Ace Sports MAXXAM 150 2R Owner's Manual
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Ace Sports MAXXAM 150 2R Owner's Manual

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150 2R
ACE-Maxxam-002-03-2007

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  • Page 1 Owner’s Manual Parts Manual Service Manual 150 2R ACE-Maxxam-002-03-2007...
  • Page 3 FOREWORD Thank you for purchasing an A.C.E. kart. We hope you will enjoy it. Before you begin operating the kart, please carefully read this Owner's Manual as it contains important safety and maintenance information. Failure to follow the warnings contained in this manual could result in serious injury or death. Be sure to follow the recommended maintenance schedule and service your kart accordingly.

  • Page 4: Table Of Contents

    INDEX OWNER' S MANUAL Page 1. WARRANTY-------------------------------------------------------------------------------------------------------------------- 2. WARRANTY REGISTRATION FORM --------------------------------------------------------------------------------- 3. ABOUT SAFETY ------------------------------------------------------------------------------------------------------------ 4. IMPORTANT SAFETY INFORMATION ------------------------------------------------------------------------------- 5. SAFETY LABELS----------------------------------------------------------------------------------------------------------- 6. ARE YOU READY TO DRIVE? ------------------------------------------------------------------------------------------ 7. IS YOUR VEHICLE READY TO DRIVE? ---------------------------------------------------------------------------- 8. SAFE DRIVING PRECAUTIONS -------------------------------------------------------------------------------------- 9.
  • Page 5 INDEX SERVICE MANUAL Page ----------------------------------------------------------------------------------------------- GENERAL INFORMATION ----------------------------------------------------- PERIODIC MAINTENANCEAND TUNE-UP PROCEDURES ENGINE -------------------------------------------------------------------------------------------------------------------------- LUBRICATION SYSTEM INSPECTIONAND SERVICING -------------------------------------------------------- FUEL SUPPLY SYSTEM INSPECTION AND SERVICING --------------------------------------------------------- ---------------------------------------------------------------------------------------- TRANSMISSION CONPONENTS ELECTRICAL STARTING SYSTEM ------------------------------------------------------------------------------------- REDUCTION MECHANISM ------------------------------------------------------------------------------------------------ -------------------------------------------------------------------------------------------- CONTROLLING MECHANISM BELT DRIVEN CVT MECHANISM INSPECTIONAND SERVICING -------------------------------------------- ------------------------------------------------------------------------------------------------------------------------- CLUTCH...

  • Page 6: Warranty

    A.C.E. Service Center, A.C.E. will - at its option - repair or replace defective parts to the original purchaser at no charge. MAXXAM 150 2R PARTS COVERAGE Warranty starts from the date of purchase by the first retail purchaser.
  • Page 7 WARRANTY PARTS NOT COVERED This warranty does not cover consumable wear and tear items such as, but not limited to: Throttle cable Brake cable Chains Seats Fasteners Air Filters Brake pads Tires Oil changes Problem occurring due to lack of proper maintenance Problem occurring due to abuse Modifications to your Maxxam that are not A.C.E.Sport approved will void the warranty.
  • Page 8 CUSTOMER SAFETY INFORMATION AND WARRANTY REGISTRATIN FORM MAXXAM 150 Warranty registration must be filed with A.C.E. Sports within 10 days of purchase or warranty will be void. In order to validate the warranty, purchaser agrees and promises to hold A.C.E.Sports and the Dealer harmless and indemnify them from all claims and demands or causes of action which may arise or be asserted against them arising or allegedly arising from any claim related to the delivery of the Vehicle or its use by the Purchaser or any third parties, including all attorney fees and legal costs whether or not any claim or assertion is deemed or found to be valid or not.

  • Page 9: About Safety

    ABOUT SAFETY In order to keep everyone safe, you must take responsibility for the safe operation of your kart. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.

