Plyfly Instructions V 10

HOW TO BUILD
YOUR
PLYFLY GO-KART!
For Ages 12+

PlyFly GoKart Instruction Guide 2015 Release
Thank you for supporting
theFLATWORKSKickstartercampaign.
Your contribution is a great help, and your
support is much appreciated.
Thank you We hope youre as excited to get
started on your new adventure as we are to
be working on theFLATWORKS.
Enjoy your new PlyflyGoKart!
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 Mohit
Ray Colwell Douglas Dayton Sam Bell
Henry E. Sam Bowling Emily H.
Carl Moulton LindseyZimmerman Andrew Marc
Mark ChengIan Anthony Tim Owens
Drummond Joshua Marcus Chris Porter
CJBCN Joe W. Matthew Clark
JamesUdubUnderwood Greg Brncick Ryan Bradley
Jesse Cannone Grandpa Rex Michael Lindahl
Luke Alex Gomes Adam Hock Hocherman
Jim Mahoney Lindsay Lauber Michael McGrath
Tim Baker Joseph Asti Dave Krugman
Karl Eberhardt Nick Vines Daniel Cianci
Tomas Petru Herk Scott Newman
David Moore Brian Jepson Russ Kadooka
David Geisinger Steve Baker Mitch
Ken Short Louis Tovar Bob
Andrew B. Bartels Mark Tracy
Brian Kaleida Anonymous
Matthew & Keri Michael Lindahl
Zee JouleLee
Tiegen
150718 PLYFLY rev A_Cover |August7,20155:06PM
III
What's Inside?
1 Exploring the kit 1 8 Pedal Assemblies 25
Warnings and safety 2 Plywood sheet reference 26
Handling and storage 2 Recommended tools 26
Why Wood? 3 Required hardware 26
Good to know 3 Required wooden parts 27
Whats in the kit? 3 Assembling the gas & the brake pedals 27
Unpacking the boxes 4
9 Frame Assembly 28
2 Getting Started 6 Plywood sheet reference 29
Getting started 7 Recommended tools 30
Recommended tools 7 Required hardware 30
Chisel & hammer method 7 Required assemblies 30
Reciprocating saw method 7 Required wooden parts 31
Assembling the frame 32
3 Seat Assembly 8
Plywood sheet reference 9 10 Putting the gokart together 37
Recommended tools 9 Overview of the recommended tools 38
Required hardware 9 Overview of the required hardware 38
Required wooden parts 10 Overview of the required but not provided 41
Assembling the seat 11 Overview of the required wooden parts 41
Overview of the required assemblies 41
4 Steering Column Assembly 12
Part 1 Install the rear axle 43
Plywood sheet reference 13
Part 2 Install the brake caliper 44
Recommended tools 13
Part 3 Install the steering column assembly 45
Required hardware 13
Part 4 Install the steering spindles 46
Required wooden parts 13
Part 5 Install the gas & brake pedals 47
Assembling the steering shaft 14
Part 6 Install the gas & brake cables 49
5 Steering Rack Assembly 15 Part 7 Install the engine and drive train 52
Plywood sheet reference 16 Part 8 Install the wheel assemblies 57
Recommended tools 16 Part 9 Install the seat assembly 58
Required hardware 16 Part 10 Install the fairings 59
11 Master List 60
Assembling the steering rack 17
Visual reference of the plywood sheets 61
6 Fixed SteeringColumn Assembly 18 List of the wooden parts 62
Plywood sheet reference 19 List of the wooden assemblies 66
Recommended tools 19 List of the tools needed 67
Required hardware 19 List of loose contents 68
Required wooden parts 20 List of the packaged contents 70
150718 PLYFLY rev A_TOC August
Assembling the steering column 20

12 Legal 72
7 SteeringSpindle Assemblies 21 Legal73
Plywood sheet reference 22
13 Terms & Conditions 74
Terms & Conditions of Purchase and Use 75
Required hardware 22
|
Assembling the left & right steering spindles 24

7,20155:06PM
IV
1 Exploring the kit
Introduction
Each Plyfly Go-Kart kit arrives in 3 boxes.
Review the contents of each box to ensure you have all the
necessary parts to begin building your next adventure!
7,20155:08PM
150718 PLYFLY rev A_CH 1 August
|
1
Warnings and safety Handling and storage
Riding karts can be dangerous. The kart is heavy.
Please use caution and prudence and follow the Use at least two people to lift or move it.
guidelinesbelow. Some surfaces may be hot after use, handle with
Avoid operating your kart in crowded or confined areas. caution. These may be from friction in bearings and
Any children that use the kart are of an appropriate brakes or fromthe engine.
age and do so under proper supervision. If gasoline is spilled on the wood, leave the kart
Therecommendedage for this kart is 12+. outside in a well ventilated area to dry before use
Avoid using your kart near any other vehicular traffic or or storage. Be very careful about exposure to potential
onpublic roads. ignition sources untilitdries.
Never try to fit more than one person in the kart. Do not tip the kart. Fuel may spill from the carburetor if
inclined too much. If you need to stand up the kart, start
Always wear a DOT-rated helmet and gloves while the engine and turn off the fuel valve. Let the engine run the
operating the kart. carburetor dry.
Never aim the kart at other people, objects or animals. Store the kart in a dry, clean area and coat the wood with
Prior to riding, every rider should familiarize apaint or coating for the longest life.
themselveswith:
Their environment
Any obstacles or dangers.
The location and function of the
emergencyshutoffswitch.
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
properlytightened 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 hairthat could get caught in the spinning
mechanismsofthe kart.
| 7,20155:08PM
2 1 Exploring the kit

