Go-Kart for Shane

Operators Manual

Team 3

Jeffery Marcelus

Brahmatej Meka

Raymond Songer

Shane Davis NSF Project

Client Contact:

Shane Davis 6 sunrise drive Columbia, CT (954)-850-5448, quarrion1227@gmail.com

Important Safety Information:

This go kart is intended for outdoor use only

This go kart should never be used in inclimate conditions (i.e. rain, snow, slush,

mud, puddle, etc.) as water damage can occur

This product is designed for on road (driveway) and off-road use where the

terrain is not too rough

Avoid public roads, streets, and public property

Never immerse any part of the go kart in water as damage to the electrical

system is possible

Do not store this go kart in extremely hot/cold environments as damage to the

electrical system can occur

Be aware of your surroundings at all time. Do not use this go kart near other

people or animals as serious injury can occur

Avoid use near small children, as they can be unpredictable

Never use this product near moving motor vehicles

Avoid any abrupt impacts as this can cause damage to the chassis and electrical

system

The weight capacity of the single seat go kart should never exceed 200 pounds,

as this will interfere with performance and drivability

Never use with more than a single person in the go kart

Never drive this product without the proper gear (i.e. long pants, shoes, shirt)

Always wear a helmet

Always be sure the harness is snug and properly fastened

Always inform others when planning to use this vehicle, as mechanical failure of

the machine while in use could leave the driver stranded or injured

Be sure to understand how to use all of the controls proficiently before driving the

go kart

Never shift the drive gear while go kart is in motion. Be sure to come to a

complete stop before shifting gears (i.e. forward to reverse, reverse to forward)

To ensure safety and performance of the go kart, it should be cleaned after each

use

Proper maintainance is required as it is a gasoline powered vehicle. Be sure to

check the fluid levels frequently before and after each use.

Be sure to charge the battery after each use

This go kart is a powerful machine and should be treated with respect

The engine and related components WILL get hot during use. Avoid contact with

these parts during and immediately after use

Parts and Accessories:

Rack and pinion

Steering linear potentiometer

Steering gear motor with chain and sprocket drive

Tie rods

Front wheels

Rear wheels

Dashboard

Driver’s seat

Control panel

o Speed controllers

o Microcontroller

o Power source

Brake actuator

Gas actuator

Disc brake (front)

Disc brake (rear)

Gasoline engine

Transmission

Roll cage

Control joystick

Key with remote

Tail lights with turn signals

Headlights with turn signals

Features:

Gas powered four stroke 90cc engine

o Automatic transmission with forward and reverse

Two control modes

o Joystick drive mode

o Conventional drive mode

Headlights

Turn signals

Single seat with articulating arms for ingress/egress

Automated driving controls

o Acceleration

o Braking

o Steering

All terrain tires

All wheel disc brakes

Full suspension with 3 inches of travel

Full roll cage

Electric start

Remote start

Car alarm system

Table of Contents

1. Introduction……………………………….

1.1 General description

1.2 How to use the go kart

2. Mechanical maintenance of the go kart

2.1 Engine

2.2 Transmission

2.3 Chassis

2.4 Steering

2.5 Seat

2.6 Tires

2.7 Brakes

2.8 Battery

3 Electrical maintenance of the go kart

3.1 Battery

3.2 Control panel

3.3 Wires

3.4 Joystick

3.5 Actuators

3.6 Potentiometer

3.7 Dashboard

4 Environmental maintenance and impact

5 Technical details

5.1 Drive/braking system

5.2 Suspension

5.3 Control panel

5.4 Steering system

5.5 Battery

5.6 Chassis

5.7 Seat

6 Troubleshooting

1. Introduction 1.1 General description

The go kart for Shane Davis is a based on a prefabricated go-kart purchased from

PowerSportsMax.com. Modifications were made to the chassis and drive system of the

go kart to allow for our client to safely operate and enjoy it. It utilizes an electric joystick

on an articulating armrest to best match the setup that he is used to with his current

wheel chair. The joystick has been specially programmed to provide all of the

movement of a conventional driving setup, which includes braking, acceleration, and

steering. To ensure safety, a roll cage has been incorporated to prevent injury to the