  • Page 10: Important Safety Information

    IMPORTANT SAFETY INFORMATION Your kart will provide you with many years of service and pleasure, provided you take responsibility for your own safety and understand the challenges you may meet while driving. There is much that you can do to protect yourself while operating your kart. You'll find many helpful recommendations throughout this manual.
  • Page 11 IMPORTANT SAFETY INFORMATION Drive within Your Limits Pushing limits is another major cause of kart accidents. Never drive beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, fatigue, or inattention can significantly reduce your ability to make good judgments and drive safely.

  • Page 12: Safety Labels

    SAFETY LABELS This section presents some of the most important information and recommendations to help you drive your kart safely. Please take a few moments to read these pages. The labels should be considered permanent parts of the kart. If a label comes off or becomes hard to read, contact your dealer for warning label replacements.

  • Page 13: Are You Ready To Drive

    ARE YOU READY TO DRIVE ? Before each drive, make sure you and your kart are both ready to drive. This section discusses how to evaluate your driving readiness, what items you should check on your kart, and adjustments to make for your comfort, convenience, or safety. Before you drive your kart for the first time, we urge you to: Read this owner's manual and the labels on your kart carefully.
  • Page 14 ARE YOU READY TO DRIVE? Additional Driving Gear In addition to a helmet and eye protection, we also recommend: Sturdy off-road motorcycle boots to help protect your feet, ankles, and lower legs. Off-road motorcycle gloves to help protect your hands. Driving pants with knee and hip pads, a driving jersey with padded elbows, and a chest/ shoulder protector.

  • Page 15: Is Your Vehicle Ready To Drive

    IS YOUR VEHICLE READY TO DRIVE? Before each drive, it is important to inspect your kart and make sure any problems you find are corrected. A pre-drive inspection is a must, not only for safety, but because having a breakdown, or even a flat tire, can be a major inconvenience. If your kart has overturned or has been involved in a collision, do not drive it until your kart has been inspected by your dealer.
  • Page 16 IS YOUR VEHICLE READY TO DRIVE? Leaks, Loose Parts Walk around your kart and look for anything that appears unusual, such as a leak or loose cable. Lights Make sure the headlights, brake light and tail light are working properly. Throttle Check the freeplay and adjust if needed.

  • Page 17: Safe Driving Precautions

    SAFE DRIVING PRECAUTIONS Off-Road Use Only Your kart and its tires are designed and manufactured for off-road use only, not for pavement. Driving on pavement can affect handling and control. You should not drive your kart on pavement. WARNING Operating this kart on paved surfaces may seriously affect handling and control of the kart, and may cause the vehicle to go out of control.
  • Page 18 SAFE DRIVING PRECAUTIONS Control Speed Driving at excessive speeds increases the chance of an accident. In choosing a proper speed, you need to consider the capability of your kart, the terrain, visibility and other operating conditions, plus your own skills and experience. WARNING Operating this kart at excessive speeds increases your chances of losing control of the kart, which can result in an accident.

  • Page 19: Specifications

    SPECIFICATIONS DIMENSIONS Overall Length ------------------------------------------------------------------------------- 85 in. (2160mm) Overall Width -------------------------------------------------------------------------------- 53 in. (1346mm) Overall Height ----------------------------------------------------------------------------- 57.4 in. (1458mm) Wheelbase ----------------------------------------------------------------------------------- 59 in. (1500mm) Front Track -------------------------------------------------------------------------------- 45.7 in. (1160mm) Rear Track -------------------------------------------------------------------------------- 39.4 in. (1000 mm) Ground Clearance -------------------------------------------------------------------------- 6.7 in. (170mm) ENGINE Type --------------------------------------------------------------------------- Forced air-cooled, 4-Stroke Engine Capacity --------------------------------------------------------------------------------------- 149.8cc...
  • Page 20 SPECIFICATIONS Brake Track --------------------------------------------------------------------------------- < 7 m@20miles/h Top Speed ------------------------------------------------- 30 miles/h (or limited as customers require) CHASSIS Front, Rear Brake --------------------------------------------------------- Hydraulic disc, left foot control Front Tire ------------------------------------------------------------------------------------------------- 20 x 7-8 Rear Tire --------------------------------------------------------------------------------------------- 22 x 10 -10 Front Suspension ---------------------------------------------------------------- Independent Dual A-Arm Rear Suspension ---------------------------------------------- Swing Arm/Double Oil Damped Shock Restraint System ---------------------------------------------------------------------- Dual 4-point Harness...

