HOW TO BUILD YOUR PLYFLY GO-KART!
For Ages 12+ PlyFly Go‑Kart Instruction Guide • 2015 Release
Thank you for supporting the FLATWORKS Kickstarter campaign.
Thank you
Your contribution is a great help, and your support is much appreciated. We hope you’re as excited to get started on your new adventure as we are to be working on the FLATWORKS.
Enjoy your new Plyfly Go‑Kart! Check back soon and see what else we make!
the Flatworks Crew,
& 150718 PLYFLY rev A_Cover |August7,20155:06PM
II
Steven Hynes
Jim
Cam McCulloch
K Brotman
Alan Miyasaki
Dennis Cox
Stephan Schnitker
Chris DePerro
Chris Patton
Family Woo
Joe Barton
Marcus Leef
Liam Newman
Tyra Hammett
No Regrets
Nathan Pelsor
Ray Colwell
Douglas Dayton
Henry E.
Sam Bowling
Carl Moulton
Tim Owens Chris Porter Matthew Clark
Joe W.
Ryan Bradley
Greg Brncick
Jesse Cannone
Michael Lindahl
Grandpa Rex
Luke
Adam “Hock” Hocherman
Alex Gomes
Jim Mahoney
Michael McGrath
Lindsay Lauber
Tim Baker
Dave Krugman
Joseph Asti
Karl Eberhardt
Daniel Cianci
Nick Vines
Tomas Petru
Herk
David Moore
Brian Jepson
David Geisinger
Steve Baker
Ken Short
Zee
Andrew Marc
Joshua Marcus
James “Udub” Underwood
Matthew & Keri
Emily H.
Anthony
CJBCN
Brian Kaleida
Sam Bell
Lindsey Zimmerman
Mark ChengIan Drummond
Andrew B. Bartels
Mohit
Louis Tovar
Scott Newman Russ Kadooka Mitch Bob
Mark Tracy Anonymous Michael Lindahl JouleLee
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Tiegen
III
What's Inside? 1 Exploring the kit
1
2 Getting Started
6
3 Seat Assembly
8
Warnings and safety Handling and storage Why Wood? Good to know What’s in the kit? Unpacking the boxes Getting started Recommended tools Chisel & hammer method Reciprocating saw method Plywood sheet reference Recommended tools Required hardware Required wooden parts Assembling the seat
7 7 7 7
9 9 9 10 11
4 Steering Column Assembly
12
5 Steering Rack Assembly
15
Plywood sheet reference Recommended tools Required hardware Required wooden parts Assembling the steering shaft Plywood sheet reference Recommended tools Required hardware Required wooden parts Assembling the steering rack
13 13 13 13 14 16 16 16 17 17
18
7 Steering Spindle Assemblies
21
Plywood sheet reference Recommended tools Required hardware Required wooden parts Assembling the left & right steering spindles
19 19 19 20 20 22 22 22 23 24
8 Pedal Assemblies
25
9 Frame Assembly
28
10 Putting the go‑kart together
37
11 Master List
60
12 Legal
72
13 Terms & Conditions
74
Plywood sheet reference Recommended tools Required hardware Required wooden parts Assembling the gas & the brake pedals Plywood sheet reference Recommended tools Required hardware Required assemblies Required wooden parts Assembling the frame Overview of the recommended tools Overview of the required hardware Overview of the required but not provided Overview of the required wooden parts Overview of the required assemblies Part 1 Install the rear axle Part 2 Install the brake caliper Part 3 Install the steering column assembly Part 4 Install the steering spindles Part 5 Install the gas & brake pedals Part 6 Install the gas & brake cables Part 7 Install the engine and drive train Part 8 Install the wheel assemblies Part 9 Install the seat assembly Part 10 Install the fairings Visual reference of the plywood sheets List of the wooden parts List of the wooden assemblies List of the tools needed List of loose contents List of the packaged contents
26 26 26 27 27 29 30 30 30 31 32
38 38 41 41 41 43 44 45 46 47 49 52 57 58 59 61 62 66 67 68 70
Legal73 Terms & Conditions of Purchase and Use
75
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6 Fixed Steering Column Assembly Plywood sheet reference Recommended tools Required hardware Required wooden parts Assembling the steering column
IV
2 2 3 3 3 4
1
Exploring the kit Introduction Each Plyfly Go-Kart kit arrives in 3 boxes.
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Review the contents of each box to ensure you have all the necessary parts to begin building your next adventure!
1
Warnings and safety
Riding karts can be dangerous.
Please use caution and prudence and follow the guidelines below. • Avoid operating your kart in crowded or confined areas. • Any children that use the kart are of an appropriate age and do so under proper supervision. The recommended age for this kart is 12+. • Avoid using your kart near any other vehicular traffic or on public roads. • Never try to fit more than one person in the kart. • Always wear a DOT-rated helmet and gloves while operating the kart. • Never aim the kart at other people, objects or animals. • Prior to riding, every rider should familiarize themselves with:
Handling and storage • The kart is heavy.
• Use at least two people to lift or move it. • Some surfaces may be hot after use, handle with caution. These may be from friction in bearings and brakes or from the engine. • If gasoline is spilled on the wood, leave the kart outside in a well ventilated area to dry before use or storage. Be very careful about exposure to potential ignition sources until it dries. • Do not tip the kart. Fuel may spill from the carburetor if inclined too much. If you need to stand up the kart, start the engine and turn off the fuel valve. Let the engine run the carburetor dry. • Store the kart in a dry, clean area and coat the wood with a paint or coating for the longest life.
‒‒ Their environment ‒‒ Any obstacles or dangers. ‒‒ The location and function of the emergency shutoff switch. • Inspect the kart prior to each run to make sure that each element is properly functioning. Test: ‒‒ Brakes lock the rear wheel. ‒‒ Shut off switch kills engine. ‒‒ Clutch, chain, sprocket and sprocket guard are properly tightened and functioning. ‒‒ The wheels are all on and tightened. ‒‒ The steering system is functioning properly. ‒‒ There are no areas of brake discs, wheels, chain or other moving elements rubbing on the wood. ‒‒ That all shaft keys (clutch, sprocket, brake disc, wheels) are installed and secured in place by a tight set screw. ‒‒ Ensure all fasteners are tight and properly torqued. ‒‒ The safety flag is installed. ‒‒ The seat is properly installed and adjusted. • Do not attempt to leave the ground with the kart. It is not designed or intended for jumping. • Ensure the rider has no articles of loose clothing or hair that could get caught in the spinning mechanisms of the kart.
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1 Exploring the kit
Why Wood?
Sure, steel karts are fun and strong, but they require a large number of specialized tools to build, repair or modify. Tools that most people don’t have. Wood, on the other hand, can be crafted with tools available in most homes and all home improvement stores. We want to provide kits that people can make their very own, by painting, fixing or modifying and wood is a natural fit for this. The wood used in this kit is a 3/4 inch Baltic Birch plywood. It is a natural fit for the go-kart due to it’s strength and appearance. The 13 plies make it incredibly strong and give the end grain a beautiful contrast. Best of all, it can be modified, repaired or reworked with common household tools.
What’s in the kit?
Each Plyfly Go-Kart kit arrives in 3 boxes. Box 1 is a flat box with the wooden structural parts. Box 2 is the engine and box 3 is the hardware. 1.2.3. That’s it! Packaging reference Description
Reference
Box 1 – wood Dimension: 30” x 60” x 3”
Good to know
It is vitally important that anyone riding a go-kart wear the proper protective gear. The rider should wear, at a minimum, a full-face DOT-rated engine cycle helmet, gloves and a helmet supporting neck brace. These items and other safety equipment are not supplied with the kits but can be found through many online or retail sellers. We aim to provide the best assembly documentation in the industry and will include written instructions and online videos for all of the crucial steps. We will be available to help you through the process, so if you need assistance, please ask. However, this is a kit and the ultimate build quality is up to you.
Box 2 –engine Dimension: 14” x 14” x 16”
Box 3 – hardware & wheels Dimensions: 24” x 12” x 12”
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For more the complete list of hardware, see Visual reference of the plywood sheets, on page 61.
PlyFly Go‑Kart Instruction Guide • 2015 Release
3
Unpacking the boxes
Each box should have the following components. Box 1 contents 2.5 HP №
DESCRIPTION
3
Plywood Sheet 3/4” depth
1
Plywood Sheet 1/4” depth
1
Flag
1
Drive Shaft Steel, Keyed, 5/8” D
4.0 HP
4.0 HP
4.0 HP
SINGLE WHEEL
SINGLE WHEEL
SINGLE WHEEL 12” WHEELS
10” WHEELS
12” WHEELS
• • •
• • •
• • •
• • •
• • •
18” L
18” L
18” L
33” L
36” L
10” WHEELS
10” WHEELS
LIVE AXLE
4.0 HP LIVE AXLE
Box 2 contents 2.5 HP №
DESCRIPTION
1
Gas Powered Engine
1
Gas Powered Engine
2.5 HP MODEL
4.0 HP MODEL
4.0 HP
4.0 HP
4.0 HP
SINGLE WHEEL
SINGLE WHEEL 12” WHEELS
10” WHEELS
12” WHEELS
•
―
―
―
―
•
•
•
•
10” WHEELS
―
10” WHEELS
LIVE AXLE
4.0 HP
SINGLE WHEEL
LIVE AXLE
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1 Exploring the kit
Box 3 Contents
DESCRIPTION
Plyfly Packaged Hardware Kit Sealed kit of go‑kart hardware
4.0 HP
4.0 HP
SINGLE WHEEL
SINGLE WHEEL
SINGLE WHEEL 12” WHEELS
10” WHEELS
12” WHEELS
1
1
1
1
1
―
―
―
―
1
1
1
1
10” WHEELS
10” WHEELS
4.0 HP LIVE AXLE
4.0 HP LIVE AXLE
Clutch #35 Chain, 11 Tooth Pulley for 5/8” shaft 2.5 HP Model
1
Clutch #35 Chain, 12 Tooth Pulley for 3/4” shaft 4.0 HP Model
―
Clutch Guard Side Engine Mounting Plate
1
1
1
1
1
1
1
1
1
1
Clutch Guard Top Top Cover Clutch Guard Cover Outside Cover Sprocket 60 Tooth, #35 Chain, 5/8” D bore Roller Chain #35 Chain, 29-5/8” L Chain Link For connecting #35 Roller Chain Control Cable 1/16” D, throttle & brake control cable Red Throttle Cable Brake conduit, 5’ L Green Throttle Cable Gas conduit, 6’ L VXB Mounted Bearing 5/8” ID Brake Caliper Brake Disc Brake Hub Long Hex Bolt Grade 5, 5/8”-11, 11” L Single Wheel Kit Only Short Hex Bolt Grade 5, 5/8”-11, 6.5” L Precision Rod 1/4” D, 18” L Drawer Slide Hardware included, 10” L Green Elastic Cord 3/16” OD, 18” Spax Screw 1 Box,#8 1-1/2” L 10” D Wheels Rear driven wheel 150718 PLYFLY rev A_CH 1 August | 7,20155:08PM
2.5 HP
1 1 1 1 2 1 1 3 1 1 1 1 4 1 1 1 1 1
1 1 1 1 2 1 1 3 1 1 1 1 4 1 1 1 1 1
10” D Wheels Undriven wheel
3
3
12” D Wheels Rear driven wheel
―
―
12” D Wheels Undriven wheel
―
―
PlyFly Flag
1
1
1 1 1 1 2 1 1 3 1 1 1
1 1 1 1 2 1 1 3 1 1 1
1 1 1 1 2 1 1 3 1 1 1
1
―
―
4 1
4
1
1
4
1
1
1 1 ― ―
1 3
1
1 1
2 2
― ―
1
1 1 1 ― ―
2 2
1
For more the complete list of hardware, see List of the packaged contents, on page 70. PlyFly Go‑Kart Instruction Guide • 2015 Release
5
2
Getting Started Introduction Preparing for a Plyfly Go-Kart build, you will need to cut out each structural wooden part from the plywood sheets. The more time spent trimming tabs cleanly will save a lot of sanding time.
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6
Getting started
Chisel & hammer method
INSTRUCTIONS
INSTRUCTIONS
2. To release the structural wooden parts from the plywood sheets, use the recommended tools and follow one of the suggested methods:
2. Strike the top of the chisel sharply with a hammer to remove wood from the notches.
1. Open the provided boxes to ensure all the parts are included.
‒‒ A chisel and hammer method ‒‒ The reciprocating saw method
1. To free a part from the plywood sheet, place the flat side of chisel against the keeper side of the part.
3. Repeat this procedure until all the parts are free. 4. To finish the edges of all the wood parts that become spalled or rough from the cutting process using an orbital sander, or sheet of sandpaper.