client in the event of an accident. The go kart is also equipped with a 5-point harness

and adjustable seating with plenty of lumbar and abdominal support to provide safety

and comfort. A gasoline engine mated to an automatic transmission provides the power

for movement. To allow for easy starting of the vehicle, it has been equipped with a

turnkey electric starter. It also has a remote start feature that allows the client to start

the go kart from 100 yards away. To ensure safety while operating the vehicle at night, it

has a complete lighting system that includes front lights, turn signals, and brake lights. It

is also equipped with a horn and alarm system. The entire vehicle is powered by a

single deep cell rechargeable battery that powers everything from the actuators and

steering motor to the microcontrollers and lights.

This go kart was designed for the use of one person at a time. It has been fitted with all

the necessities to allow Shane to comfortably control it. The seat was reused from a

power wheel chair, so it has ample support through the lumbar and torso of Shane. The

side arms swing up individually to allow for easy movement in and out of the vehicle. It

also has a five point harness that assures security while the go kart is in motion. The

seat is also capable of collapsing down on itself, which allows for easy access to the

solenoids and engine maintenance. See figure 1.

Figure 1a. Driver’s seat with support arms down

Figure 1b. Driver’s seat with support arms up

Figure 1c. Driver’s seat folded down

The steering is controlled by a Dayton gear motor, which has been designed to provide

75 inch pounds of torque to the steering column. It is connected to the steering column

via a chain and sprocket set up that essentially allows for a 2 to 1 ratio between the

motor and steering column. This means that for every 1 turn that the motor makes, the

steering column makes 2 complete turns. The rack and pinion is connected to the front

wheels through tie rods, which allow the wheels to move freely over rough terrain while

turning. Feedback to the microcontroller is provided by a linear potentiometer that is

connected directly to the front of the chassis and rack and pinion. This system keeps

the front wheels from over turning and potentially causing damage to the rack and

pinion. See figure 2.

Figure 2a. Steering motor.

Figure 2b. rack and pinion with potentiometer.

The braking system is controlled by a Firgelli high speed actuator. It is rated to push 150

pounds, which is ample force to move the brake. The actuator comes equipped with a

potentiometer, which allows it know when it has reached the preset maximum distance.

When the brake is released, the actuator retracts and returns to its original starting

position. See figure 3.

Figure 3. Braking system.

Acceleration is also controlled by a Firgelli high speed actuator. In this case, however,

the actuator retracts in on itself from a preset position, which applies force to a cable,

which in turn depresses the gas pedal. After releasing the gas, the actuator extends

back out to its preset position. This set up can be seen more clearly in figure 4.

Figure 4a. Acceleration system actuator.

Figure 4b. Acceleration system cable and pulley.

1.2 How to use the go kart

As per the clients request, this go kart comes with 2 modes of operation. The first mode

of operation is through a joystick, which allows for control of the go kart much like in a

wheel chair. The second form of operation is a more conventional system, where the

brake and gas pedal can be depressed by foot and the steering wheel turns the wheels.

There are several procedures that need to be followed prior to any use of this go kart.

Make sure that all fluids are full, this includes checking the oil and gasoline. If either are

low, be sure to top them off. The gas tank is located at the rear of the kart, behind the

drivers seat, as seen in figure 5. Be sure that the battery is fully charged, as this

controls the entire electrical system. The battery can be found at the rear of the go kart,

behind the gas tank, as seen in figure 6. Before starting the go kart, be sure that the

transmission is in neutral and NOT in forward/reverse. The go kart will NOT start if in

forward/reverse. Be sure that all the electrical systems are clear of debris, which

includes dirt, mud, dust, etc. If debris is present, clean it off before proceeding to start

the go kart.

Figure 5. Gas tank.

Figure 6. Battery.

Before starting the go kart, be sure that you are familiar with all of the controls. This is

essential for the safe operation of this vehicle. After the driver is comfortably seated and

snuggly fastened into the drivers seat, see figure 7, the go kart can be started. Apply the

brake (either with the joystick or foot) and proceed to turn the ignition key clockwise, see

figure 7. This will start the go kart. After the go kart has had a chance to warm up for no

less than 2 minutes, the driver can put the kart into drive or reverse using the gear shift

lever, which is located on the left side of the go kart, see figure 8. At this point the driver

can release the brake and apply the gas pedal (either with the joystick or foot). BE

SURE TO CHECK FOR PEDESTRIANS OR ANIMALS BEFORE DRIVING.