  • Page 21: Operation

    OPERATION A. Operation controls WARNING - Do not attempt to start or operate the engine until you are completely familiar with the location and use of each control necessary to operate this vehicle. The operator must know how to stop this machine before starting and driving it. a.
  • Page 22 OPERATION B. Pre-Drive Inspection WARNING Perform this pre-drive inspection everyday before driving vehicle. If not performed, serious damage to the vehicle or personal injury may result. a. Check engine oil level. Check for leaks, add oil if required. b. Check fuel level. Add fuel as necessary and do not overfill. Check for leaks. c.
  • Page 23 OPERATION Component locations MIRROR Figure 2...
  • Page 24 OPERATION C. Passengers The vehicle allows for two riders only. Combined maximum weight of driver and the passenger should not exceed 180kg or 400lbs. D. Seat Adjustment The seat must always be securely fastened in the position which best affords the operator control of the foot pedals, steering wheel, and the remote stop button.

  • Page 25: Service Instructions

    OPERATION/SERVICE INSTRUCTIONS F. Starting And Operating Instructions a. Before starting the engine, be sure that the driver is seated properly in the kart with the seat belt. b. Test the kart in an open space at the beginning to learn how to start, turn and stop. c.

  • Page 26: Lubrication

    SERVICE INSTRUCTIONS B. Engine Lubrication You must change the oil in the crankcase after the first 5 hours of operating your new engine (see Fig. 7) and after 10 hours of use thereafter. This will insure proper lubrication of internal parts and prevent costly repairs due to excessive wear. WARNING Used oil must be disposed of at a proper collection center a.
  • Page 27 SERVICE INSTRUCTIONS D. Carburetor Adjustment Never make unnecessary adjustments. The factory recommended settings are correct for most applications. a. Warm up the engine (5~10min) b. Tighten the air screw gently. Backout 2-3/8 turns counter clockwise. c. Connect the tachometer, adjust the throttle to limit the idle speed. The standard value is 1400RPM.
  • Page 28 SERVICE INSTRUCTIONS H. Chain Adjustment Check the chain adjustment after the first two hours of use. Readjust if it has more than 1/2” flex. a. Loosen Nut #1. b. Adjust Nut #2. Turn Nut #2 clockwise in 1/2 turn increments, then turn nut #1 until tight. Follow this procedure until chain is at proper tension (see Fig.

  • Page 29: Repair

    REPAIR A. Front Wheel Replacement Do not disassemble the castle nuts when you replace the front wheels. It is only necessary to remove the four (4) lug nuts to remove the wheel. (See Fig. 12) Tighten the nuts after replacing the wheels. Figure 12 B.
  • Page 30 REPAIR C. Front Wheel Alignment a. The front wheels should have a “toe-in” from 1/8” to 1/4”. To check for alignment, measure distance A and B between the centerline (CL) of the wheels. The proper toe-in dimension A should be 1/8” – 1/4” greater than dimension B. b.

  • Page 31: Periodical Checks And Service

    PERIODICAL CHECK AND SERVICES The maintenance intervals in the following table are based upon average driving conditions. Driving in unusually dusty areas requires more frequent servicing. Time of service Initial service Quarterly Yearly Monthly (first week) Items Tire pressure/wear Brake performance Tightness of screws Air cleaner Carburetor...

  • Page 32: Wiring Diagram

    WIRING DIAGRAM...