Reciprocating saw method Recommended tools DESCRIPTION
REFERENCE
INSTRUCTIONS
1. Select the correct blade for the cutting wood 2. Place the plywood sheet on saw horses or a workbench, or clamp it in a vice, depending on which is best suited for your purpose.
Chisel
Note Make sure you have sufficient light to see your cutting marks easily
3. To free a part from the plywood sheet, position the blade close to the edge of the wood tab (where you will begin your cut) Note Complete the cut by continuing through the material, being careful to support any piece that may drop when the cut is finished until the blade is free of it.
Hammer
4. Repeat this procedure until all the parts are free.
Orbital sander
5. To finish the edges of all the wood parts that become spalled or rough from the cutting process using an orbital sander, or sheet of sandpaper.
Sandpaper
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Jigsaw or Reciprocating saw (optional)
For more information on What’s in the kit?, see page 3.
PlyFly Go‑Kart Instruction Guide • 2015 Release
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3
Seat Assembly Introduction Before beginning this assembly, be sure to chisel out and sand parts 22 - 33. These 12 components are required to fully assemble the go‑kart seat
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Plywood sheet reference DESCRIPTION
REFERENCE
Sheet 1 3/4” Plywood Sheet
‒‒Parts 24
Recommended tools DESCRIPTION
REFERENCE
Dead blow hammer or mallet
Electric driver
Required hardware 24
‒‒Parts 22-23 ‒‒Parts 25-27
Sheet 3 3/4” Plywood Sheet
№
DESCRIPTION
REFERENCE
32 Spax Screw #8, 1-1/2” L PN 12519
22
23
26
Sheet 4 1/4” Plywood Sheet
27
25
‒‒Parts 28-31
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31
29
28
30
PlyFly Go‑Kart Instruction Guide • 2015 Release
9
Required wooden parts DESCRIPTION
REFERENCE
DESCRIPTION
REFERENCE
Part 28 Seat Bolster Left PLYWOOD SHEET 4
Part 22 Seat Side Left PLYWOOD SHEET 3
Part 29 Seat Bolster Right PLYWOOD SHEET 4
Part 30 Seat Thigh Bolster Left PLYWOOD SHEET 4
Part 23 Seat Side Right ‒‒Gas tank side PLYWOOD SHEET 3
Part 31 Seat Thigh Bolster Right PLYWOOD SHEET 4
Part 24 Seat Crossbar PLYWOOD SHEET 1
Part 32 Seat Back PLYWOOD SHEET 4
Part 25 Seat Crossbar PLYWOOD SHEET 3
Part 26 Seat Crossbar PLYWOOD SHEET 3
Part 33 Seat Bottom PLYWOOD SHEET 4
PLYWOOD SHEET 3
N ote If you received a 1/4” plywood sheet that is finished on one side and you intend to paint the Plyfly go‑kart seat; reverse the wooden parts 28‑33 (so the unfinished side is outward facing and ready to receive paint).
10
3 Seat Assembly
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Part 27 Seat Crossbar Bracket
Assembling the seat INSTRUCTIONS
1. Align parts 22 & 23 with the slots facing outwards. 2. Using a mallet, tap part 27 into the slots on parts 22 &23.
7. Secure part 32 to the seat frame using screws. ‒‒ Use 8 screws. ‒‒ Total of 8 locations.
Note the part orientation and location.
8. Using a mallet, tap part 29 into seat frame. 27
Note location and orientation of part 29. 29
23 22
3. Secure part 27 using 2 screws. ‒‒ Use 1 screw per side. 9. Repeat step 8 with part 28 on the opposite side.
‒‒ Total of 2 locations, 2 screws. Note secure part 27, by screwing the part in from the outside of part 22 & 23.
10. Secure parts 28 & 29 to seat frame using screws. ‒‒ Use 4 screws. ‒‒ Total of 4 locations. 11. Using a mallet, tap part 33 into the tab connections of parts 26 &27. Note location and orientation of part 33. 33
1
2
4. Using a mallet, tap parts 24, 25, & 26 into the remaining slots. Note the location and orientation of the parts 24-26. 24
25
26
12. Secure part 33 using screws. ‒‒ Use 8 screws. ‒‒ Total of 8 locations. 13. Using a mallet, tap part 31 into place using a mallet. Note location and orientation of part 31.
5. Secure parts 24, 25, & 26 by using screws. ‒‒ Use 2 screws per part, 1 screw per side. 150718 PLYFLY rev A_Seat August | 7,20155:06PM
‒‒ Total of 6 locations, 6 screws.
31
6. Using a mallet, tap part 32 into the tab connections of parts 24 & 25. Note the location and orientation of the part 32.
32
14. Repeat step 13 with part 30 on the opposite side. 15. Secure parts 30-31 to seat frame using screws. ‒‒ Use 4 screws. ‒‒ Total of 4 locations. PlyFly Go‑Kart Instruction Guide • 2015 Release
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4
Steering Column Assembly Introduction
Before beginning this assembly, be sure to chisel out and sand parts 19-20. These 3 components are required to fully assemble the steering shaft.
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Plywood sheet reference
Recommended tools
DESCRIPTION
REFERENCE
DESCRIPTION
Sheet 1 3/4” Plywood Sheet
‒‒Part 20
Dead blow hammer or mallet
REFERENCE
Hammer
Electric driver
Required hardware 20
Sheet 2 3/4” Plywood Sheet
№
DESCRIPTION
REFERENCE
4 Small Metal Bushing Flanged 3/8” ID, 1/4” L
‒‒Part 19 ‒‒Part 21
PN 12538
4 Spax Screw #8, 1-1/2” L PN 12519
Required wooden parts DESCRIPTION
21 5
19
REFERENCE
Part 19 Steering Column Shaft
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PLYWOOD SHEET 2
Part 20 Steering Pinion PLYWOOD SHEET 1
Part 21 Steering Wheel PLYWOOD SHEET 2
PlyFly Go‑Kart Instruction Guide • 2015 Release
13
Assembling the steering shaft INSTRUCTIONS
1. Press bushings into each side of part 20. Note there are 2 bushings, 1 bushing per side.
6. Secure the parts using screws. ‒‒ Use 2 screws on part 20 ‒‒ Total of 2 locations. 7. Using a mallet, tap part 21 to the assembly. Note the location and orientation of part 21. The bushings should point in the same direction. 21
2. Hammer securely until the top of each bushing is flush. 3. Press bushings into each side of part 21. Note there are 2 bushings, 1 bushing per side..
19
20
8. Secure the parts using screws. 4. Hammer securely until the top of each bushing is flush 5. Using a mallet, tap part 19 to part 20.
‒‒ Use 2 screws on part 21. ‒‒ Total of 2 locations.
Note The orientation of the parts.
19
20 150718 PLYFLY rev A_Steer columnA |ugu27s0,t150 :P 6M
14
4 Steering Column Assembly
5
Steering Rack Assembly Introduction
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Before beginning this assembly, be sure to pre-cut and sand parts 9 - 12. These 4 components are required to fully assemble the go‑kart steering rack.
15
Recommended tools
Plywood sheet reference DESCRIPTION
REFERENCE
Sheet 1 3/4” Plywood Sheet
‒‒Parts 9-10
DESCRIPTION
REFERENCE
Dead blow hammer or mallet
Hammer
Screwdriver 9
10
Sheet 2 3/4” Plywood Sheet
12
‒‒Parts 11-12
Electric driver
11
Required hardware №
4
DESCRIPTION
REFERENCE
Spax Screw #8, 1-1/2” L PN 12519
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5 Steering Rack Assembly
Required wooden parts DESCRIPTION
REFERENCE
Assembling the steering rack INSTRUCTIONS
1. Using a mallet, tap parts 9 & 10 into the slots on part 11. Part 9 Steering Rack Bracket
Note the part orientation
11
PLYWOOD SHEET 1
9
10
Part 10 Steering Rack Bracket PLYWOOD SHEET 1
Part 11 Steering Rack PLYWOOD SHEET 2
2. Secure parts 9 & 10 using screws. ‒‒ Use 1 screw per part. ‒‒ Total of 2 locations, 2 screws. Part 12 Steering Rack Center Bracket
3. Using a mallet, tap part 12 into the tab connections on parts 9 & 10. Note the part 12 orientation – the gear teeth should point in the same direction.
12
PLYWOOD SHEET 2
4. Secure part 12 to the assembly using screws. ‒‒ Use 2 screws.
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‒‒ Total of 2 locations.
PlyFly Go‑Kart Instruction Guide • 2015 Release
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6
Fixed Steering Column Assembly Introduction Before beginning this assembly, be sure to pre-cut and sand parts 13 - 18. These 6 components are required to fully assemble the go‑kart fixed steering column.
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Plywood sheet reference DESCRIPTION
REFERENCE
Sheet 1 3/4” Plywood Sheet
‒‒Parts 13
Recommended tools DESCRIPTION
REFERENCE
Dead blow hammer or mallet
Hammer
13
Required hardware №
Sheet 2 3/4” Plywood Sheet
DESCRIPTION
REFERENCE
‒‒Parts 14-18 2 14
15
Small Tee Nut Zinc Plated, 5/16”-18 PN 12510
18
12 Spax Screw #8, 1-1/2” L PN 12519
17
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PlyFly Go‑Kart Instruction Guide • 2015 Release
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Required wooden parts DESCRIPTION
REFERENCE
Assembling the steering column INSTRUCTIONS
1. Press tee nuts into parts 15 & 18 Note the orientation of part 15.
Part 13 Steering Column Left
15
PLYWOOD SHEET 1
Note the orientation of part 18.
18 Part 14 Steering Column Right PLYWOOD SHEET 2
2. Using a hammer, tap the tee nut until the top is flush with the wooden part. 3. Using a mallet, tap parts 15, 16, 17, & 18 into the corresponding slots on part 13. Note the location and orientation of each part.
17
18
16
15
Part 15 Steering Column Top PLYWOOD SHEET 2
Part 16 Steering Column Phone Mount PLYWOOD SHEET 2
Part 17 Steering Column Bracket
13
PLYWOOD SHEET 2
4. Align part 14 to the assembly so that the part mirrors part 13 exactly.
PLYWOOD SHEET 2
5. Using a mallet, tap part 14 into the tab connections. 6. Secure the parts using screws on each part. ‒‒ Use 1 screw per part, per side. ‒‒ Total of 4 locations, 4 screws. 7. Secure the parts on the opposite side, turn the assembly on its side, and then screw in each part. ‒‒ Use 1 screw per part, per side. ‒‒ Total of 4 locations, 4 screws.
20
6 Fixed Steering Column Assembly
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Part 18 Steering Pinion Mount
7
Steering Spindle Assemblies Introduction
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Before beginning this assembly, be sure to chisel out and sand parts 1-8. These 8 components are required to fully assemble 2 steering spindle. Each assembly contains 4 parts.
21
Plywood sheet reference DESCRIPTION
REFERENCE
Sheet 1 3/4” Plywood Sheet
‒‒Part 1 ‒‒Parts 3-4 ‒‒Parts 6-8
Recommended tools DESCRIPTION
REFERENCE
Dead blow hammer or mallet 3
Hammer
Electric Driver 4
Sheet 2 3/4” Plywood Sheet
7
8
1
6
‒‒Part 2 ‒‒Part 5
Required hardware №
DESCRIPTION
REFERENCE
2
2
Short Hex Bolt Grade 5, 5/8”-11, 6.5” L PN 12503
6
Large Metal Bushing Flanged, 3/4” OD, 5/8” ID PN 12504
5
2
Small Tee Nut Zinc Plated, 5/16”-18 PN 12510
PN 12519
22
7 Steering Spindle Assemblies
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20 Spax Screw #8, 1-1/2” L
Required wooden parts DESCRIPTION
REFERENCE
Part 1 Steering Spindle Outer Spacer PLYWOOD SHEET 1
Part 2 Steering Spindle Outer Spacer PLYWOOD SHEET 2
Part 3 Steering Spindle Inner Spacer PLYWOOD SHEET 1
Part 4 Steering Spindle Inner Spacer PLYWOOD SHEET 1
Part 5 Steering Spindle Bottom Left PLYWOOD SHEET 2
Part 6 Steering Spindle Bottom Right PLYWOOD SHEET 1
Part 7 Steering Spindle Top
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PLYWOOD SHEET 1
Part 8 Steering Spindle Top PLYWOOD SHEET 1
PlyFly Go‑Kart Instruction Guide • 2015 Release
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Assembling the left & right steering spindles INSTRUCTIONS
1. Press bushings into parts 1‑2, 5‑6, & 7‑8
7. Using a mallet, cap the parts 1, 3, 5 with part 7. 8. Using a mallet, cap the parts 2, 4, 6 with part 8.
Note the orientation of part 1 & 2.