Figure 7. Drivers seat with harness.

Figure 8. Control panel (ignition point).

Figure 9. Gear shift lever.

The joystick functions much like a power wheel chair function. Braking is always

accomplished by pulling straight back on the joystick, this doesn’t change no matter if

the go kart is in drive or reverse. By pushing forward on the joystick, the gas pedal will

be engaged and you will move forward, if the gear lever is shifted in drive. By

depressing the brake pedal, which can be accomplished by pulling back on the joystick

and shifting the go kart into reverse by pulling back on the gear shift lever, the go kart

can be driven in reverse. This is accomplished the same way that you would drive if the

go kart is in drive. By pushing forward on the joystick while the gear shift lever is in

reverse, the go kart will go in reverse. Steering is accomplished by pushing the joystick

side to side. By pushing the joystick left, the front wheels will turn left, and by pushing

the joystick right, the front wheels will turn right. In all scenarios, when the joystick is

released and brought back to center, the entire go kart will return to equilibrium. This

means that the wheels will come back to center and the brake and gas will be

disengaged.

This go kart is not meant for extremely rough terrain. Driving it on the grass and packed

dirt is perfect for what it is meant to do. If driven on too rough of terrain the electronic

components could pull loose and the entire go kart will be non-operational. This go kart

should also never be used in wet or icy conditions, as water will short out the system

and effect the electronics. Avoid making contact with obstacle while driving this vehicle

as it can cause injury to driver and the go kart itself.

After use there are several steps that should be taken to ensure longevity of the vehicle.

Make sure the engine is off and the key is removed from the ignition. Next make sure

that the emergency brake, see figure 10, is applied and the gear shift lever is returned

to neutral for next use. The power switch should then be switched to off so that the

electronic components are turned off. Once everything has been turned off, it is safe to

exit the go kart. Be sure to remove all mud and dirt that has accumulated during use. If

left it can cause serious harm to the electronics and chassis. Be sure to store the go

kart in a cool dry place, as extreme hot and colds can cause damage to the electronics.

Connect the battery to the battery charger and allow it to charge for next use. The

battery charger will shut off automatically after full charge has been reached, however,

the charger cables should be removed after it has reached full charge. This procedure

will ensure that the go kart will last a very long time and maintain reliability.

Figure 10. Emergency brake.

2. Maintenance 2.1 Engine

The engine must be maintained just like any other 4 stroke engine. All fluids need to be

clean and changed frequently to ensure longevity of the engine. Depending on

frequency of use, the oil should be change every 30 hours or so, but it should be

checked before starting every time. The oil and air filters should also be replaced every

time the oil is changed. This is a 90cc engine, so any small engine shop should have

replacement filters. By following regular engine maintenance, the engine can be

expected to last the life of the go kart.

2.2 Transmission

Prior to each use the transmission fluid levels should be checked. If they are low, it

should be topped off. Every year or 100 hours, the fluid should be completely drained

and fresh fluid should be added. This will maximize the life of the transmission

2.3 Chassis

Regular cleaning of the chassis is HIGHLY recommended as this will keep it from

corroding and wearing down. Do not let loose dirt build up on the floor or other parts of

the go kart as this can cause damage to the electrical systems and damage the paint.

Be sure to check that all bolts are tightly fastened. If loose, tighten. If the chassis is

damaged or welds break, take it to a professional to re-weld. Do NOT use the go kart if

any welds or bolts are loose.

2.4 Steering

Before each use, make sure the chain and sprocket system is connected and

functioning properly. Check that the potentiometer and rack and pinion are connected

properly. Also check that the rack and pinion and tie rods are connected properly. If any

of these connections are loose, tighten them before use. Be sure that the front wheels

maintain proper alignment, meaning the wheels are straight every time the go kart is

turned off. If the wheels are not straight, straighten them by turning the rack and pinion

with a wrench.