  • Page 33: Initial Assembly Instructions

    INITIAL ASSEMBLY INSTRUCTIONS TOOLS NEEDED Floor jack 24mm socket/extension 8mm wrench 14mm socket/extension Needle nose pliers 10mm wrench/socket 17mm wrench/socket Protective gloves 12mm wrench/socket 19mm wrench/socket LIFT THE KART In order to assemble the front suspension and steering, the front of the kart must be lifted high enough to install the front tires.
  • Page 34 INITIAL ASSEMBLY INSTRUCTIONS FRONT TIRES Remove lug nuts from front hub. Place tire in position by aligning the holes in the wheel with the lugs. Tighten lug nuts with 14mm socket with extension. Perform this same procedure on both left and right sides. CARGO RACK Position the rack so that the inserted ends align with the holes in the frame behind the seat.
  • Page 35 INITIAL ASSEMBLY INSTRUCTIONS REAR TIRE Slide rear wheel/hub assembly onto axle. Splines must be aligned in order for the assembly to properly fit. Place small washer, then large washer on axle Tighten castle nut with 24mm socket with extension. Lock with cotter pin and needle nose pliers Perform this same procedure on both left and right sides BRUSH BARS Place main bars in proper location by putting the open ends over the bar mounts located on the...
  • Page 36 INITIAL ASSEMBLY INSTRUCTIONS WHEEL CAP STEERING WHEEL Place the steering wheel on mount, align the Place one rubber wheel cap on each wheel. holes and tighten with 10mm wrench/socket. Snap steering wheel cap into place. FENDERS Install front fenders by inserting the turned down stud of the fender mount into the fender sleeve on the frame.

  • Page 37: Battery

    INITIAL ASSEMBLY INSTRUCTIONS BATTERY Put on protective gloves. Remove strip covering acid ports from battery Place funnel into acid ports on battery. With funnel aligned in battery press acid container firmly into funnel allowing the acid to flow into the battery. Allow all acid to drain from container.
  • Page 38 239 County Road 4435 Brundidge, AL 36081 www.acesportsonline.com P: 1-888-562-9ACE F: 1-888-562-8ACE...

  • Page 39: Parts Manual

    PARTS MANUAL COMPONENT LOCATIONS...

  • Page 40: Cylinder Head Assembly

    FIG.1 CYLINDER HEAD ASSEMBLY...
  • Page 41 MAXXAM PARTS MANUAL Fig.1 CYLINDER HEAD ASSEMBLY REF. PART NO. DESCRIPTION Cylinder Head Comp 513-1000 Spark Plug (C7HSA NGK) 513-1077 Cylinder Head Gasket 513-1001 Carburetor Gasket Insulator 513-1002 Carburetor Insulator 513-1003 Intake Pipe Comp 513-1004 Insulator Band 513-1081 Head Cover Gasket 513-1005 O-Ring 27x2 513-1006...

  • Page 42: Cylinder Assembly

    FIG.2 CYLINDER ASSEMBLY Fig.2 CYLINDER ASSEMBLY DESCRIPTION PART NO. REF. 513-1013 Cylinder Body Comp 513-1014 Cylinder Gasket 500-1305 Washer Sealing M06 500-1002 Dowel Pin M10x16 500-1009 Flange Bolt M06x12-ZN.D 513-1015 Tensioner Lifter Gasket 513-1016 Tensioner Lifter Assy 513-1017 Cam Chain Guide Comp 500-1313 Flange Bolt M06x20...
  • Page 43 FIG.3 CRANKCASE ASSEMBLY (1) Fig.3 CRANKCASE ASSEMBLY(1) PART NO. REF. DESCRIPTION 513-2015 R Crankcase Cover Comp 513-1019 Crankcase Cover Gasket 500-1015 Cap Tappet Adjusting Hole 513-1020 Oil Filtering Screen 557-1003 Oil Filtering Spring 513-1021 Oil Level Stick 513-1083 AC Generator Cord Clamper 513-1022 Oil Seal 19.8x30x5 513-1074...
  • Page 44 FIG.4 CRANKCASE ASSEMBLY(2)
  • Page 45 MAXXAM PARTS MANUAL Fig.4 CRANKCASE ASSEMBLY(2) REF. PART No. DESCRIPTION 513-2013 R Crankcase Assy 513-1024 Engine Hanger Rubber Bushing 513-1025 Crankcase Gasket L. Crankcase Assy 513-1026 Bushing RR Cushion Under Rubber 500-1004 Flange Lock Nut M08 500-1052 Washer M08 500-1053 Stud Bolt M08x187.5 500-1030 Stud Bolt M08x195.5...
  • Page 46 FIG.5 CRANKSHAFT CONROD & PISTON ASSEMBLY Fig.5 CRANKSHAFT CONROD & PISTON ASSEMBLY REF. DESCRIPTION PART NO. Crankshaft & Conrod Assy 513-1034 Flange Nut- Compression M12 513-1088 Washer 12-149 HV 12-140HV 500-1038 Lock Nut M22 500-1023 Washer M22 500-1024 Kick Drive Gear 513-1086 Washer M12 500-1032...