Note the location of the bushings.
7
8
2
1
Note Be sure to insert the bushing on the opposite side of the alignment mark. Parts 5 & 6 are left and a right side biased.
5
9. Secure the parts using screws on each part. ‒‒ Use 2 screws on part 5
6
‒‒ Use 2 screws on part 6 ‒‒ Use 4 screws on part 7 ‒‒ Use 4 screws on part 8 ‒‒ Total 20 locations, 20 screws. 10. Using a hammer, insert the 5/8” long bolt into each steering spindle assembly. Note the location of the bushings
Note the location of the bushings.
7
8
2. Using a hammer, tap the bushings until the top is flush with the wooden part. 3. Using a mallet, tap parts 1 into the outer slot on part 5. 4. Using a mallet, tap parts 2 into the outer slot on part 6. 5. Using a mallet, tap parts 3 into the inner slot on part 5. 6. Using a mallet, tap parts 4 into the inner slot on part 6. Note the location of the bushings. The bushing should face outwards. Try to ensure 90°
2 3
5 24
7 Steering Spindle Assemblies
4
6
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1
8
Pedal Assemblies Introduction
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Before beginning this assembly, be sure to chisel out and sand parts 34 - 39. These 6 components are required to fully assemble the go‑kart gas and brake pedals. Each assembly contains 3 parts.
25
Plywood sheet reference DESCRIPTION
REFERENCE
Sheet 1 3/4” Plywood Sheet
‒‒Parts 34 ‒‒Parts 36-39
Recommended tools DESCRIPTION
REFERENCE
Dead blow hammer or mallet 38
39
Hammer
Electric Driver
36
37
Sheet 3 3/4” Plywood Sheet
34
‒‒Parts 35
Required hardware №
4
DESCRIPTION
REFERENCE
Plastic Bushing Flanged, 1/4” ID, 3/8” OD PN 12509
35
8
Spax Screw #8, 1-1/2” L PN 12519
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8 Pedal Assemblies
Required wooden parts DESCRIPTION
REFERENCE
Assembling the gas & the brake pedals INSTRUCTIONS
1. Insert and hammer into place the bushings into parts Part 34 Brake Pedal PLYWOOD SHEET 1
‒‒ Part 36 ‒‒ Part 37 ‒‒ Part 38 ‒‒ Part 39 Note the part orientation. The final 2 assemblies are mirror images of each other.
Part 35 Gas Pedal
38
39
36
37
PLYWOOD SHEET 3
Part 36 Pedal Side PLYWOOD SHEET 1
2. Using a mallet, tap parts 36 & 37 into the slots on part 34. Note part location and orientation of parts 36-37. Be sure to square the parts.
Part 37 Pedal Side PLYWOOD SHEET 1
34
Part 38 Pedal Side
36
PLYWOOD SHEET 1
37
Part 39 Pedal Side PLYWOOD SHEET 1
3. Secure parts 34, 36 & 37 using screws. ‒‒ Use 2 screws per part & per side. ‒‒ Total of 4 locations, 4 screws. 4. Repeat step 2 using parts 35, 38 & 39. Note part location and orientation of parts 36-37. Be sure to square the parts.
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35
38 39
5. Secure parts 35, 38 & 39 using screws. ‒‒ Use 2 screws per part & per side. ‒‒ Total of 4 locations, 4 screws. PlyFly Go‑Kart Instruction Guide • 2015 Release
27
9
Frame Assembly Introduction Before beginning this assembly, be sure to chisel out and sand parts 40-55. These 11 components and assemblies1‑3 are required to fully assemble the go‑kart frame.
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28
Plywood sheet reference DESCRIPTION
REFERENCE
DESCRIPTION
REFERENCE
Sheet 1 3/4” Plywood Sheet
‒‒Parts 40-43 ‒‒Part 49
Sheet 4 1/4” Plywood Sheet
‒‒Part 47 ‒‒Part 50
41
40
43
42
50
49
47
Sheet 2 3/4” Plywood Sheet
‒‒Parts 44-46 ‒‒Part 48 ‒‒Part 52 45
46
52
‒‒Part 51 ‒‒Part 53-54 ‒‒Part 55
44
55
51
53
54
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48
Sheet 4 1/4” Plywood Sheet
PlyFly Go‑Kart Instruction Guide • 2015 Release
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Recommended tools DESCRIPTION
Required assemblies DESCRIPTION
REFERENCE
Dead blow Hammer or mallet
REFERENCE
1 Steering rack Assembly Parts 9-12
Hammer
Electric Driver
2 Screwdriver
Required hardware №
1
DESCRIPTION
Drawer Slide Hardware included, 10” L PN 12508
Large Metal Bushing Flanged, 3/4” OD, 5/8” ID 5 4
Fixed steering column Assembly Parts 13-18
REFERENCE
3 Steering column Assembly Parts 19-21
SINGLE WHEEL KIT PN 12504 LIVE AXLE KIT PN 12504
10 Large Tee Nut Zinc Plated, 3/8”-16 PN 12545
10 Small Tee Nut Zinc Plated, 5/16”-18 PN 12510
30 Spax Screw #8, 1-1/2” L PN 12519
VXB Mounted Bearing 5/8” ID PN 12521
4
Hex head cap screw 5/16”-18, 1.25 L PN 12543
4
Flat Washer 5/16” ID, 7/8” OD PN 12516
30
9 Frame Assembly
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3
Required wooden parts DESCRIPTION
Part 40 Frame Rail Inner Left PLYWOOD SHEET 1
REFERENCE
DESCRIPTION
REFERENCE
Part 48 Frame Rail Rear PLYWOOD SHEET 2
Part 41 Frame Rail Inner Right PLYWOOD SHEET 1
Part 49 Frame Rail Engine Mount PLYWOOD SHEET 1
Part 42 Frame Rail Outer Left PLYWOOD SHEET 1
Part 50 Engine Mounting Plate PLYWOOD SHEET 3
Part 43 Frame Rail Outer Right PLYWOOD SHEET 1
Part 51 Floor Panel PLYWOOD SHEET 4
Part 44 Front-end Bottom PLYWOOD SHEET 2
Part 52 Frame Gusset PLYWOOD SHEET 2
Part 45 Front-end Top
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PLYWOOD SHEET 2
Part 46 Frame Rail Bracket PLYWOOD SHEET 2
Part 47 Sprocket Guard PLYWOOD SHEET 3
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Assembling the frame INSTRUCTIONS
1. To begin this assembly
5. Press the large tee nuts into
‒‒ Start at Step 2 if you have a SINGLE WHEEL KIT.
‒‒ Part 42‑43
‒‒ Start at Step 4 if you have a LIVE AXLE KIT.
‒‒ Part 47
2. Press the bushing into part 40. Note the location of the bushing on part 40. Install on the opposite side of the L.
40
‒‒ Part 50; on the opposite side of the small tee nut installation. Note the location of 2 large tee nuts on part 42. Install on the same side of the L. 1
3. Using a hammer, tap the bushing until the top is flush with the wooden part. 4. Press the small tee nuts into ‒‒ Part 40‑41
42
2
Note the location of 2 large tee nuts on part 43. Install on the same side of the L.
43
1
2
‒‒ Part 49 ‒‒ Part 50; be sure to follow installation pattern for the correct engine model. Note the location of 2 large tee nust on part 47.
Note the location of the small tee nut on part 40; install on the same side of the L.
47
40
Note the location of the small tee nut on part 41. Install on the same side of the L.
2
Note the location of 4 large tee nuts on part 50. Install on opposing side of the small tee nut installion on part 50.
1
41
1
50
1
2
3
4
Note the location of 4 small tee nuts on part 49.
49
1
3
2
4
6. Using a hammer, tap the tee nuts until the top is flush with the wooden part. ‒‒ Parts 41‑43, 47, 49 & 50.
1
50
‒‒ Total of 20 locations. 7. Screw in the fillester head machine screws into the tee nuts located parts 40 & 41.
3
1
2.5 HP
2
50
4.0 HP
4 2
32
9 Frame Assembly
3
4
‒‒ Tighten down until it stands flush with 3/8” protrusion.
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‒‒ Use 20 tee nuts; 10 small and 10 large.
Note the location of 4 small tee nuts on part 50
8. Press 2 bushings into part 45. Note the location of the bushing on part 45 1
2
16. E xtend the drawer slide until the last two holes on the drawer slide are accessible from the underside through the slot located on part 44. Note the location of the referenced slot on part 44.
9. Using a hammer, tap the bushings until the top is flush with the wooden part. 10. Press 2 bushings into part 44. Note the location of the bushings on part 44 1
2
11. Using a hammer, tap the bushings until the top is flush with the wooden part. 12. Install the drawer slide on part 44, by extending the slide to its furthest extended position. 13. Align the 4 screw holes on the drawer slide with holes found in the recess on part 44. Note the location and position of the mounting holes. The drawer slide should fit into the recessed pocket on part 44. 1
2
3
Mount 1 to the drawer slide. Note the correct assembly
17. Secure 1 using screws. ‒‒ Use the remaining screws included in the Drawer Slide Kit. 18. Using a mallet, tap part 40 into the tab connections on the left side of part 44. Note the location and orientation of the tee nut on part 40; the letter L should face inward to the centerline of the go‑kart.
40
44
4
14. Secure the drawer slide to part 44 using screws. ‒‒ Use a screwdriver and the screws provided in the Slide Drawer Kit. ‒‒ Use 4 screws ‒‒ Total 4 locations
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15. Test the drawer slide fit by moving the slide back and forth.
19. Using a mallet, tap part 41 into the tab connections on the left side of part 44. Note the letter L should face part 41, away from the centerline of the go‑kart.
41
‒‒ Be sure there are no interferences between any screw head and the slide.
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25. Secure part 44 to the assembly using screws.
20. Repeat steps 18 and 19 using
‒‒ There is a purposeful gap in alignment to allow part 51 to sit flush with the assembly.
‒‒ Part 42 ‒‒ Part 43 Note the letter L should face part 41, away from the centerline of the go‑kart.
‒‒ Use 12 screws. ‒‒ Total of 12 locations. 26. Flip the assembly right side up again.
43
27. Using a mallet, tap part 46 into place. Note the orientation and position the tabs on part 46.
46 42
21. Using a mallet, tap 2 into the tab connections in the center of part 44. Note the orientation and location of the assembly.
2
28. Using a mallet, tap part 47 into the center slot of part 46. Note the orientation and position of part 47.
22. Using a mallet, tap part 45 slots into the tab connections of go‑kart front-end (parts 40‑43). Note the correct orientation for part 45; the bushings face(down) part 44.
45
47
46
29. Secure parts 46 to part 47 using screws. ‒‒ Use 2 screws. ‒‒ Total of 2 locations.
‒‒ Use 12 screws. ‒‒ Total of 12 locations. 24. Flip the assembly over and using a mallet, tap any unseated tabs into place.
‒‒ It is best to do this with 2 hanging off the edge of a table or saw horses.
34
9 Frame Assembly
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23. Secure part 45 using screws.
30. Using a mallet, tap part 48 into the 5 connection tabs. Note the orientation and position of cut‑out tabs, it should face upward. To ensure alignment of all 5 tab connections; prior to using a mallet, tack 1 corner of part 48 with a screw that is not tightened down all the way.
34. Using a mallet, tap part 49 into place. Note the orientation and position of part 49.
49
48
31. Secure part 48 to the assembly using screws on the rear face, left and right side faces. ‒‒ Use 12 screws. ‒‒ Total of 12 locations. 32. Using a mallet, tap part 52 into place. Note the orientation and position of part 52.
35. Secure part 49 using screws. ‒‒ Use 8 screws. ‒‒ Total of 8 locations.
36. Flip assembly over allowing 2 to hang off table or saw horses. 37. Install the 3 mounted bearings
52
Note the orientation, location and position of each mounted bearing.
1
2
3
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33. Secure part 52 using screws. ‒‒ Use 2 screws. ‒‒ Total of 2 locations.
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38. Using a mallet, tap part 51 into place. 39. Secure part 51 to the assembly using 21 screws. ‒‒ Total of 21 locations, 21 screws. 40. Flip assembly right side up. 41. Lay part 50, with the small tee nuts facing upwards, into place. Note the orientation and position of tee nut pattern on part 50.