Why Wood? Whats in the kit?
Sure, steel karts are fun and strong, but they require a large Each Plyfly Go-Kart kit arrives in 3 boxes. Box 1 is a flat box
number of specialized tools to build, repair or modify. Tools with the wooden structural parts. Box 2 is the engine and
that most people dont have. Wood, on the other hand, can box3 is the hardware.
be crafted with tools available in most homes and all home 1.2.3. Thats it!
improvement stores. We want to provide kits that people
can make their very own, by painting, fixing or modifying and Packaging reference
wood is a natural fit for this.
Description Reference
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 its 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 Box 1 wood
tools. 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. Box 2 engine
We aim to provide the best assembly documentation in Dimension: 14 x 14 x 16
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,
pleaseask. However, this is a kit and the ultimate
buildquality is up to you.
Box 3 hardware & wheels

Dimensions: 24 x 12 x 12
For more the complete list of hardware, see Visual reference of the plywood sheets, on page 61.
7,20155:08PM
|
PlyFly GoKart Instruction Guide 2015 Release 3

Unpacking the boxes
Each box should have the following components.
Box 1 contents
2.5 HP 4.0 HP 4.0 HP 4.0 HP 4.0 HP
SINGLE WHEEL SINGLE WHEEL SINGLE WHEEL LIVE AXLE LIVE AXLE
DESCRIPTION
10 WHEELS 10 WHEELS 12 WHEELS 10 WHEELS 12 WHEELS

3 Plywood Sheet
3/4 depth

1 Plywood Sheet
1/4 depth
1 Flag

1 Drive Shaft
18 L 18 L 18 L 33 L 36 L
Steel, Keyed, 5/8 D
Box 2 contents
2.5 HP 4.0 HP 4.0 HP 4.0 HP 4.0 HP
DESCRIPTION
10 WHEELS 10 WHEELS 12 WHEELS 10 WHEELS 12 WHEELS

1 Gas Powered Engine

2.5 HP MODEL


4.0 HP MODEL

| 7,20155:08PM
4 1 Exploring the kit

Box 3 Contents
2.5 HP 4.0 HP 4.0 HP 4.0 HP 4.0 HP
DESCRIPTION 10 WHEELS 10 WHEELS 12 WHEELS 10 WHEELS 12 WHEELS
Plyfly Packaged Hardware Kit Sealed kit of gokart hardware 1 1 1 1 1

Clutch #35 Chain, 11 Tooth Pulley for 5/8 shaft 2.5HPModel 1
Clutch #35 Chain, 12 Tooth Pulley for 3/4 shaft 4.0HPModel 1 1 1 1

Clutch Guard Side Engine Mounting Plate 1 1 1 1 1
Clutch Guard Top Top Cover 1 1 1 1 1
Clutch Guard Cover Outside Cover 1 1 1 1 1
Sprocket 60 Tooth, #35 Chain, 5/8 D bore 1 1 1 1 1
Roller Chain #35 Chain, 29-5/8 L 1 1 1 1 1
Chain Link For connecting #35 Roller Chain 1 1 1 1 1
Control Cable 1/16 D, throttle & brake control cable 2 2 2 2 2
Red Throttle Cable Brake conduit, 5 L 1 1 1 1 1
Green Throttle Cable Gas conduit, 6 L 1 1 1 1 1
VXB Mounted Bearing 5/8 ID 3 3 3 3 3
Brake Caliper 1 1 1 1 1
Brake Disc 1 1 1 1 1
Brake Hub 1 1 1 1 1
Long Hex Bolt Grade 5, 5/8-11, 11 L SingleWheelKitOnly 1 1 1
Short Hex Bolt Grade 5, 5/8-11, 6.5 L 4 4 4 4 4

Precision Rod 1/4 D, 18 L 1 1 1 1 1
Drawer Slide Hardware included, 10 L 1 1 1 1 1
Green Elastic Cord 3/16 OD, 18 1 1 1 1 1
Spax Screw 1 Box,#8 1-1/2 L 1 1 1 1 1
10 D Wheels Rear driven wheel 1 1 2
10 D Wheels Undriven wheel 3 3 2

7,20155:08PM
12 D Wheels Rear driven wheel 1 2

|
12 D Wheels Undriven wheel 3 2

PlyFly Flag 1 1 1 1 1
For more the complete list of hardware, see List of the packaged contents, on page 70.