  • Page 47: Camshaft Assembly

    FIG.6 CAMSHAFT ASSEMBLY Fig.6 CAMSHAFT ASSEMBLY REF. DESCRIPTION PART NO. Tappet Adjusting Nut 500-1006 Tappet Adjusting Screw 500-1007 Valve Rocker Arm 513-2004 Exhaust Rocker Arm Shaft 513-1027 Camshaft Chain 513-1039 Camshaft Comp 513-1073 Intake Rock Arm Shaft Comp 513-1072 Stopper Plate Comp 513-2008 Dowel Pin M10x16 500-1002...

  • Page 48: Left Cover Assembly

    FIG.7 LEFT COVER ASSEMBLY Fig.7 LEFT COVER ASSEMBLY REF. PART NO. DESCRIPTION L Cover 540-1006 L Cover Gasket 513-1040 Screw ST 4.2x8-F-H 500-1060 L Cover Plate 513-2009 Flange Bolt M06x40 600-0063 Flange Bolt M06x65 500-1061 Breather Drain Tube Clamper 613-0015 Dowel Pin M08x14 500-1308 Spindle Comp Kick Starter Assy...

  • Page 49: Fan Cover And Shroud Assembly

    FIG.8 FAN COVER AND SHROUD ASSEMBLY Fig.8 FAN COVER AND SHROUD ASSEMBLY REF. PART NO. DESCRIPTION 513-1043 Fan Cover Comp 513-2010 Starter Cable Clamper 513-2011 Cooling Duct 513-3014 Lower Shroud 513-1078 Lower Shroud Seal 513-3015 Upper Shroud Comp 513-3022 High Tension Cord Clip 513-1079 Upper Shroud Seal 500-1062...

  • Page 50: Oil Pump Assembly

    FIG.9 OIL PUMP ASSEMBLY Fig.9 OIL PUMP ASSEMBLY REF. DESCRIPTION PART NO. Oil Pump Chain 513-1044 Flange Lock Nut M06 500-1064 Oil Pump Driven Sprocket 513-2012 Flange Bolt M6x25 500-1302 Oil Pump Sub Assy 513-1045...

  • Page 51: Driven Pulley And Clutch Subassembly

    FIG.10 DRIVEN PULLEY AND CLUTCH SUBASSEMBLY Fig.10 DRIVEN PULLEY AND CLUTCH SUBASSEMBLY PART NO. REF. DESCRIPTION 539-1004 Outer Clutch Assy 513-1046 Drive Belt 513-1047 Driven Pulley Assy...

  • Page 52: Transmission Assembly

    FIG.11 TRANSMISSION ASSEMBLY Fig.11 TRANSMISSION ASSEMBLY DESCRIPTION REF. PART NO. 513-1048 Transmission Cover 513-1049 Transmission Cover Gasket 513-2200 Radial Ball Bearing E6203 513-2201 Radial Ball Bearing E6202 513-2202 Radial Ball Bearing E6204 500-1025 Flange Bolt M08x12 500-1052 Washer M08 513-1050 Oil Seal 20x32x6 513-1087 Final Gear-40 teeth...

  • Page 53: Electric System

    FIG.12 ELECTRIC SYSTEM Fig.12 ELECTRIC SYSTEM REF. PART NO. DESCRIPTION Stator Comp-8 pose 513-2005 Stator Comp-6 pose 513-1053 Flywheel Comp-8 pose 513-1054 Flywheel Comp-6 pose 513-1154 Cooling Fan Comp 513-1055 Flange Bolt M06x18 500-1065...