2.5 Seat

Be sure the seat is securely fastened to the chassis at all times. The connections can

become loosened after use on rough surfaces. The bolts can be found on the underside

of the chassis. The pivoting arms and collapsing seat hinge may need to be lubricated

after repeated use. Any grease spray, such as WD40 will be fine for this application.

2.6 Tires

Each tire should be checked for wear prior to each use. If the tires appear worn, replace

them. Make sure to maintain the proper tire pressure for the front and back wheels. The

rear tires are bigger so they require a different pressure than the front tires.

2.7 Brakes

The brake pads and calipers should be checked regularly for wear. If wear is present on

either, be sure to replace them before using the go kart. The braking system is

extremely important to the safety of the driver and others. It is extremely important to

maintain proper brake fluid. The fluid level can be checked in the fluid regulator, which

can be found at the front of the go kart, in front of the brake pedal.

2.8 Battery

The battery should be securely fastened in the battery box at all times. Prior to each use

be sure to check that all electrical connections are tight. If either the battery or electrical

connections are loose, be sure to tighten them as needed.

3 Electrical maintenance of the go kart 3.1 Battery

The battery terminals should be securely fastened at all times. If a loose connection is

found, be sure to tighten it before use as it could short out the electric components.

3.2 Control panel

The control panel keeps the microcontroller and speed controllers organized and

powered properly. Do not remove or change any connections on the control panel as

this can cause and short and cause the go kart to behave erratically or not at all. The

control panel should be checked prior to each use to be sure that no connections have

become loose. Check to be sure that no bare wires are touching. If bare wires are

touching disconnect the battery before touching the wires. If you feel that something

within the control panel is out of place, refer to the troubleshooting guide before

changing.

3.3 Wires

All wires should be housed within the floor panel. Check to be sure that the wires are

connected securely to their appropriate system frequently. Be sure that there are no

bare wires coming into contact with anything metal (i.e. the chassis). Power should be

shut off immediately if bare wires are found before touching. Refer to the

troubleshooting guide and appropriate systems before re-wiring.

3.4 Joystick

The joystick should be kept away from moisture at all costs. It is a very sensitive piece

of equipment and should be treated with care. Be sure that all loose dirt and dust are

clear of the joystick at all times. Check to be sure that the connections are tight

frequently. If the connections or loose, or the housing becomes loose, be sure to tighten

each before using the go kart.

3.5 Actuators

The actuators are housed in a sturdy metal case, however, be sure to keep them clear

of all moisture, as water can cause them to cease functioning. Be sure to check for

loose dirt around the piston before and after each use, as this can cause the gears

inside to bind up. Check that the wiring is secure frequently.

3.6 Potentiometer

The feed back potentiometer, located at the front of the go kart, is essential to the

steering system. Be sure that no damage occurs to this unit during use. There should

be no loose dirt around the piston as this can interfere with the readout that it provides.

Be sure that the wires are secure prior to and after each use.

3.7 Dashboard

The dashboard is where all the main switches can be found. It is very important to be

sure that this dashboard does not get wet, as it houses many electrical connections

required to keep the go kart working. If dirt accumulates on the console be sure to clean

it off with a damp rag.

4 Environmental maintenance and impact

The specifications in this design have the same environmental impact as existing gas-

powered go-karts. Since it is gas powered, it will release carbon dioxide and other

fumes into the atmosphere. Another environment constrain is the disposal of the

electrical components when they stop working. The battery must be disposed properly

because batteries contain environmentally harmful substances such as mercury, lead,

nickel, cadmium, and other metals. When introduced into landfills these substances can

leak slowly into the surrounding land and groundwater. The other electrical components

must be disposed appropriately at distinct recycling centers as well.

5 Technical description

In order to create a go kart such as this, there are many subunits that come together to

make it all possible. Each subunit will be discussed clearly and a picture of each system

will be provided. The final product can be seen in figure 11.

Figure 11. Final prototype of go kart.

5.1 Drive/braking system

The drive and braking system utilizes Firgelli high speed linear actuators while in

joystick operation. With an ascending/descending speed of 2-inches per second, the

actuators are able to react very quickly to any input that the client puts into the joystick.