50
42. Secure part 50 to the assembly using washers & hex head cap screw. ‒‒ Use 4 washers ‒‒ Use 4 hex head cap screw. ‒‒ Total 4 locations. Note the orientation and position of the hex hed bolts; tee-nuts should face up.
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36
9 Frame Assembly
10
Putting the go‑kart together Introduction Before beginning this final assembly, be sure to have assemblies 1‑7 completed. These 8 assemblies are required to fully assemble the go‑kart.
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This chapter contains 10 individual procedural parts to successfully complete the full go‑kart assembly.
37
Overview of the recommended tools DESCRIPTION
REFERENCE
Overview of the required hardware №
DESCRIPTION
REFERENCE
PART 1
Dead blow Hammer or mallet
1 Sprocket 5/8” bore diameter 60 Tooth, #35 Chain PN 12522
Hammer
1 Drive Shaft Steel, Keyed, 5/8” D, 18” L SINGLE WHEEL KIT PN 12580
Electric Driver
Allen Wrench or ratcheting Allen wrench
1 Drive Shaft Steel, Keyed, 5/8” D, 33” L LIVE AXLE KIT – 10” WHEELS PN 12581
1 Drive Shaft Steel, Keyed, 5/8” D, 36” L LIVE AXLE KIT – 12” WHEELS PN 12582
1 Brake Disc Metric Allen Wrench included with mounted bearing
PN 12532
1 Brake Disc Hub PN 12533
Socket Wrench 1 Long Hex Bolt Axle Grade 5, 5/8”-11, 11” L SINGLE WHEEL KIT PN 12502 Needle Nose Pliers
4 Button Socket Head Cap Screw Zinc Plated, Steel, 5/16”-24, 1/2” L TOTAL OF 4 PROVIDED PN 12559
4 Thin Nut Grade 5, 5/16”-24 Note There are 2 types of button socket head cap screws provided in every kit. They appear to be similar in size but are not. The easiest way to differentiate the 2 sizes, is by the number of screws provided.
PN 12520
1 Key 3/16” square, 1”L PN 12539 PART 2
PN 12531
1 Short Aluminum Spacer 1/2” OD, 1/4” ID, 7/8” L PN 12547
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10 Putting the go‑kart together
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1 Brake Caliper
Overview of the required hardware
Overview of the required hardware
1 Long Aluminum Spacer 1/2” OD, 1/4” ID, 1‑1/16” L
6 Zip Tie 10lb Nylon, White, 7/8” D, 4” L
№
DESCRIPTION
PN 12548
2 Oversized Flat Washer Zinc, M6 PN 12549
2 Socket Head Cap Screw Black oxide, M6, 55mm L PN 12550 PART 3
1 Nylon Spacer 3/4” OD, 3/8” ID, 1‑1/4” L PN 12546
4 Flat Washer 5/16” ID, 7/8” OD PN 12516
1 Short Shoulder Screw 3/8” D, 1” L, 5/16”-18 PN 12513
1 Long Shoulder Screw
3/8” D, 2‑1/4” L, 5/16”-18 PN 12514
PART 4
2 Short Hex Bolt Grade 5, 5/8”-11, 6.5” L PN 12503
2 Lock Nut 5/8” ID PN 12506
4 Flat Washer 5/8” ID, 1‑3/8” OD PN 12505 PART 5
1 Precision Rod 1/4” D, 18” L
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PN 12507 PART 6
1 Control Cable 1/16” D, throttle & brake control cable PN 12525
1 Red Throttle Cable Brake conduit, 5’ L PN 12527
1 Green Throttle Cable Gas conduit, 6’ L PN 12528
REFERENCE
№
DESCRIPTION
REFERENCE
PN 12558 PART 7
1 Gas Powered Engine 2.5 HP MODEL
1 Gas Powered Engine 4.0 HP MODEL
Box 2
Box 2
1 Clutch #35 Chain, 11 Tooth Pulley for 5/8” D 2.5 HP MODEL PN 12576 1 Clutch #35 Chain, 12 Tooth Pulley for 3/4” D 4.0 HP MODEL PN 12577 1 Roller Chain #35 Chain, 29-5/8” L PN 12524
1 Master Chain Link #35 Roller Chain connector PN 12534
1 Part 56 Clutch Guard Side Engine Mounting Plate PN 12005
1 Part 57 Clutch Guard Top Top Cover PN 12006
1 Part 58 Clutch Guard Cover Outside Cover PN 12007
1 Control Cable 1/16” D, throttle & brake control cable PN 12525
1 Throttle cable clamp PN 12537
1 Extension Spring Black-Oxide, Precision PN 12560
1 Throttle Return Clip 4.0 HP MODEL PN 12561
8 Sheetmetal Screw Galvanized, #6 PN 12551
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Overview of the required hardware
Overview of the required hardware
5 Button Socket Head Cap Screw Zinc Plated, Steel, M8, 12mm L
2 Undriven wheel 10” D LIVE AXLE KIT PN 12591
№
DESCRIPTION
TOTAL OF 5 PROVIDED PN 12515
1 Hex head cap screw 5/16”-18, 1.25 L 4.0 HP MODEL PN 12543 1 Hex Cap Screw 1/4”-20, 1” L 2.5 HP MODEL PN 12554 1 Flat Washer 5/16” ID, 7/8” OD PN 12516
1 Fender washer 5/16” ID, 1-1/8” OD PN 12555
1 Lock washer 5/16” ID 1 Clutch Key 3/16”, 1/2” L PN 12557
2 Set Screw Clutch PN 12563
1 Pan head M6, 12 mm L
4.0 HP MODEL PN 12564
PART 8
Flat Washer 5/16” ID, 7/8” OD
3 SINGLE WHEEL KIT PN 12516 2 LIVE AXLE KIT PN 12516 2 Shaft Collar 5/8” ID PN 12540
REFERENCE
№
DESCRIPTION
REFERENCE
1 Rear driven wheel 12” D SINGLE WHEEL KIT PN 12592 3 Undriven wheel 12” D SINGLE WHEEL KIT PN 12593 1 Key 3/16” square, 1”L PN 12539 PART 9
2 Fillister Head Screw 5/16”-18, 3/4” L PN 12553
1 T-Handle Quick Release Pin PN 12542
1 Flag Plyfly flag PN 12535
PART 10
20 Spax Screw 1 #8, 1-1/2” L PN 12519
1 Green Elastic Cord 3/16” OD, 18” L PN 12517
Note There are 2 types of button socket head cap screws provided in every kit. They appear to be similar in size but are not. The easiest way to differentiate the 2 sizes, is by the number of screws provided.
2 Lock Nut 5/8"-11 PN 12506
3 Undriven wheel 10” D SINGLE WHEEL KIT PN 12591 2 Rear driven wheel 10”D LIVE AXLE KIT PN 12590
40
10 Putting the go‑kart together
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1 Rear driven wheel 10”D SINGLE WHEEL KIT PN 12590
Overview of the required but not provided DESCRIPTION
REFERENCE
Motor Oil
Approximately 1 quart of 10W30 Motor Oil
Gas
Regular unleaded gas.
Overview of the required assemblies DESCRIPTION
REFERENCE
2 Fixed steering column Assembly PARTS 13‑18
3 Overview of the required wooden parts DESCRIPTION
Part 53 Fairing Left PLYWOOD SHEET 4
Part 54 Fairing Right PLYWOOD SHEET 4
Part 55 Fairing Front PLYWOOD SHEET 4
REFERENCE
Steering column Assembly PARTS 19‑21
4 Seat Assembly PARTS 22‑33
5 Gas Pedal Assembly PARTS 34, 36‑37
6 Brake Pedal Assembly PARTS 35, 38‑39
7 Left Spindle Assembly PARTS 1, 3, 5, 7
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8 Right Spindle Assembly PARTS 2, 4, 6, 8
9 Frame Assembly PARTS 21‑28
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Required hardware
Chapter 10
1
№
1
PART
REFERENCE
Sprocket 5/8” bore diameter 60 Tooth, #35 Chain PN 12522
Recommended tools DESCRIPTION
DESCRIPTION
REFERENCE
1
Drive Shaft Steel, Keyed, 5/8” D, 18” L SINGLE WHEEL KIT PN 12580
Dead blow Hammer or mallet 1
Drive Shaft Steel, Keyed, 5/8” D, 33” L LIVE AXLE KIT – 10” WHEELS PN 12581
Allen Wrench 1
Drive Shaft Steel, Keyed, 5/8” D, 36” L LIVE AXLE KIT – 12” WHEELS PN 12582
Socket Wrench
N ote There are 2 types of button socket head cap screws provided in every kit. They appear to be similar in size but are not. The easiest way to differentiate the 2 sizes, is by the number of screws provided.
1
Brake Disc
1
Brake Disc Hub
1
Long Hex Bolt Axle Grade 5, 5/8”-11, 11” L SINGLE WHEEL KIT PN 12502
4
Button Socket Head Cap Screw Zinc Plated, Steel, 5/16”-24, 1/2” L
PN 12532
PN 12533
TOTAL OF 4 PROVIDED PN 12559
4
Thin Nut Grade 5, 5/16”-24 PN 12520
Key 3/16” square, 1”L PN 12539
42
10 Putting the go‑kart together
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1
5. Insert the drive shaft by sliding it through the outer mounted bearing located on part 43 only.
Part 1 Install the rear axle INSTRUCTIONS
1. Assemble the hub and brake disc using the button head screws and locknuts. ‒‒ Use 4 button head screws and 4 locknuts ‒‒ Total of 4 locations.
‒‒ If there is too much resistance to insert the drive shaft, temporarily loosen the mounting screws so the mounted bearing is loose; or remove the mounted bearing, slide the drive shaft and then re‑mount the mounted bearing. ‒‒ Rotate the bearing in its seat so that it is parallel to the center frame rails.
Note orientation of the parts.
6. Once the drive shaft is through the outer mounted bearing, insert the brake disc on the end. ‒‒ Use the key to lock the brake disc to the drive shaft. Note the orientation of the disc brake.
43
2. Loosen set screws on all 3 of the mounted bearings ‒‒ Be sure no screw extends into the interior of the bearings; as this will prevent the drive shaft insertion. 3. Insert the drive shaft and bolts ‒‒ SINGLE WHEEL KIT; continue to step 4. ‒‒ LIVE AXLE KIT; continue to step 5. 4. Insert the long hex bolt from the interior of the frame through the bushing located on part 40 and the mounted bearing located on part 42. ‒‒ If there is too much resistance to insert the long hex bolt, temporarily loosen the mounting screws so the mounted bearing is loose; or remove the mounted bearing, slide the long hex bolt through and then re‑mount the mounted bearing.
7. Continue to slide the drive shaft through the assembly, through the center mounted bearing, and then insert the sprocket on then end. ‒‒ Use the key to lock the brake disc to the drive shaft. ‒‒ SINGLE WHEEL KIT is complete. ‒‒ LIVE AXLE KIT continue to step 8. Note location and orientation of the bushing
Note location of the long hex bolt.
42
40 8. Continue to insert the drive shaft through the assembly and through the final mounted bearing located on part 42.
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Note the drive shaft extends equal distances on both sides of the assembly.
9. Ensure all the hardware on mounted bearings are fully tightened.
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43
Part 2 Install the brake caliper
Chapter 10
2
The brakes will initially be installed and then adjusted. INSTRUCTIONS
1. Insert the socket head cap screws with an oversized flat washer through the holes located on part 43,
PART
‒‒ Use 1 socket head cap screw with 1 oversized flat washers per location. ‒‒ Total 2 locations
Recommended tools DESCRIPTION
REFERENCE
2. Insert into the aluminum spacers on the opposite side of part 43. Note the location and orientation of the brake caliper. As well as the locations of the short spacer and the long spacer.
Dead blow Hammer or mallet
43
Allen Wrench
Socket Wrench
Required hardware №
1
1
DESCRIPTION
REFERENCE
Brake Caliper PN 12531
Short Aluminum Spacer 1/2” OD, 1/4” ID, 7/8” L PN 12547
3. Place brake caliper into the cutout located at the rear of part 43 and insert the hardware. 4. Secure the brake caliper in place, using the metric Allen wrench provided. Note the location and orientation of the brake caliper.
1
Long Aluminum Spacer 1/2” OD, 1/4” ID, 1‑1/16” L PN 12548
2
Oversized Flat Washer Zinc, M6
43
PN 12549
2
PN 12550
44
10 Putting the go‑kart together
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Socket Head Cap Screw Black oxide, M6, 55mm L
Part 3 Install the steering column assembly
Chapter 10
3
INSTRUCTIONS
1. Position 3 , so that the gear aligns with those on 1 . ‒‒ Be sure the gear alignment marks located on parts 20 & 12 line up.