  • Page 54: Electric Starter Assembly

    FIG.13 ELECTRIC STARTER ASSEMBLY Fig.13 ELECTRIC STARTER ASSEMBLY REF. PART NO. DESCRIPTION Flange Starting Clutch 513-1056 Starter Reduction Gear Shaft 513-1090 Reduction Gear 513-1058 Flange Bolt M06x16 500-5302 Starter Motor Assy 513-1059 O-Ring 24.0x3.1 613-0021...

  • Page 55: Drive Pulley Subassembly

    FIG14 DRIVE PULLEY SUBASSEMBLY Fig.14 DRIVE PULLEY SUBASSEMBLY DESCRIPTION REF. PART NO. 513-1060 e l l...

  • Page 56: Carburetor

    FIG.15 CARBURETOR...
  • Page 57 MAXXAM PARTS MANUAL Fig.15 CARBURETOR REF. PART NO. DESCRIPTION Gasket Set A 513-1061 Jet Set 613-0031 Float Set 513-1091 Float Chamber Set 513-1092 Screw Set A 500-1012 Screw Set B 500-1013 Valve Plate Set 513-1063 Auto Bystarter Assy 513-1064 Air Cut Valve Set 513-1065 Compression Coil Spring 513-1093...

  • Page 58: Frame Group

    FIG.16 FRAME GROUP...
  • Page 59 MAXXAM PARTS MANUAL Fig.16 FRAME GROUP PART NO. REF. DESCRIPTION C.B.C. Cross Bar. FR (Blue) 612-0151 C.B.C. Cross Bar. FR (Yellow) 612-0251 C.B.C. Cross Bar. FR (Red) 612-0351 C.B.C. Bar. (Blue) 612-0152 C.B.C. Bar. (Yellow) 612-0252 612-0352 C.B.C. Bar. (Red) C.B.C.

  • Page 60: Steering Shaft Assembly

    FIG.17 STEERING SHAFT ASSEMBLY...
  • Page 61 MAXXAM PARTS MANUAL Fig.17 STEERING SHAFT ASSEMBLY DESCRIPTION REF. PART NO. Steering Cap 536-3025 Bolt M06x20 500-1102 Washer M06 500-3018 Steering Wheel 536-3027 Rack and Pinion Assy 636-0001 Steering Shaft Bushing 536-3003 Brake Pedal Pad 552-3037 Needle Bearing-2617 622-0001 Bolt M08x35 600-0060 Lock Washer M08 500-1069...

  • Page 62: Suspension Arm Assembly

    FIG.18 SUSPENSION ARM ASSEMBLY...
  • Page 63 MAXXAM PARTS MANUAL Fig.18 SUSPENSION ARM ASSEMBLY DESCRIPTION PART NO. REF. R Strut & Spindle 536-1003 Flange Bolt M08x105 500-1081 Upper Suspension Arm Collar 536-3013 Upper Suspension Arm Bush 536-3014 Upper Suspension Arm 536-3015 Flange Lock Nut M08 500-1043 Castle Nut M12 500-1088 Ball Head Dust Seal 536-3016...

  • Page 64: Rear Cargo Rack/Seat/Belt

    FIG.19 REAR CARGO RACK/SEAT/BELT...
  • Page 65 MAXXAM PARTS MANUAL Fig.19 REAR CARGO RACK/SEAT/BELT DESCRIPTION PART NO. REF. 509-3021 Tail Light Bulb 21w/5w -12v 609-0004 Tail Light - (K30-50) long wire 95 500-1031 Lock Nut M06 634-0001 Rear Cargo Rack (Blue) 634-0002 Rear Cargo Rack (Yellow) 634-0003 Rear Cargo Rack (Red) 600-0009 Flange Bolt M08x16-color...
  • Page 66 FIG.20 ENGINE/MUFFLER/AIR CLEANER...
  • Page 67 MAXXAM PARTS MANUAL Fig.20 ENGINE/MUFFLER/AIR CLEANER REF. DESCRIPTION PART NO. Reverse Assy 639-0013 539-3002 Internal Collar Reverse Castle Nut M16 500-1037 Bolt M10x20 500-1317 500-1114 Bolt M08x16 Reverse Bracket 639-0001 Flange Bolt M08x40 500-1026 Reverse Connector Panel 639-0002 600-0066 Slotted Bolt M08×20 Flange Lock Nut M10 500-3014 Air Cleaner Clamp...