To keep the design simple, the actuators have been connected directly to the brake and

gas pedals of the go-kart. When not in use the actuators will be in a neutral mode that

allows them to move freely and not interfere with the pedal operation. When in use, the

gas actuator pulls the pedal to the floor, simulating a driver input pushing on the gas

pedal. The brake actuator pushes directly on the pedal, which also simulates a driver

input.

The gas actuator, seen in the picture above, is purposefully designed to pull back on the

cable which has been run through a pulley and applies force on the gas pedal by pulling

on it.

The brake actuator starts all the way compressed and pushes out on the braking hinge.

This applies force directly to the brake pedal and in turn slows down the go kart.

5.2 Suspension

This go-kart is equipped with a front and rear coil-over suspension system connected to

all four tires by front and rear axles. This is an upgrade from other go-karts that have

only rear suspension to make the go-kart easier to handle from the weight of the gas

engine mounted in the rear. This upgrade is pivotal, as it allows our client a much

smoother and enjoyable ride. The suspension system is capable of a full 3 inches of

travel both front and rear.

The picture above is of the rear suspension system on the right side of the go kart

(pictured in red). These shock absorbers all work independently of one another from

front to rear, which allows for a much smoother ride.

5.3 Control panel

The control panel is comprised of all the electric components that control each individual

system of the go kart. There are two microcontrollers made by Arduino. One of the

microcontrollers operates the braking and acceleration, while the other microcontroller is

responsible for the steering. The microcontroller is the brain of the go-kart and it has

been programmed using the Aduino library. The microcontrollers are responsible for

gathering all of the information from the steering, the acceleration, and the braking and

bringing those inputs together to perform the requested action. The potentiometer feeds

back to the microcontroller so that the go kart knows where the front wheels are and

how much force is being applied to the brake and gas pedals.

This is one of the two speed controllers present on the go kart. This particular speed

controller has been programmed to control both the acceleration and braking actuators.

The steering microcontroller is identical.

The control panel also houses the speed controllers. The speed controllers were

provided by Firgelli Automations and they are responsible for reversing the polarity on

each individual system so that it can return to its appropriate position. The speed

controllers are extremely important because without them, the actuators and steering

motor would only be able to go in one direction. Then entire control panel has one

power input that supplies power to the entire board.

These two speed controllers are responsible for changing the polarity on the actuators

and steering motor, allowing them to move in both directions without changing the wires

manually.

5.4 Steering system

The steering system is the most intricate design of the entire go kart. There is a linear

and rotational potentiometer used in conjunction with each other. The linear

potentiometer is used along with the joystick control so that the client can drive using

only his left hand. The potentiometer acts as a position sensor for the front wheels when

they are turned by sending a signal back to the microcontroller. When the client turns

the wheel to the left, the microcontroller senses a change in the resistance being sent to

it from the potentiometer. Thus, when the client brings the joystick back to center the

microcontroller will sense this and know to re-correct to the right until the potentiometer

is centered again. This will keep the steering in control at all times with constant

feedback from the potentiometer to the microcontroller and the microcontroller to the

motor controlling the wheels.

In conjunction with the joystick controller, the client is able to use the steering wheel as

well. The steering column is severed right below the steering wheel all the way down to

the rack and pinion to make room for the motor that powers the steering. Directly below

the steering wheel is a rotational potentiometer that has been mounted to read the

clients input from the steering wheel and send it to the microcontroller, which will then

send a signal to the motor driving the front wheels and cause them to turn.

The rotational potentiometer is capable of 1080 degrees of movement, or 3 full turns.

When the wheels are straight the potentiometer is centered at 540 degrees, or the

midway point of the potentiometers max. When the steering wheel is turned to the left,

from 540 and below, the microcontroller will see the change in resistance and turn the

wheels to the left, and when the wheel is brought back to center and then beyond 540

degrees the wheels will turn to the right. This system allows the client to enjoy using a

conventional steering wheel because there is very little force required to move the

steering wheel and the motor does all the work to turn the wheels.

These two systems work with each other, but only one at a time. When the steering

wheel is engaged, the joystick is shut off and when the joystick is being used the

steering wheel is shut off.