PART
Note‑the orientation and alignment of the gear teeth
Recommended tools DESCRIPTION
3
REFERENCE
Electric Driver
20 12
Allen Wrench or ratcheting Allen wrench
2. Insert the shoulder screws. ‒‒ Insert the short shoulder screw through the bushing located on part 20 of 3 .
Required hardware №
DESCRIPTION
1
‒‒ Insert the long shoulder screw with the nylon spacer through the tee nut located on part 21. REFERENCE
Nylon Spacer 3/4” OD, 3/8” ID, 1‑1/4” L
‒‒ Total 2 locations, 2 shoulder screws. Note‑the orientation of the bolt; be sure the head faces down (toward the ground).
PN 12546
4
Flat Washer 5/16” ID, 7/8” OD PN 12516
1
21
Short Shoulder Screw 3/8” D, 1” L, 5/16”-18 3
PN 12513
1
Long Shoulder Screw 3/8” D, 2‑1/4” L, 5/16”-18 PN 12514
21
Required assemblies DESCRIPTION
REFERENCE
3. To secure, tighten both the shoulder screws 3 . ‒‒ Total 2 locations.
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1 Steering rack Assembly Parts 9-12
3 Steering Column Assembly PARTS 19‑21
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Part 4 Install the steering spindles
Chapter 10
4
INSTRUCTIONS
1. Slide the steering rack all the way to the right. 2. Insert 7 with the bolt facing out.
PART
‒‒ Check that the bushings on 7 are completely seated before installing. Note the location and orientation of the assemblies.
Recommended tools DESCRIPTION
8
REFERENCE
Hammer
7
Required hardware №
DESCRIPTION
2
REFERENCE
Short Hex Bolt Grade 5, 5/8”-11, 6.5” L PN 12503
2
Lock Nut 5/8” ID
Note the location and orientation of the alignment marks.
7
PN 12506
4
3. Align the gear teeth of 7 with the gear alignment mark located on the steering rack assembly gear.
Fender Washer 3/4” OD, 5/8” ID PN 12505
Required assemblies DESCRIPTION
REFERENCE
4. Insert the short hex bolt with a washer, starting from the bottom and insert through the bushings found on 7 and then through the top of the frame. Note the order of the hardware insertion. 7
7 Left Spindle Assembly PARTS 1, 3, 5, 7
5. Using a hammer, tap into place. 6. Insert a washer over the short hex bolt and secure it with a locknut. Note the order of the hardware insertion.
Right Spindle Assembly PARTS 2, 4, 6, 8
7
7. Repeat steps 1 through 6 on the opposite side using 8 . 46
10 Putting the go‑kart together
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8
Part 5 Install the gas & brake pedals
Chapter 10
5
INSTRUCTIONS
1. Each assembly has a long tab with a hole. The position of the pedal is dictated by these holes. The holes should be pointing towards the middle of the fixed steering column.
PART
Note the right and left pedals tabs, holes, and their position in the Assembly.
DESCRIPTION
2
1
Recommended tools
REFERENCE
Dead blow Hammer or mallet
6
Electric Driver
5
2. Position 5 on the right of the fixed steering column.
3. Position 6 on the left of the fixed steering column. Note location and orientation of the assembly 5 & 6.
Required hardware №
DESCRIPTION
1
5
6
REFERENCE
Precision Rod 1/4” D, 18” L PN 12507
Required Assemblies DESCRIPTION
5
REFERENCE
4. Insert the precision rod through the holes located in 5 and then through the holes located in 6 . Note location of the precision rod.
Gas Pedal Assembly Parts 34, 36-37
6
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Brake Pedal Assembly Parts 35, 38-39
5. Using a hammer, tap into place. 6. Test the alignment of each pedal assembly. ‒‒ Each pedal should be able to move freely and independently (some drag is expected).
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47
Reference Assemblies
Chapter 10
6
DESCRIPTION
2
PART
Fixed steering column Assembly
Recommended tools DESCRIPTION
REFERENCE
PARTS 13‑18
REFERENCE
5
Needle Nose Pliers
Gas Pedal Assembly Parts 34, 36-37 Allen Wrench
6 Brake Pedal Assembly Parts 35, 38-39
Socket Wrench
9 Required Assemblies №
1
DESCRIPTION
REFERENCE
Frame Assembly PARTS 21‑28
Control Cable 1/16” D, throttle & brake control cable PN 12525
1
Red Throttle Cable Brake conduit, 5’ L PN 12527
1
Green Throttle Cable Gas conduit, 6’ L PN 12528
6
Zip Tie 10lb Nylon, White, 7/8” D, 4” L PN 12558
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48
10 Putting the go‑kart together
4. Continue to run the red cable on the left side of the go‑kart
Part 6 Install the gas & brake cables INSTRUCTIONS
‒‒ Through the cable ties located on 9 ,
1. Loop 4 zip ties through the holes located on 2 .
‒‒ Loosely tighten the zip ties, leaving a large loop so later, the cables can slide through easily. Note the locations of the zip ties.
‒‒ through the slots located on part 40 & 43, ‒‒ and into the brake caliper assembly. Note path of the red cable.
2
43 41
1
2
3
9
4
2. Loop 2 zip ties through the holes located 9 . ‒‒ Loosely tighten the nylon cable ties, leaving a large loop so later, the cables can slide through easily. Note the locations of the zip ties.
1
9
5. Run the green cable on the right side of the go‑kart ‒‒ Through the interior of 2 and then
‒‒ through the cable ties located on 2 and then
‒‒ through the hole located on the right side of part 17.
Note the location and direction of the green cable. Be sure to seat the green cable in the notches located on part 17 of 3 .
2
14
3. Run the red cable on the left side of the go‑kart
2
3
17
19
‒‒ Through the interior of 2
‒‒ through zip ties located on part 13 and then ‒‒ through the hole located on the left side of part 17.
150718 PLYFLY rev A_GoKart |Augus7 t2,0155:08PM
Note the location and direction of the red cable. Be sure to seat the red cable in the notches located on part 19 of 3 .
13
3
2
17
19
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6. Continue to run green cable on the right side of the go‑kart ‒‒ Through the cable ties located on 9 ,
11. Feed the brake control cable through a washer into the fitting located on the brake. Note path of the brake control cable through the brake caliper.
‒‒ through the slots located on part 40 & 43, ‒‒ and leave slack to secure to the engine later. Note path of the red cable.
43
41
12. Secure the control cable in place using a small wrench or pliers. 13. Test brake pedal to ensure proper movement of brake.
7. Secure the nylon cable ties by tightening them. 8. Use the needle nose pliers to clip any excess cable tie material. 9. Feed the brake control cable through the hole located in the 6 and into the red cable. Note path of the brake control cable through the brake pedal.
6
10. Fish the brake control cable through the red cable all the way to the end.
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10 Putting the go‑kart together
Required but not provided
Chapter 10
7
№
PART
Recommended tools DESCRIPTION
IMAGE REFERENCE
DESCRIPTION
REFERENCE
Oil Type & Amount
TYPE & AMOUNT
Gas Type
TYPE
Required hardware №
DESCRIPTION
1 Gas Powered Engine
Dead blow Hammer or mallet
2.5 HP MODEL
Metric Allen Wrench included with mounted bearing
1 Gas Powered Engine 4.0 HP MODEL
REFERENCE
Box 2
Box 2
1 Clutch #35 Chain, 11 Tooth Pulley for 5/8” D 2.5 HP MODEL PN 12576
Wrench
1 Clutch #35 Chain, 12 Tooth Pulley for 3/4” D 4.0 HP MODEL PN 12577
Socket Wrench
1 Roller Chain #35 Chain, 29-5/8” L PN 12524
1 Master Chain Link #35 Roller Chain connector
Electric Driver
PN 12534
Note Be sure not to lose attached key, set screws and bolt to hold clutch in place.
Required assemblies DESCRIPTION
5
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Gas Pedal Assembly Parts 34, 36-37
REFERENCE
1 Part 56 Clutch Guard Side Engine Mounting Plate PN 12005
1 Part 57 Clutch Guard Top Top Cover PN 12006
1 Part 58 Clutch Guard Cover Outside Cover PN 12007
1 Control Cable 1/16” D, throttle & brake control cable PN 12525
1 Throttle cable clamp PN 12537
9 Frame Assembly PARTS 21‑28
1 Extension Spring Black-Oxide, Precision PN 12560
1 Throttle Return Clip 4.0 HP MODEL PN 12561
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Required hardware №
DESCRIPTION
8 Sheetmetal Screw Galvanized, #6 PN 12551
5 Button Socket Head Cap Screw Zinc Plated, Steel, M8, 12mm L
Part 7 Install the engine and drive train REFERENCE
The engine arrives with no oil, no configuration is required. INSTRUCTION
1. Stand the engine on part 50 located on 9 , aligning the engine mounting holes to the tee nut pattern (installed previously) appropriate for the engine model. Note the location of the engine mount.
TOTAL OF 5 PROVIDED PN 12515
50
1 Hex head cap screw 5/16”-18, 1.25 L 4.0 HP MODEL PN 12543 1 Hex Cap Screw 1/4”-20, 1” L 2.5 HP MODEL PN 12554 1 Flat Washer 5/16” ID, 7/8” OD PN 12516
1 Fender washer 5/16” ID, 1-1/8” OD PN 12555
1 Lock washer 5/16” ID 1 Clutch Key 3/16”, 1/2” L
9
Note the location of the tee nut bolting pattern on part 50. 1
50
2
3
1
2.5 HP
50
3
4.0 HP
4 2
4
PN 12557
2 Set Screw Clutch
Note the direction and orientation of the engine within the go-kart.
PN 12563
1 Pan head M6, 12 mm L
4.0 HP MODEL PN 12564
‒‒ 2.5 HP MODEL continue to step 3. ‒‒ 4.0 HP MODEL continue to step 4.
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10 Putting the go‑kart together
150718 PLYFLY rev A_GoKart |Augus7 t2,0155:08PM
2. For next installation step:
3. Remove the 2 bolts holding the throttle linkage; to be able to secure the engine to part 50. ‒‒ Remove 2 bolts.
8. Slide part 56 into the space located on the engine side. Note the location of slot.
‒‒ Total of 2 locations. Note the location of the 2 throttle linkage bolts.
56
1
2
9. Secure part 56, using M8 screws. ‒‒ Use 3 screws.
4. Using a socket wrench secure the engine bolts to part 50. ‒‒ Use 4 bolts.
‒‒ Total of 3 locations. Note the locations of the 3 screws.
‒‒ Total of 4 locations. 5. For next installation step: ‒‒ 2.5 HP MODEL continue to step 6. ‒‒ 4.0 HP MODEL continue to step 8. 6. Secure the throttle linkage back into place using the bolts. ‒‒ Use 2 bolts. ‒‒ Total of 2 locations. 7. Install the extension spring, by hooking one end through the hole located on the throttle linkage. Then using pliers, stretch the extension spring and hook it through the second hole on the opposite side of the throttle linkage. Note the location of the extension spring.
1
1
3
2
10. Slide the clutch over the engine crank shaft. ‒‒ Be sure the set screws on the clutch are backed‑out enough to be able to slide the clutch over the crankshaft. ‒‒ Be sure the small sprocket is facing toward the engine and the set screws are facing away from the engine. ‒‒ Be sure to align the keyway on the clutch with the keyway on the drive shaft.
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Note the orientation of clutch; the small sprocket should face the engine.
2 !
PlyFly Go‑Kart Instruction Guide • 2015 Release
53
11. Insert 1/2” clutch key through the center of the clutch. 12. Using an Allen wrench tighten the set screws. ‒‒ 2 set screws.
15. Connect the chain by sliding the posts of the master link into the holes located at the ends of the chain. Note the order of the assembled hardware.
‒‒ Total of 2 screws. Note the locations of the 3 set screws.
2
1 16. Add the master link plate. Note the order of the assembled hardware.
13. Using a wrench, tighten the hex head cap screw assembled with a lock washer and a fender washer to secure the clutch. ‒‒ Tighten hex head cap screw until the lock washer is compressed. ‒‒ If necessary, pull the starter cord to prevent the crankshaft from rotating while tightening. Note the order of the assembled hardware.
17. Secure the master link, using the retaining clip; snapping it into place. Note the order of the assembled hardware.
18. Tension the chain. ‒‒ Slide the engine forward until chain is taut.
‒‒ Be sure to align the clutch sprocket with the drive shaft sprocket vertically.