  • Page 68: Rear Swing Arm

    FIG.21 REAR SWING ARM 45 21...
  • Page 69 MAXXAM PARTS MANUAL Fig.21 REAR SWING ARM REF. PART NO. DESCRIPTION RR Brake Pad Set 552-3012 652-0008 RR Caliper Assy 600-0012 Strap Bolt M08x160 650-0001 Rear Swing Arm Comp 500-1313 Flange Bolt M06x20 500-1031 Lock Nut M06 500-5302 Flange Bolt M06x16 637-0012 Rr.

  • Page 70: Rear Housing

    FIG.22 REAR HOUSING...
  • Page 71 MAXXAM PARTS MANUAL Fig.22 REAR HOUSING REF. DESCRIPTION PART NO. 500-1070 Flange Bolt M08x25 552-3014 RR Brake Disc 500-1043 Flange Lock Nut M08 627-0001 Rear Axle 631-0004 Drive Chain 623-0001 Rear Housing Sprocket 600-0049 Flange Bolt M08x30 539-3008 Dust Seal 50x34-7 527-1002 Housing Comp RR Axle BRG 522-3002...

  • Page 72: Wire Harness/Electrical

    FIG.23 WIRE HARNESS/ELECTRICAL...
  • Page 73 MAXXAM PARTS MANUAL Fig.23 WIRE HARNESS/ELECTRICAL PART NO. DESCRIPTION REF. 609-0003 Wire Harness 500-1076 Lock Nut M05 509-3035 Switch Panel Cover 500-1066 Pan Screw M05X12 509-3036 Power Outlet 609-0015 Wire Harness tie wrap 609-0005 Key Switch 609-0006 Engine Stop Button 609-0016 Light Switch 500-5302...
  • Page 74 FIG.24 REVERSE ASSY.

  • Page 75: Reverse Assembly

    MAXXAM PARTS MANUAL Fig.24 REVERSE ASSEMBLY DESCRIPTION REF. PART NO. 639-0003 Gear Case. R 639-0004 Gear Case. L 639-0005 Gear Shiting Yoke Cover 622-0002 Bearing 639-0006 Gear Shaft Counter Comp 639-0007 Drive Gear Bushing 639-0008 Drive Gear 639-0009 Drive Gear Collar 639-0010 Rubber Oil Seal 622-0003...

  • Page 76: Tool Kit

    FIG.25 TOOL KIT Fig.25 TOOL KIT PART NO. DESCRIPTION REF. 608-0001 Tool Bag 608-0002 Open-Ended Wrench 17x19 608-0003 Open-Ended Wrench 13x15 608-0004 Open-Ended Wrench 12x14 608-0005 Open-Ended Wrench 8x10 608-0006 Slip-Joint Pliers 608-0007 Spark Plug Wrench 608-0008 Tube Wrench 608-0009 608-0010 Screw Drive Handle Stem...
  • Page 77 FIG.26 STICKER PARKING WARNING Moving parts can crush and 3031112 cut. Keep hands clear. Do not operate with guard removed. MAXXAM REVERSE LEVER PARKING BRAKE 150 2R WARNING WARNING WARNING NO RIDING THIS GO-KART CAN BE HAZARDOUS TO OPERATE LONG if driven carelessly.
  • Page 78 A.C.E. S PORTS LLC 239 County Road 4435 Brundidge. AL 36010 Phone: 1-888-562-9 ACE Fax: 1-888-562-8 ACE www.acesportsonline.com...

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