING: Excessive speed
in these conditions may cause bodily harm to the driver,
passenger, or those nearby.
29. Do NOT attempt to roll, flip, spin-out, or jump while operating
the CrossFire 150. Forcing the vehicle into these conditions may
cause bodily harm and/or damage to the vehicle.
30. When the vehicle is not in use, the engine should be turned off,
the parking brake engaged, and the fuel petcock turned to off.
65
Unpacking Parts
The first step in preparing your CrossFire 150 for driving is
removing the parts from the shipping box. Your CrossFire 150
should resemble the picture below when the top and sides of the
box are removed. See Figure below.
Unpacking
1. Remove all loose parts and place in an open area where they are
easily accessible and will not be damaged. It may be necessary
to cut the zip ties to access all loose parts.
2. After all loose parts are removed, begin assembling the go-kart.
3. All loose parts are listed below. If you are missing any parts, or
require assistance in your assembly process please contact us at
1-877-855-0196 or www.tpg-info.com
4. Please refer to the parts list on the following page.
(1)
(1)
(2)
(1)
(1)
(2)
(1) Set
(1)
(2) Side Supports
Front Bumper
Rear Support Tube
Front Support
Side Rails
Rear/Center Support
Gas Tank
Headrest
Tires
(4)
7
Pads (set)
Brush Guard Padding
Before assembly, place the tubular pads in their proper locations.
The three pads needed for this step are long and have no writing on
them. Locate the two (2) Side rails and place a pad on each as shown
below. Locate the Rear/Center Support and place a pad on it as
shown below. Be sure that the pads are secure along their seam and
tied tightly into place. Place these parts back with the others after the
pads have been properly installed.
There are four locations on the frame of the go-kart that need to
have pads attached. For assembly, be sure to use the two pads with
the CrossFire writing and the two short pads. See figure below for
proper locations.
Be sure that the pads are secure along their seams and that they are
securely tied in place at each end.
Before First Ride
Filling The Battery
The following procedure should only be performed by an adult
utilizing extreme caution. While attempting this procedure,
individuals should wear rubber gloves, eye protection, and have
water available in case the electrolyte solution comes into contact
with skin or eyes. Children should not attempt to complete this
procedure, and should NOT be allowed near the area when
attempting to fill the battery. This procedure should be completed
first so that the battery is charged when the kart assembly is complete
WARNING: POISON - CAUSES SEVERE BURNS
Contains sulfuric acid. Avoid contact with skin, eyes, and clothing.
To prevent accidents, rinse the empty electrolyte solution container
with water after use.
- If solution comes in contact with the skin, flush the area with
water.
- If solution is swallowed contact a physician immediately.
- If solution comes in contact with the eyes flush with water for
fifteen minutes. Get immediate medical attention.
KEEP OUT OF REACH OF CHILDREN
Procedure
- This procedure should be performed in a location out of reach of
children and animals.
- Remove the battery and the electrolyte solution from the shipping
crate. (See figures on page 12 to assist with this process)
- Place the battery on a level surface and remove the metallic sealing
from the top.
- Holding the electrolyte container upside down so the sealed
openings are facing the ground, align each sealed opening of the
bottles with the corresponding openings on top of the battery
terminal.
- Strongly push the electrolyte container into the openings of the
battery terminal so that the all of the seals on the electrolyte
container break, allowing electrolyte solution to flow into the
battery. Do NOT attempt to puncture the electrolyte container
unless the six sealed openings are properly aligned with the six
openings on the top of the battery terminal.
(x2)
9 10
- Air bubbles will begin rising from each opening of the electrolyte
solution when they are punctured.
- If air bubbles are not rising in each individual tube, tap the top side
of the electrolyte bottles.
- Leave the electrolyte bottles in their draining position until all of
the electrolyte solution has drained. Do NOT attempt to remove
the electrolyte bottles while they are draining.
- Do NOT attempt to puncture or cut any part of the electrolyte
container.
- Do NOT allow children near the battery at any point during the
installation process.
- When the electrolyte solution has finished draining, pull the bottles
gently from the top of the battery terminal and properly discard in a
location out of reach of children or animals.
- The battery needs to sit for Thirty (30) minutes before charging.
Letting the battery sit will allow the electrolyte to penetrate the
plates and provide a longer battery life as well as better battery
performance.
- After sitting for thirty (30) minutes, the battery is ready for
charging.
Place the cap strip loosely over the holes in the top of the battery.
Do NOT push the caps all the way into the holes.
- After the battery has been sitting for thirty minutes, push the caps
firmly into place in the holes. This will seal the battery. Do NOT
attempt to remove the caps after sealing the battery.
11 12
12
34
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78
kart and possible injury to operators/riders, Do NOT operate this kart
unless the rear shocks have been placed in the operating position.
The rear shocks must be adjusted before the go-kart is operated. The
rear shocks are located on each side of the kart, next to the
engine. To adjust the rear shocks, remove the bolt holding the
bottom of the shock in place and move the shock to the opening in
the bracket directly in front of the position in which the unit was
shipped. Be sure to tighten the bolt to ensure that the shock will not
slide out of place during operation. To prevent damage to the kart or
severe injury to passengers, the rear shocks must be moved.
WARNING: Do NOT attempt to move the shocks if the
kart frame is not supported. If the kart frame is not properly
supported, it could fall causing serious injury.
Front Tie Rods
The front tie rods need to be attached to the spindle on each side. To
do this, remove the washer, castle nut, and cotter pin from the tie rod.
Slide the bolt on the tie rod down through the hole in the spindle so
that the threads are sticking through the bottom. Place the flat
washer, spring washer, and castle nut on in that order. Tighten the
castle nut. Be sure that the hole in the bolt that the cotter pin slides
into lines up with openings in the top of the castle nut. This will
allow for the cotter pin to slide into position. After sliding the cot-
ter pin through the castle nut openings and the hole in the bolt, bend
the end without the curve (one side at a time) to a ninety (90) degree
angle (away from the center) to prevent it from sliding out of place.
Repeat this process for the tie rods on each side of the kart.
Do NOT operate this go-kart without attaching the tie rods as shown.
13 14
WARNING: Do NOT open sealed caps to add water
to the battery.
- Batteries contain sulfuric acid. Eye protection should
ALWAYS be used when working around battery acid.
- If battery gets hot to the touch while charging, immediately
remove from charging and allow battery to cool down.
- While attaching the red and black cables for charging, be sure
that the charger is not plugged into the outlet.
- Charge the battery in a well ventilated area out of reach of
children and animals.
- Do NOT smoke around batteries
- Do NOT expose batteries to open flames
Charging The Battery
- The battery must be charged before use.
- Connect the positive (+) red clamp from the battery charger to the
positive (+) pole of the battery.
- Connect the negative (-) black clamp from the battery charger to
the negative pole of the battery.
- Do NOT plug the charger into the outlet until the clamps have been
placed in their proper location on the battery.
- The battery should charge between 500-700 milliampere for 6-10
hours.
- When the battery has finished charging, unplug the charger from
the outlet, then proceed to remove the clamps from the charger.
- Press down firmly on the cap strip to slide it into place. Do NOT
hammer or strike the caps to force them into place.
- Do NOT attempt to remove the electrolyte caps after sliding them
into place.
Assembly
Rear Shocks
The rear shocks have two positions; shipping and operating. The
shocks must be moved from the shipping position to the operating
position before the kart may be driven. To prevent damage to the
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