20. Test the rear wheel drive by spinning the drive shaft. ‒‒ Be sure the shaft can spin freely with the chain. 21. For instructions on how to install the throttle control cable ‒‒ 2.5 HP MODEL continue to step 22. ‒‒ 4.0 HP MODEL continue to step 26.
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10 Putting the go‑kart together
150718 PLYFLY rev A_GoKart |Augus7 t2,0155:08PM
14. Slide the chain, over both sprockets.
19. Secure the engine in place using the bolts located on part 50.
22. Secure the green cable loosely in the throttle control linkage.
26. Secure the green cable loosely in the clamp. Note the location of the green cable.
Note the location of the green cable.
23. Feed the throttle control cable through the hole located on the throttle control linkage and then into the green cable. Note the location of the green cable.
27. Feed the throttle control cable through the hole located on the throttle linkage. Note the locations of the throttle control cable.
1
1 2
24. For the next installation instruction, continue to step 32. 25. Thread the green cable into the right side of the engine. Note the location of the green cable.
2 28. Install the extension spring, by hooking one end to the hole located on the throttle linkage.
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Note the location of the extension spring.
PlyFly Go‑Kart Instruction Guide • 2015 Release
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29. Using pliers, hook the other end of the extension spring to the throttle return clip. Note the location of the extension spring.
32. Continue to feed the throttle control cable all the way through to 5 . Note the location of the throttle control cable.
5
33. Secure the throttle control cable using the throttle cable clamp at the bottom of 5 .
‒‒ Be sure the control cable is taut, before tightening the throttle clamp.
30. Secure the throttle return clip to the engine using a screw. ‒‒ Use 1 M6 screw.
34. Secure the green cable fully at the start location of the throttle linkage. 35. Test the gas pedal to ensure proper movement of throttle. 36. Place part 57 over part 56.
‒‒ Total 1 location
Note the location part 57.
Note the location of the throttle return clip.
57
!
1 56
31. Slightly loosen this nut so that the throttle can move freely when the gas pedal is pressed. Note the location of the nut.
37. Secure part 57 to part 56, using sheet metal screws. ‒‒ Use 4 sheet metal screws. ‒‒ Total of 4 locations. 38. Place part 58. Note the location part 58.
!
58
39. Secure part 58 to part 57, using sheet metal screws. ‒‒ Use 4 sheet metal screws. ‒‒ Total of 4 locations. 56
10 Putting the go‑kart together
150718 PLYFLY rev A_GoKart |Augus7 t2,0155:08PM
57
Part 8 Install the wheel assemblies
Chapter 10
8
INSTRUCTIONS
1. Mount the undriven wheels (the wheels with bearings) by sliding them over the axles.
PART
‒‒ SINGLE WHEEL KIT continue to step 2. ‒‒ LIVE AXLE KIT continue to step 4. 2. Mount 3 undriven wheels.
Recommended tools DESCRIPTION
‒‒ 2 located on the front axles.
REFERENCE
‒‒ 1 located on the back, left axle. ‒‒ Total of 3 locations.
Socket Wrench
3.
SINGLE WHEEL KIT
continue to step 5.
4. Mount 2 undriven wheels. ‒‒ 2 located on the front axles.
Wrench
‒‒ Total of 2 locations. 5. Secure the undriven wheels using lock nuts. Hint To keep the wheels from rotating, place a large slotted screwdriver into the heads of the front axle bolts.
Required hardware №
DESCRIPTION
Flat Washer 5/16” ID, 7/8” OD 3 2
SINGLE WHEEL KIT PN 12516
2
Shaft Collar 5/8” ID
LIVE AXLE KIT PN 12516
PN 12540
2
Lock Nut 5/8"-11 PN 12506
‒‒ SINGLE WHEEL KIT continue to step 7. ‒‒ LIVE AXLE KIT continue to step 9. 7. Install 1 shaft collar. ‒‒ 1 on the back, right drive shaft. 8.
SINGLE WHEEL KIT
continue to step 10.
9. Install 2 shaft collars. ‒‒ 2 located on the rear drive shaft. ‒‒ Total of 2 locations. 10. Secure the shaft collar using an Allen wrench. 11. Mount the driven wheel (the wheels with the fixed hub) by sliding them over the drive shaft.
1
Rear driven wheel 10”D SINGLE WHEEL KIT PN 12590
3
Undriven wheel 10” D SINGLE WHEEL KIT PN 12591
12. Mount 1 driven wheel.
Rear driven wheel 10”D LIVE AXLE KIT PN 12590
13. SINGLE WHEEL KIT continue to step 15.
2
2
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6. Slide the shaft collar over drive shaft. REFERENCE
Undriven wheel 10” D LIVE AXLE KIT PN 12591
1
Rear driven wheel 12” D SINGLE WHEEL KIT PN 12592
3
Undriven wheel 12” D SINGLE WHEEL KIT PN 12593
1
Key 3/16” square, 1”L
‒‒ Use the key to lock the driven wheel to the drive shaft. ‒‒ SINGLE WHEEL KIT continue to step 12. ‒‒ LIVE AXLE KIT continue to step 14. ‒‒ 1 located on the back, right drive shaft. ‒‒ Total of 1 location. 14. Mount 2 driven wheels. ‒‒ Use the key to lock the driven wheel to the drive shaft. ‒‒ 2 located on the rear drive shaft. ‒‒ Total of 2 locations. 15. Secure the driven wheel to the drive shaft using the set screws. ‒‒ Be sure the set screw aligns with the keyway. 16. Secure the axle to the driven wheel using the shaft collar. ‒‒ Use a socket wrench to tighten the locknut; while holding the locknut on alternate side with wrench.
PN 12539
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57
Part 9 Install the seat assembly
Chapter 10
9
INSTRUCTIONS
1. Place the Fillister head screws into the parts 41 & 42 located on 9 .
PART
Note the location of the Fillister head screws.
41
Recommended tools DESCRIPTION
REFERENCE
42
Dead blow Hammer or mallet
Required hardware №
DESCRIPTION
2
REFERENCE
Fillister Head Screw 5/16”-18, 3/4” L
3. Position 4 at the forward most position.
‒‒ Align the side slots located on 4 to the screw heads located on parts 41 & 42.
PN 12553
1
4. Slide 4 backwards into position so that the pins slide all the way through slots.
T-Handle Quick Release Pin
5. To secure 4 in place, insert the T-handle, pin side, through part 41 located on the right side of the go‑kart.
PN 12542
1
2. Secure the Fillister head screws to be flush with the wooden surface of part 41.
6. Insert the flag through holes located on the back right side of Seat Assembly and the go‑kart frame.
Flag Plyfly flag
Note the location of the flag holes.
PN 12535
Required assemblies DESCRIPTION
REFERENCE
4 Seat Assembly PARTS 22‑33
Frame Assembly PARTS 21‑28
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10 Putting the go‑kart together
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9
Part 10 Install the fairings
Chapter 10
10
INSTRUCTIONS
1. Place the front tab of part 53 into the slot located on part 40.
STEP
Note the location of the tab on part 40.
Recommended tools DESCRIPTION
40
REFERENCE
Dead blow Hammer or mallet
53
2. Using the mallet, tap part 53 into the recess. 3. Secure part 53 to the assembly using screws. ‒‒ Use 7 screws. ‒‒ Total of 7 locations.
Electric Driver
4. Repeat steps 1 through 3 on the opposite side using part 54. 5. Thread the green elastic cord, from the top through left hole located in part 16 of 2 .
Required hardware №
Note the part 16
DESCRIPTION
REFERENCE
16
20 Spax Screw 1 #8, 1-1/2” L PN 12519
1
6. Tie an overhand knot on the bottom side. 7. Thread the green elastic cord, from the top through right side hole located in part 16 of 2 .
Green Elastic Cord 3/16” OD, 18” L PN 12517
Note the location of part 16.
2
16
Required wooden parts DESCRIPTION
REFERENCE
Part 53 Fairing Left PLYWOOD SHEET 4
Part 54 Fairing Right
8. Pull green elastic cord tight and tie overhand knot on the underside. 9. Align part 55 to the front of 2 . Note the location of the orientation of part 55.
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PLYWOOD SHEET 4 2
Part 55 Fairing Front
55
PLYWOOD SHEET 4
Note If you received a 1/4” plywood sheet that is finished on one side and intend to paint the fairings; reverse wooden parts 53‑55 (so the unfinished side is facing outward and ready to receive paint). For more information on Visual reference of the plywood sheets, see page 61.
10. Screw part 55 to the assembly using 6 screws. ‒‒ Use 6 screws. ‒‒ Total of 6 locations FINISHED!! TIME TO RIDE!! PlyFly Go‑Kart Instruction Guide • 2015 Release
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11
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60
Master List
Visual reference of the plywood sheets
Visual reference of the plywood sheets
Sheet 1 3/4” Plywood Sheet
Sheet 3 3/4” Plywood Sheet
DESCRIPTION
REFERENCE
41
40
43
42
38
DESCRIPTION
49
3
REFERENCE
22 50
39
35
36
13 9
37
4
‒‒Parts 1, 3-4 ‒‒Parts 6-10 ‒‒Part 13
34
7
8
‒‒Parts 20 ‒‒Parts 24 ‒‒Parts 34
1 10
6 20 24
‒‒Parts 36-43 ‒‒Parts 49
Sheet 2 3/4” Plywood Sheet
12
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16
21 5
‒‒Parts 2, 5 ‒‒Parts 11-12 ‒‒Parts 14-18
23
26
‒‒Parts 22-23 ‒‒Parts 25-27
27
25 47
‒‒Parts 35 ‒‒Part 47
‒‒Parts 50
Sheet 4 1/4” Plywood Sheet
11
48
14
46
15
45 18
52 19
‒‒Parts 20-21 ‒‒Parts 44-46 ‒‒Parts 48
2
31
44
17
‒‒Parts 52
29
‒‒Parts 28-33 ‒‒Parts 51
28
30
‒‒Parts 53-55
Note If you received a 1/4” plywood sheet that is finished on one side and you intend to paint the Plyfly go‑kart seat or fairings; reverse wooden parts 28‑33 and parts 53‑55 (so the unfinished side is outward facing and ready to receive paint). For a complete list of wooden parts, go to “List of the wooden parts” on page 62.
