Wasp R500 Commercial kart Inspection & Maintena...

Wasp R500 Commercial kart Inspection & Maintenance Manual




The following guide takes you step by step through basic maintenance of your  'R500 Commercial' Rally Kart.

For further technical advice please do not hesitate to contact us directly.



Go to - R500 Rally Kart Spares

Introduction -

The GoKart will need careful attention in it's early hours as it runs in. Please note that as well as other components the brakes will not operate at it's fullest potential as the pads bed in to the disc. Do not push the gokart in this period, but allow it to settle in slowly. To maintain good, long lasting safe performance all parts should be regularly checked & inspected using the checklist below, before the gokart is put into action. It is recommended that the completed kart is checked by a qualified engineer before it's first use.


Choosing the correct speed -

TAC Transmission - For beginners requiring low speed , using a posi-screw driver wind in the throttle screw on the engine.

Safety checklist -

Firstly, work in a clean, safe environment when doing any maintenance work on your gokart. It is good practice to produce a check list (or log) of maintenance to prevent any part or area of the gokart being neglected. Some areas will require more frequent attention than other. This does alter with the many varied conditions, type of usage & duration of usage. Your log & maintenance should be customised to your situation without neglecting any part. The gokart should be inspected before every time it is used by a suitably trained or experienced person. Any maintenance on or refuelling of the gokart must only be carried out with the engine cold & turned off, without a driver in the gokart.

Fixings -

Check & tighten all kart fixings (nuts, bolts, pins etc.) with particular attention to steering components & joints. Brake components fixings & clevis pins, front & rear wheel hub nuts. Security  of axle, hubs & carriers. (Use the correct fixings & never re-use locnuts).

Brakes -

Check for effective operation, good overall condition & correctly adjusted. (See brake maintenance sheet supplied with brake for replacement of pads, pistons etc.) The most efficient method is to remove the whole brake calliper from the frame & carry out work on a bench.

Cables -

Check all cables run freely, with excess play taken out either by using the adjusters or by moving the cable nipples. Check the return springs are working effectively & are free from obstruction. (Lubricate if necessary). Replace frayed or damaged cables where necessary.

Steering -

Check for effective & free operation. Investigate any heavy steering (clean & lubricate the moving parts or if damaged or worn replace). Check the security of all the parts in the steering train. Thoroughly inspect all parts in the train from steering wheel to ground wheel, for bent, worn, fatigued or damaged parts & replace where necessary.

Harness & wrist retainers -

Check security to the chassis frame & correct operation. Any excess webbing should be prevented from hanging loose when a driver is secured in the seat. If the webbing is cut, frayed or damaged in anyway, DO NOT USE. Replace.

Wheels & tyres -

Replace bent or damaged rims, damaged valves, missing hub caps, cut or worn tyres. Check security of fixings & that all tyre pressures are equal. Wheel & axle bearings rotate freely without play. (With none keyed, single bolt fix wheels, check mounting bolt for evidence of any play. Replace loose or worn fixings.) Check the circlips at the end of the axle & that they are both in place.

Engine -

Start by reading the manual supplied with the engine. Increasing the oil & air filter maintenance especially in dusty environments is recommended. Use only the fuel & oil grades recommended. Do not mix fuels or introduce additives unless specified by the engine manufacturer.

Fuel -

When the kart is not in use turn off the fuel & store the kart in a dry, well ventilated, secure area. For long term storage the fuel may be drained, or the engine run with the tap turned off. This prevents stale fuel causing sludge in the carburettor. If in doubt contact the engine manufacturer. Take the greatest of care when refuelling so as not to spill fuel.
NEVER re-fuel an engine that is hot or running. The engine should be turned off & allowed to cool before re-fuelling. Re-fuel in a well ventilated area. Take great great to ensure the fuel cap has been correctly & securely replaced. Check the cap & seal are in good order. In the event of the gokart being placed at an adverse angle or in a 'roll over' situation DO NOT restart the engine immediately. If the fuel was not turned off there is a risk of flooding the engine. In essence if there is any risk of flooding, excess fuel or split fuel there is a high risk of fire.

Stop switch -

Check function, connections, cable insulation & security.

Frame & roll-cage -

Check for overall good condition, including stub axles, steering parts, brake rod & pedals. Touch up paint where chipped or scratched. Check for fatigue especially around welded joints & areas of high stress. Do not use the kart if you are unsure, seek expert advice.

Rear axle -

Run the axle by hand with the chain removed, using reference points check there is no eccentric movement (Bent axles should be replaced). Check the axle runs free without binding. When placed back on the ground push & pull the frame from side to side. There should be no floating on the axle. Check grub screws & bearings for wear, cracked or damaged sprocket & disc carriers. The axle should be cleaned & a thin film of grease applied.

Transmission -

It is good practice to remove & insulate the sparking plug cap as well as having the ignition switched off, when working on the transmission. This prevents accidental starting of the engine. Check overall condition & security of the drive chain & guard. (Never run without the guard fitted.) The clutch runs in an extremely harsh environment with dust, dirt, water , constant stop starting, braking & accelerating. It is part of the kart that receives a great deal of punishment. Therefore to maintain it's best performance it must be kept clean & dry. Regular light oiling of the sprocket bush will increase it's life, however, excessive oil will cause clutch slip & the risk of burning on the clutch drum. The chain should be cleaned & then relubricated with a low fling chain spray grease. (This penetrates the rollers & sets.) The chain should be checked for wear & damage in conjunction with the sprockets. (Replace if worn or hooked or bent). The connecting link spring clip should have it's nose following the direction of rotation of the chain.

Chain tensioning-

The chain can be tensioned by moving the engine forward in the frame. N.B. It is very important that the chain is not run drum tight, & that the engine has not twisted left or right. As this will cause abnormal chain & sprocket wear & also damage the clutch. Line up the two sprockets with a flat edge across their surfaces. (A 12" piece of key steel that has been checked flat is a handy tool to use). The rear driven sprocket may be moved if required by loosening it's carrier clamp & re-tightening. If you are unsure about chain tensioning please contact us for expert advice.

General Advice-

For the gokart & associated parts, use only the recommended fixings & as with all components on the gokart if in doubt seek expert advice. Do not use the gokart if it does not pass inspection. Finally, The gokart should be given a trial run to check that everything works safely e.g Helmets, protective clothing etc. should also be inspected. Store your gokart in a secure, dry, well ventilated area with the fuel & ignition turned off.

Now read the Driver Briefing & Driving Code of Good Practice.

Always remember motor sport can be dangerous.