The motor that is being used is a Dayton gear motor that puts out 75-in pounds of

torque, which is enough to move the front wheels. The steering is controlled by the

microcontroller, which is in constant communication between the motor and

potentiometers. When the joystick is moved to the left or right the electric motor turns

the rack and pinion in the direction indicated. When using the steering wheel, the

rotational potentiometer sends a signal to the motor, which turns the wheels in the

direction that the steering wheel is turned.

5.5 Battery

The go-kart design uses a single 12V high performance battery for the electric start and

the electrical components present on the go-kart to make it function. The battery that

will is an Optima Blue top battery. It is a 12V, 75 Amp hour unit that puts out plenty of

power to start the kart and keep the electrical components running.

5.6 Chassis

The chassis of the go kart is a prefabricated design from PowerSportsMax.com. It has

dimensions of 36 inches in width, 58.8 inches in length, and 43 inches in height. It has a

maximum weight capacity of 220 pounds, however, with the added weight of the battery

and electronic components, it is only recommended to have a maximum rider weight of

200 pounds.

The roll cage design of this is part of the pre-fabricated chassis. The shape of the roll

cage is a basic v-shape design from the front to rear end of the go-kart. It is comprised

of steel tubing bars that are also on both sides of the go-kart to prevent the driver from

falling out.

The roll cage is clearly visible in black surrounding the driver in the event of an accident.

The chassis can be seen here in pink.

5.7 Seat

The seat that was chosen is a very important aspect of the go-kart. The client is unable

to control his trunk and legs so the seat had to be able to keep him in place. For these

reasons, the seat is contoured on the sides to help keep the client in place. The seat

that is being used was removed from an electric wheel chair and provides the support

that is necessary for the client. It is also adjustable in position so that the client can tilt it

forward and back depending on whether he needs to use the pedals or the joystick. The

adjustability is pinnacle so that the client can be comfortable while driving, but the

bucket seat design will also keep him put during high speed maneuvers.

To ensure safety, a five-point harness is attached to the frame and sub-frame around

the bucket seat to keep him securely in place. The client disclosed that his trunk is not

strong enough to remain properly upright while enduring high G turns and acceleration.

This harness is designed to keep him secured and upright in the bucket seat while the

kart is in use. It has a lap belt that is connected to another belt between the legs and

there are two shoulder belts that all connect to one central buckle. The buckle on this

particular belt has large features that allow for easy ingress/egress. The five-point

harness also keeps the driver within reach of all the controls so they are in control of the

vehicle at all times.

6 Troubleshooting

Gas Engine

Will Not Start:

Check gas and oil

Kill switch set to "off"

Choke improperly set

Engine flooded

Spark plug wire not connected

Clogged or wet air filter: The air filter functions as the lungs of the engine, if it is

wet or clogged with dirt the engine is unable to "breathe" and may be difficult or

impossible to start. Check your filter on a regular basis, more often if you ride in

dusty conditions. Clean air filters also prevent the engine from ingesting dirt and

sand that damage internal working parts.

Throttle cable is grounding to engine stop terminal

Faulty start switch or battery (electric start units)

Stale Fuel: Gasoline in a vented fuel tank can go stale within 60 days. Stale gas

smells like varnish and leaves "gummy" deposits that clog the tiny jets of the

engine's carburetor. If your engine has been sitting up with stale gasoline in the

fuel tank your carburetor may require a soaking in carburetor cleaner to remove

these deposits. Remove all rubber pieces including the throttle shaft seal (o-ring)

before soaking. After the carburetor is free of all bad gas deposits it should be

reinstalled with new gaskets in place. Make sure your fuel tank is clean and free

of stale gas as well.

Will Not Stay Running:

Check gas and oil: If your engine has water in the gasoline, it will start, run for a

few seconds, then as soon as the water hits the carburetor the engine will die.

You can look in the bottom of the gas tank and see water "beading" around if it's

present. If your engine's gas tank and carbonator does contain water it must be

removed completely.