PlyFly Go‑Kart Instruction Guide • 2015 Release
61
List of the wooden parts DESCRIPTION
Part 1 Steering Spindle Outer Spacer PLYWOOD SHEET 1
Part 2 Steering Spindle Outer Spacer PLYWOOD SHEET 2
Part 3 Steering Spindle Inner Spacer
reference image
List of the wooden parts DESCRIPTION
reference image
Part 9 Steering rack Bracket PLYWOOD SHEET 1
Part 10 Steering rack Bracket PLYWOOD SHEET 1
Part 11 Steering rack PLYWOOD SHEET 2
PLYWOOD SHEET 1
Part 4 Steering Spindle Inner Spacer PLYWOOD SHEET 1
Part 5 Steering Spindle Bottom Left PLYWOOD SHEET 2
Part 6 Steering Spindle Bottom Right PLYWOOD SHEET 1
Part 7 Steering Spindle Top PLYWOOD SHEET 1
PLYWOOD SHEET 1
62
11 Master List
PLYWOOD SHEET 2
Part 13 Steering column Left PLYWOOD SHEET 1
Part 14 Steering column Right PLYWOOD SHEET 2
Part 15 Steering column Top PLYWOOD SHEET 2
Part 16 Steering column Phone Mount PLYWOOD SHEET 2
150718 PLYFLY rev A_EM |August7,20155:06PM
Part 8 Steering Spindle Top
Part 12 Steering rack Center Bracket
List of the wooden parts DESCRIPTION
List of the wooden parts DESCRIPTION
Part 17 Steering column Bracket
Part 25 Seat Crossbar
PLYWOOD SHEET 2
PLYWOOD SHEET 3
Part 18 Steering Pinion Mount
Part 26 Seat Crossbar
PLYWOOD SHEET 2
PLYWOOD SHEET 3
Part 19 Steering column Shaft
Part 27 Seat Crossbar Bracket
PLYWOOD SHEET 2
PLYWOOD SHEET 3
Part 20 Steering Pinion
Part 28 Seat Bolster Left
PLYWOOD SHEET 1
PLYWOOD SHEET 4
Part 21 Steering Wheel
Part 29 Seat Bolster Right
PLYWOOD SHEET 2
PLYWOOD SHEET 4
Part 22 Seat Side Left
Part 30 Seat Thigh Bolster Left
PLYWOOD SHEET 3
PLYWOOD SHEET 4
Part 23 Seat Side Right ‒‒gas tank side
Part 31 Seat Thigh Bolster Right
PLYWOOD SHEET 3 150718 PLYFLY rev A_EM |August7,20155:06PM
reference image
reference image
PLYWOOD SHEET 4
Part 24 Seat Crossbar
Part 32 Seat Back
PLYWOOD SHEET 1
PLYWOOD SHEET 4
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63
List of the wooden parts DESCRIPTION
Part 33 Seat Bottom
reference image
List of the wooden parts DESCRIPTION
reference image
Part 41 Frame Rail Inner Right PLYWOOD SHEET 1
PLYWOOD SHEET 4
Part 34 Brake Pedal
Part 42 Frame Rail Outer Left PLYWOOD SHEET 1
PLYWOOD SHEET 1
Part 35 Gas Pedal
Part 43 Frame Rail Outer Right PLYWOOD SHEET 1
PLYWOOD SHEET 3
Part 36 Pedal Side
Part 44 Frontend Bottom
PLYWOOD SHEET 1
PLYWOOD SHEET 2
Part 37 Pedal Side
Part 45 Frontend Top
PLYWOOD SHEET 1
PLYWOOD SHEET 2
Part 38 Pedal Side
Part 46 Frame Rail Bracket
PLYWOOD SHEET 1
PLYWOOD SHEET 2
Part 39 Pedal Side
Part 47 Sprocket Guard
PLYWOOD SHEET 1
PLYWOOD SHEET 3
PLYWOOD SHEET 1
Part 48 Frame Rail Rear PLYWOOD SHEET 2
64
11 Master List
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Part 40 Frame Rail Inner Left
List of the wooden parts DESCRIPTION
reference image
Part 49 Frame Rail Engine Mount PLYWOOD SHEET 1
Part 50 Engine Mounting Plate PLYWOOD SHEET 3
Part 51 Floor Panel PLYWOOD SHEET 4
Part 52 Frame Gusset PLYWOOD SHEET 2
Part 53 Fairing Left PLYWOOD SHEET 4
Part 54 Fairing Right PLYWOOD SHEET 4
Part 55 Fairing Front
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PLYWOOD SHEET 4
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List of the wooden assemblies DESCRIPTION
REFERENCE
List of the wooden assemblies DESCRIPTION
1
REFERENCE
6
Steering rack Assembly Parts 9-12
Brake Pedal Assembly Parts 35, 38-39
2
7
Fixed steering column Assembly Parts 13-18
Left Spindle Assembly Parts 1, 3, 5, 7
3
8
Steering column Assembly Parts 19-21
Right Spindle Assembly Parts 2, 4, 6, 8
4
9
Seat Assembly Parts 22-33
Frame Assembly Parts 21-28
5 Gas Pedal Assembly Parts 34, 36-37
66
11 Master List
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Note If you received a 1/4” plywood sheet that is finished on one side and you intend to paint the Plyfly go‑kart seat or fairings; reverse wooden parts 28‑33 and parts 53‑55 (so the unfinished side is outward facing and ready to receive paint). For a complete list of wooden parts, go to “List of the wooden parts” on page 62.
List of the tools needed DESCRIPTION
REFERENCE IMAGE
List of the tools needed DESCRIPTION
Chisel
Screwdriver
Hammer
Allen Wrench or ratcheting allen wrench
Dead blow Hammer or mallet
Metric Allen Wrench included with mounted bearing
Sandpaper
Socket Wrench
Orbital Sander (optional)
Wrench
Jigsaw or Reciprocating Saw (optional)
REFERENCE IMAGE
Needle Nose Pliers
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Electric Driver
Impact Driver (optional)
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List of loose contents
4.0 HP
4.0 HP
4.0 HP
4.0 HP
SINGLE WHEEL
SINGLE WHEEL 12” WHEELS
LIVE AXLE
10” WHEELS
LIVE AXLE
12” WHEELS
2.5 HP MODEL
1
―
―
―
―
Clutch #35 Chain, 12 Tooth Pulley for 3/4” D
―
1
1
1
1
#35 Chain, 60 Tooth, 5/8” D bore
1
1
1
1
1
Roller Chain #35 Chain, 29-5/8” L
1
1
1
1
1
12534 Master Chain Link
#35 Roller Chain connector
1
1
1
1
1
Part 56 Clutch Guard Side Engine Mounting Plate
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1/16” D, throttle & brake control cable
2
2
2
2
2
Red Throttle Cable Brake conduit, 5’ L
1
1
1
1
1
Gas conduit, 6’ L
1
1
1
1
1
12521
VXB Mounted Bearing 5/8” ID
3
3
3
3
3
12531
Brake Caliper
1
1
1
1
1
12532 Brake Disc
1
1
1
1
1
12533 Brake Disc Hub
1
1
1
1
1
1
1
1
―
―
4
4
4
4
4
№
KIT DESCRIPTION
12576
Clutch #35 Chain, 11 Tooth Pulley for 5/8” D
12577
4.0 HP MODEL
12522 Sprocket
12524
12005
Part 57
12006 Clutch Guard Top
Top Cover Part 58
12007 Clutch Guard Cover
Outside Cover
12525 Control Cable
12527
12528 Green Throttle Cable
12502 Long Hex Bolt
Grade 5, 5/8”-11, 11” L SINGLE WHEEL KIT
12503 Short Hex Bolt
Grade 5, 5/8”-11, 6.5” L
68
11 Master List
10” WHEELS
10” WHEELS
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2.5 HP SINGLE WHEEL
List of loose contents
2.5 HP
4.0 HP
4.0 HP
4.0 HP
4.0 HP
SINGLE WHEEL
SINGLE WHEEL
SINGLE WHEEL 12” WHEELS
LIVE AXLE
10” WHEELS
LIVE AXLE
12” WHEELS
1
1
1
1
1
SINGLE WHEEL KIT
1
1
1
―
―
Drive Shaft Steel, Keyed, 5/8” D, 33” L
―
―
―
1
―
―
―
―
―
1
Hardware included, 10” L
1
1
1
1
1
12517
Green Elastic Cord 3/16” OD, 18” L
1
1
1
1
1
12519
Spax Screw 1 Box, #8, 1-1/2” L
1
1
1
1
1
Rear driven wheel
1
1
―
2
―
10” D Wheels Undriven wheel
3
3
―
2
―
―
―
1
―
2
―
―
3
―
2
1
1
1
1
1
№
KIT DESCRIPTION
12507
Precision Rod 1/4” D, 18” L
12580 Drive Shaft
Steel, Keyed, 5/8” D, 18” L
12581
LIVE AXLE KIT – 10” WHEELS
12582 Drive Shaft
Steel, Keyed, 5/8” D, 36” L LIVE AXLE KIT – 12” WHEELS
12508 Drawer Slide
12590 10” D Wheels
12591
12592 12” D Wheels
Rear driven wheel
12593 12” D Wheels
Undriven wheel
12535 Flatworks Flag
10” WHEELS
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Plyfly safety flag
10” WHEELS
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List of the packaged contents
2.5 HP
4.0 HP
4.0 HP
4.0 HP
4.0 HP
SINGLE WHEEL
SINGLE WHEEL
SINGLE WHEEL 12” WHEELS
LIVE AXLE
10” WHEELS
LIVE AXLE
12” WHEELS
11
11
11
10
10
12505 Flat Washer
4
4
4
4
4
12506 Lock Nut
5
5
5
4
4
12509 Plastic Bushing
4
4
4
4
4
12
12
12
12
12
№
KIT DESCRIPTION
12504 Large Metal Bushing
Flanged, 3/4” OD, 5/8” ID
5/8” ID, 1‑3/8” OD
5/8” ID
Flanged, 1/4” ID, 3/8” OD
10” WHEELS
Small Tee Nut Zinc Plated, 5/16”-18
12513
Short Shoulder Screw 5/16”-18, 3/8” D, 1.00” L,
1
1
1
1
1
12514
Long Shoulder Screw 5/16”-18, 3/8” D, 2.25” L
1
1
1
1
1
12515
Button Socket Head Cap Screw Zinc Plated, Steel, M8, 12mm L
5
5
5
5
5
12516
Flat Washer 5/16” ID, 7/8” OD
15
15
15
15
15
4
4
4
4
4
1
1
1
1
1
12538 Small Metal Bushing
4
4
4
4
4
12539 Key
3
3
3
4
4
12540 Shaft Collar
1
1
1
2
4
12542 T-Handle Pin
1
1
1
1
1
8
8
8
8
8
12544 Socket Head Cap Screw
6
6
6
6
6
12545 Large Tee Nut
6
6
6
6
6
Grade 5, 5/16”-24
12537 Throttle Cable Clamp
Flanged 3/8” ID, 1/4” L
3/16” square, 1”L
5/8” ID
Quick Release Pin
12543 Hex head cap screw
5/16”-18, 1.25 L 4.0 HP MODEL
Black Oxide Alloy Steel, 3/8”-16, 1.25 L
Zinc Plated, 3/8”-16
11 Master List
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12510
12520 Thin Nut
70
10” WHEELS
List of the packaged contents
2.5 HP
4.0 HP
4.0 HP
4.0 HP
4.0 HP
SINGLE WHEEL
SINGLE WHEEL
SINGLE WHEEL 12” WHEELS
LIVE AXLE
10” WHEELS
LIVE AXLE
12” WHEELS
3/4” OD, 3/8” ID, 1‑1/4” L
1
1
1
1
1
Short Aluminum Spacer 1/2” OD, 1/4” ID, 7/8” L
1
1
1
1
1
12548 Long Aluminum Spacer
1
1
1
1
1
12549 Oversized Flat Washer
2
2
2
2
2
12550 Socket Head Cap Screw
Black oxide, M6, 55mm L
2
2
2
2
2
Sheetmetal Screw Galvanized, #6
8
8
8
8
8
12553 Fillister Head Screw
2
2
2
2
2
12558 Zip Tie
6
6
6
6
6
12559 Button Socket Head Cap Screw
4
4
4
4
4
12560 Extension Spring
1
1
1
1
1
1
―
―
―
―
12555 Fender washer
1
1
1
1
1
12556 Lock washer
1
1
1
1
1
12557 Clutch Key
1
1
1
1
1
―
1
1
1
1
―
1
1
1
1
Clutch
2
2
2
2
2
Pan head M6, 12 mm L
―
1
1
1
1
№
KIT DESCRIPTION
12546 Nylon Spacer
12547
1/2” OD, 1/4” ID, 1‑1/16” L
Zinc, M6
12551
5/16”-18, 3/4” L
10lb Nylon, White, 7/8” D, 4” L
Zinc Plated, Steel, 5/16”-24, 1/2” L
Black-Oxide, Precision
12554 Hex Cap Screw
1/4”-20, 1” L
2.5 HP MODEL
5/16” ID, 1-1/8” OD
5/16” ID
3/16”, 1/2” L
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12561 Throttle Return Clip 4.0 HP MODEL
12562 Button Head Cap Screw
5/16”-24, 3/4” L
12563 Set Screw
12564
4.0 HP MODEL
10” WHEELS
10” WHEELS
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Legal
Legal
Assumption of Risk, Waiver and Release of Liabilities and Indemnity Agreement I, the undersigned, on behalf of myself, (and, if applicable, my minor child or ward listed below), as well as my spouse, heirs, estate, insurers and assigns (all collectively hereinafter referred to as “I” or “me” or “my”, as the case may be), in consideration of being permitted to use and operate (whether via a test drive prior to purchase or otherwise) the go kart equipment of The Flatworks, LLC, a Rhode Island Limited Liability Company (hereinafter “Flatworks”), at its premises and facilities located at 11 Waites Wharf, Newport, Rhode Island or at any other locale, and for other good and valuable consideration, do hereby covenant and agree as follows: 1. I fully understand and acknowledge that I, like all potential customers of Flatworks and others desiring to test drive or otherwise use and operate its go-kart equipment, as a condition of such use and operation, must first: a) read, understand, and agree to this Assumption of Risk, Waiver and Release of Liabilities and Indemnity Agreement (the “Agreement”); and b) read, understand, adhere to, and abide by the safety rules and instructions of Flatworks related to the use and operation of its go-kart equipment. 2. I fully understand and acknowledge that: a) using and operating a motorized go-kart is an inherently dangerous activity and that participation in this activity involves risks of damage to or loss of my property or the property of others and risks of bodily injury to me or others, including injuries such as bruises, lacerations, sprains, fractures and, in extreme cases, disability, paralysis and death; b) such dangers and risks may be caused, in whole or in part, by my own actions or inactions, the actions or inactions of others, the condition of the go-kart equipment and the condition and the layout of the facilities on which they are used, and/or the negligence of others, including the Protected and Released Parties (as defined below); and c) there may be other dangers and risks associated with this activity which at this time are unknown or that are not readily foreseeable by me or others.
150718 PLYFLY rev A_Legal August | 5,201510:38PM
3. I fully understand and acknowledge the demands of this inherently dangerous and risky activity relative to my personal knowledge, experience, skills, aptitude and abilities, as well as my current physical and medical condition and level of fitness, and nevertheless knowingly and voluntarily accept and assume such dangers and risks, and further assume full responsibility for any and all liabilities, losses or damages, including any direct or consequential damages, resulting from or related to my participation in this activity, including, but not limited to: any and all damage to or loss of my property or the property of others; personal injuries to me or others of any type, including disability and death; and any legal fees, costs or other expenses related to such damages and/or injuries, expressly including, but not limited to, those alleged to be caused, in whole or in part, by the negligence of the Protected and Released Parties (as defined below).
and/or injuries, expressly including, but not limited to, those alleged to be caused, in whole or in part, by the negligence of the Protected and Released Parties, I, for myself and for anyone acting on my behalf, further agree to hold harmless, defend, and indemnify the Protected and Released Parties from any such claims, suits, actions, liabilities, losses, damages, fees, costs or expenses. 6. In the event of a medical emergency, I hereby authorize Flatworks and any other Protected and Released Parties to, if deemed necessary in their discretion, to administer emergency first aid, CPR, and use an AED, and to secure emergency medical care or transportation (i.e., EMS). I agree to assume all costs of such emergency medical care and transportation. 7. I acknowledge that this Agreement constitutes the entire agreement by and among me and the Protected and Released Parties pertaining to the subject matter hereof and supersedes all prior agreements and understandings pertaining thereto, and agree that this Agreement may not be changed, modified or amended in whole or in part except in writing, signed by all of the parties hereto. 8. I agree that this Agreement and the rights of the parties hereunder shall be interpreted in accordance with the laws of the State of Rhode Island, as broadly and inclusively as permitted under such laws, and all rights and remedies shall be governed by such laws without regard to principles of conflict of laws. I further agree that if any portion of this Agreement is held invalid, the balance shall, notwithstanding, continue in full legal force and effect. 9. I agree that if any disputes or controversies shall arise from this Agreement or otherwise in connection with my use and operation of Flatworks’ go-kart equipment, my participation in any related activities, or my presence on the premises and facilities of the Protected and Released Parties, I shall first engage in good faith efforts to mediate such dispute. Should the issue not be resolved by mediation, I further agree that all such disputes or controversies shall be submitted to binding arbitration in accordance with the Commercial Arbitration Rules of the American Arbitration Association then in effect. 10. I hereby acknowledge, by signing below and by writing my initials in the margin of all of the pages, that I have read this Agreement and fully understand all of its terms and conditions. I understand that I am giving up substantial legal rights, including rights that I may otherwise have to sue for damages in the event of my death, or injury or loss occasioned by my use of the go-kart equipment of Flatworks. I acknowledge that I am signing this Agreement freely and voluntarily, and intend by my signature, that this Agreement constitute a complete and unconditional waiver, release, and discharge of the Protected and Released Parties from any and all manner of claims, suits, actions, liabilities, losses, damages, fees, costs or expenses arising from or related to the inherent risks of this activity, to the greatest extent allowed by laws of the State of Rhode Island.
4. I hereby agree to waive, release, discharge and covenant not to sue Flatworks or any other person or entity associated or affiliated with these entities, including, but not limited to, their owners, shareholders, directors, officers, members, partners, employees, volunteers, agents, subsidiaries, related and affiliated entities, and successors and assigns (all hereinafter referred to as the “Protected and Released Parties”) from liability for any and all claims, suits, demands, liabilities, losses or damages arising from or relating to my use and operation of Flatworks’ go-kart equipment, my participation in any related activities, and my presence on the premises and facilities of the Protected and Released Parties. This waiver, release, discharge and covenant not to sue applies, but is not limited to, any and all liabilities, losses or damages, including any direct or consequential damages, resulting from or related to my participation in this activity, including, but not limited to: any and all damage to or loss of my property or the property of others; personal injuries to me or others of any type, including disability and death; and any legal fees, costs or other expenses related to such damages and/or injuries, expressly including, but not limited to, those alleged to be caused, in whole or in part, by the negligence of the Protected and Released Parties. 5. If, despite my aforesaid express assumption of risk, and my aforesaid express waiver, release, discharge and covenant not to sue, I, or anyone acting on my behalf, brings a claim or suit, or takes any other action, against any of the Protected and Released Parties for any and all liabilities, losses or damages, including any direct or consequential damages, resulting from or related to my participation in this activity, including, but not limited to: any and all damage to or loss of my property or the property of others; personal injuries to me or others of any type, including disability and death; and any legal fees, costs or other expenses related to such damages
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Terms & Conditions
THE FLATWORKS, LLC Terms & Conditions of Purchase and Use
THE FOLLOWING TERMS AND CONDITIONS APPLY TO ALL PRODUCTS DESIGNED, MANUFACTURED AND SOLD BY THE FLATWORKS, LLC. THESE TERMS AND CONDITIONS INCLUDE PROVISION WHICH ALLOCATE THE RISKS ASSOCIATED WITH THE USE OF THE PRODUCTS AND LIMIT MY LEGAL RIGHTS TO RECOVER DAMAGES IN THE EVENT OF INJURY OR LOSS OCCASIONED BY SUCH USE, INCLUDING DISCLAIMERS, EXCULPATORY PROVISIONS (ASSUMPTIONS OF RISK AND RELEASES), WAIVERS, INDEMNIFICATION PROVISIONS, LIMITATIONS OF LIABILITY, LIMITED WARRANTIES, A COVENANT NOT TO SUE, AN ABBREVIATED LIMITATIONS PERIOD FOR CLAIMS, AND AN ARBITRATION PROVISION.
5. Indemnification. In the event that User, or anyone acting on his or her behalf, brings a claim or suit, or takes any other action, against any Flatworks for any liabilities, losses or damages, including any direct or consequential damages, resulting from or related to his or her use of the Products, including, but not limited to: any and all damage to or loss of my property or the property of others; personal injuries to User or others of any type, including disability and death; and any legal fees, costs or other expenses related to such damages and/or injuries, expressly including, but not limited to, those alleged to be caused, in whole or in part, by equipment malfunction from whatever cause, or any other negligence or fault of Flatworks, User, for himself or herself, and for anyone acting on his or her behalf, further agree to hold harmless, defend, and indemnify Flatworks from any such claims, suits, actions, liabilities, losses, damages, fees, costs or expenses.
1. Definitions. As used herein, the following terms shall have the following meanings: a) “Flatworks”, shall mean The Flatworks, LLC, a Rhode Island Limited Liability Company and any and all of its affiliates, subsidiaries, associates, owners, members, officers, agents, employees, and volunteers, and its successors and assigns.
6. Limited Replacement Warranty. Flatworks warrants to any Original Purchaser that the Products shall to be free from defects in materials and workmanship for a period of one-hundred eighty (180) days from the date of purchase, provided that they have not been subject to apparent accident, alteration, abuse, neglect or misuse. Flatwork’s sole liability under this warranty is limited to the repair or replacement of Products that are returned within this warranty period.
b) “Original Purchaser” shall mean the person to whom the Product was originally sold as evidenced by the sales invoice from Flatworks. c) “Products” shall mean all products and related accessories designed, manufactured and sold by Flatworks. d) “User” shall mean the purchaser and/or the end user of any Product. 2. Acknowledgement of High Risk Activity. Products sold by Flatworks include motorized go-karts and related accessories. User hereby acknowledges that: a) using and operating a motorized go-kart is an inherently dangerous activity and that participation in this activity involves risks of damage to or loss of my property or the property of others and risks of bodily injury to himself, herself, or others, including injuries such as bruises, lacerations, sprains, fractures and, in extreme cases, disability, paralysis and death; b) such dangers and risks may be caused, in whole or in part, by User’s own actions or inactions, the actions or inactions of others, the condition of the go-kart equipment and the condition and the layout of the facilities on which they are used, and/or the negligence of others; and c) there may be other dangers and risks associated with this activity which at this time are unknown or that are not readily foreseeable by User or others.
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3. Assumption of Risk. User fully understands and acknowledges the dangers and risks involved with the use of the Products relative to his or her personal knowledge, experience, skills, aptitude and abilities, as well as his or her physical and medical condition and level of fitness, and nevertheless knowingly and voluntarily accepts and assumes such dangers and risks, and further assumes full responsibility for any and all liabilities, losses or damages, including any direct or consequential damages, resulting from or related to his or her use of the Products, including, but not limited to: any and all damage to or loss of his or her property or the property of others; personal injuries to User or others of any type, including disability and death; and any legal fees, costs or other expenses related to such damages and/or injuries, expressly including, but not limited to, those alleged to be caused, in whole or in part, by equipment malfunction from whatever cause, or any other negligence or fault of Flatworks. 4. Release and Waiver of Liability, Covenant Not to Sue. Other than the liability assumed under the limited warranty set forth herein below, which liability is confined to the repair or replacement of its Products under limited circumstances, User hereby waives, releases, discharges and covenants not to sue Flatworks from liability for any and all claims, suits, demands, liabilities, losses or damages arising from or relating to his or her use of the Products. This waiver, release, discharge and covenant not to sue applies, but is not limited to, any and all liabilities, losses or damages, including any direct or consequential damages, resulting from or related to the use of the Products, including, but not limited to: any and all damage to or loss of his or her property or the property of others; personal injuries to the User or others of any type, including disability and death; and any legal fees, costs or other expenses related to such damages and/or injuries, expressly including, but not limited to, those alleged to be caused, in whole or in part, by equipment malfunction from whatever cause, or any other negligence or fault of Flatworks.
THE ABOVE STATED LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. FLATWORKS NEITHER ASSUMES OR AUTHORIZES ANY OTHER PERSON OR ENTITY TO ASSUME FOR IT, ANY OTHER LIABILITY IN CONNECTION WITH THE DESIGN, MANUFACTURE OR SALE OF ITS PRODUCTS, WHETHER FROM ITS WEBSITES, CATALOGS OR OTHERWISE. THE LIMITED WARRANTY SHALL NOT APPLY TO ANY PRODUCT WHICH HAS BEEN SUBJECT TO ACCIDENT, NEGLECT, ALTERATION, ABUSE OR MISUSE. 7. General Disclaimers. All Original Purchasers, as a condition of purchase, agree to be bound by the following terms and conditions: a) Inspection Prior to Use. All Products must be inspected upon delivery for use to ensure that they have not been damaged in shipment or otherwise. If any Product is damaged, such Product should not be used and should be promptly returned to Flatworks for inspection, replacement or repair, as the case may be. b) Use of Products. Prior to the use and operation of any Product, the Original Purchaser must read, understand, adhere to, and abide by any instructions, manuals, directions and safety rules related to the Product, including, without limitation, those related to the assembly, use, operation, and maintenance of the Product. Flatworks shall have no responsibility whatsoever for the misuse or unauthorized and improper use of its Products. c) Duty to Inform Others and Indemnification. Prior to allowing others to use any Product, the Original Purchaser must require that such person (or his or her legal guardian, if a minor) reads, understands and agrees to adhere to and abide by these Terms and Conditions and any instructions, manuals, directions and safety rules related to the Product. The Original Purchaser further agrees, for himself or herself, and for anyone acting on his or her behalf, to hold harmless, defend, and indemnify Flatworks from any claims, suits, actions, liabilities, losses, damages, fees, costs or expenses arising out of such person’s use of any Product. 8. Applicable Law. These Terms and Conditions and the rights of all affected parties hereunder shall be interpreted in accordance with the laws of the State of Rhode Island, as broadly and inclusively as permitted under such laws, and all rights and remedies shall be governed by such laws without regard to principles of conflict of laws. If any portion of these Terms and Conditions shall be held invalid, the balance shall, notwithstanding, continue in full legal force and effect. 9. Resolution of Disputes. Any dispute, claim or controversy arising out of or in connection with the purchase or use of the Products shall be resolved by means of binding arbitration held within the State of Rhode Island in accordance with the Commercial Arbitration Rules of the American Arbitration Association then in effect. Any demand for arbitration must be commenced within one (1) year after the dispute, claim or controversy arises.
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