Loose spark plug wire or bad plug

Clogged or wet air filter

Faulty stop switch

Oil guard sensor is tripping

Throttle cable is grounding to engine stop terminal

Carburetor not functioning properly

Seems Low On Power:

Throttle cable not properly adjusted

Binding or dragging brake, bearings or axle

Unlubricated, loose or worn chain

Incorrect tire pressure

Engine rpm's not set properly

Throttle Will Not Return To Idle:

Throttle cable not properly adjusted

Throttle linkage not lubricated

Throttle linkage fastener too tight

Broken, weak, or stretched throttle pedal return spring

Broken, weak, or stretched engine throttle return spring

Engine throttle linkage binding

STOP AND START SWITCHES

Start Switch Does Not Work

Electric Start Units:

Check battery voltage and connections

Check start switch connectors

Faulty start switch

Faulty solenoid

Stop Switch Does Not Work:

Loose ground wire

Bad connection or broken wire

Loose terminal on engine

Faulty toggle switch

Faulty engine ground terminal

ELECTRICAL SYSTEM

Headlights Do Not Work:

Headlight burnt out

Bad connection or broken wire

Low Battery Voltage

Poor ground

Joystick Doesn’t Work

Bad connection or broken wire

Low Battery Voltage

Poor ground

Check power to microcontroller and speed controllers

DRIVE SYSTEMS

Centrifugal Clutch Equipped

Kart Moves While Engine Is Idling

Worn, overheated, or abused clutch - NOT OILED

Drive chain too tight

Engine idle is set too high

DRIVE SYSTEMS

Kart Moves While Engine Is Idling

Drive belt installed wrong (30 Series only, flat side of belt should be towards the

engine)

Wrong drive belt installed (a belt that is too short will cause the machine to

"creep" at idle)

Malfunctioning driver pulley (on crankshaft)

Malfunctioning driven pulley (on jackshaft)

Incorrect driver pulley spacing

Engine idle set too high

Pulleys not aligned (will also destroy belts)

Rapid Belt Wear:

Drive belt installed wrong

Wrong drive belt installed

Overloading drive system (climbing hills too steep, pulling heavy loads...)

Riding the brake

Malfunctioning driver pulley

Malfunctioning driven pulley

Binding or dragging brake, bearings or axle

Pulleys not aligned

Poor, Sluggish Or Jerky Acceleration:

Malfunctioning drive system

Throttle cable not properly adjusted

Unlubricated, loose, or worn drive chain

Binding or dragging brake, bearings or axle

Engine not functioning properly

Low Speed:

Throttle cable not properly adjusted

Binding or dragging brake, bearings or axle

Malfunctioning drive system

Improper tire pressure

Engine not functioning properly

Drive Chain

Chain Falls Off Sprockets:

Chain tension too loose

Unlubricated, stretched or worn drive chain

Worn, overheated, or abused clutch

Sprockets not aligned

Bent, worn, or loose sprockets and or sprocket hubs

Loose drive wheel

Bent or loose axle

Bent frame

BRAKE SYSTEMS

Water or other impurity in brake fluid

Rusted or corroded master or wheel cylinders

Actuation system malfunction

Air or vacuum leaks

Hydraulic system leaks

Air in brake lines

STEERING

Steering doesn’t work:

Causes:

Rack and pinion is jammed/disconnected

Motor is not connected/getting improper voltage

Chain and sprocket are loose/jammed

Linear potentiometer is giving wrong feedback

Low battery

Solutions:

Reconnect/replace rack and pinion

Check that all the electrical connections are tight

Remove any debris in chain and sprocket/reconnect chain and sprocket

Charge battery

Check for loose wiring at potentiometer. If potentiometer is damaged replace it

Steering system is completely unresponsive, but motor is turning

Causes:

The sprocket on the steering column is loose and spinning freely

The sprockets are out of line with each other

The steering column is loose and out of line with the motor

Solutions:

Tighten the bolt on the side of the sprocket attached to the steering column

Realign the sprockets if they’re out of line and tighten accordingly

Realign the steering column with the motor

Steering Effort Too High:

Make sure the electrical motor is powered

Make sure the battery is powered

Battery

Battery is dying quickly

Causes:

System has not been turned off properly

There is a short in the system

Battery is old

Solutions:

Be sure to turn the system off properly

Check for any bare wires that could be causing the battery to drain

Replace battery