2 Getting Started
Introduction
Preparing for a Plyfly Go-Kart build, you will need to cutout
eachstructural wooden part from the plywood sheets.
The more time spent trimmingtabs cleanly will save
alotofsandingtime.

| 7,20155:08PM
6
Getting started Chisel & hammer method
INSTRUCTIONS INSTRUCTIONS
1. Open the provided boxes to ensure all the parts are 1. To free a part from the plywood sheet, place the flat side
included. of chisel against the keeper side of the part.
2. To release the structural wooden parts from the 2. Strike the top of the chisel sharply with a hammer to
plywoodsheets, use the recommended tools and follow remove wood from the notches.
one of the suggested methods: 3. Repeat this procedure until all the parts are free.
A chisel and hammer method 4. To finish the edges of allthe wood parts that become
The reciprocating saw method spalled or rough from the cutting process using an orbital
sander, or sheet of sandpaper.
Reciprocating saw method

Recommended tools INSTRUCTIONS
DESCRIPTION REFERENCE 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)
Hammer 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.
4. Repeat this procedure until all the parts are free.
5. To finish the edges of allthe wood parts that become
spalled or rough from the cutting process using an orbital
Orbital sander sander, or sheet of sandpaper.
Sandpaper
Jigsaw or
Reciprocating saw
(optional)
7,20155:08PM
For more information on Whats in the kit?, see page 3.

|

3 Seat Assembly
Introduction
Before beginning this assembly, be sure to chisel out and sand
parts22-33. These 12 components are required to fully assemble
the gokartseat
150718 PLYFLY rev A_Seat August

| 7,20155:06PM
8
Plywood sheet reference Recommended tools
DESCRIPTION REFERENCE DESCRIPTION REFERENCE
Sheet 1
Parts 24
3/4 Plywood Sheet
Dead blow hammer
or mallet
Electric driver
Required hardware
24 DESCRIPTION REFERENCE
Sheet 3 Parts 22-23

3/4 Plywood Sheet Parts 25-27 32 Spax Screw
#8, 1-1/2 L
PN 12519
22
23
26 27 25
Sheet 4
Parts 28-31
1/4 Plywood Sheet
31
7,20155:06PM
|
29 28 30

Required wooden parts
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
Part 27
Seat Crossbar Bracket

PLYWOOD SHEET 3
ote If you received a 1/4 plywood sheet that is finished on one side and
N
|
you intend to paint the Plyfly gokart seat; reversethewoodenparts2833

7,20155:06PM
(sotheunfinishedsideis outward facing and

ready toreceivepaint).
10 3 Seat Assembly
Assembling the seat
INSTRUCTIONS
1. Align parts 22 & 23 with the slots facing outwards. 7. Secure part32 to the seatframe usingscrews.
2. Using amallet, tap part27 into the slots on parts22&23. Use 8 screws.
Note the part orientation and location. Total of 8 locations.
8. Using amallet, tap part29 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.
Total of 2 locations, 2 screws. 9. Repeat step 8 with part28 on the opposite side.
Note secure part 27, by screwing the part in from the outside of part 22 & 23. 10. Secure parts 28 & 29 to seat frame usingscrews.
Use 4 screws.
Total of 4 locations.
11. Using amallet, tap part33 into the tabconnections of
parts26&27.
Note location and orientation of part 33.
33
1 2
4. Using amallet, tap parts24,25,&26 into the

remainingslots.
Note the location and orientation of the parts 24-26.
24
12. Secure part 33 using screws.

25
Use 8 screws.
26
13. Using amallet, tap part31 into place usingamallet.
Note location and orientation of part 31.
5. Secure parts 24,25,&26 by usingscrews.

Use 2 screws per part, 1 screw per side.
31
Total of 6 locations, 6 screws.
6. Using amallet, tap part32 into the tabconnections of
7,20155:06PM
parts24&25.
Note the location and orientation of the part 32.
|
32
14. Repeat step 13 with part30 on the opposite side.
15. Secure parts 30-31 to seat frame usingscrews.
Use 4 screws.

4 Steering Column
Assembly
Introduction
Before beginning this assembly, be sure to chisel out and
sandparts19-20. These 3 components are required to
fullyassemble the steering shaft.
150718 PLYFLY rev A_Steer columnA

|ugu27s0,t150
:P
6M
12
Sheet 1
Part 20 Dead blow hammer
3/4 Plywood Sheet
or mallet
Hammer
Electric driver
Required hardware
DESCRIPTION REFERENCE
20
4 Small Metal Bushing

Sheet 2 Part 19 Flanged 3/8 ID, 1/4 L
3/4 Plywood Sheet Part 21 PN 12538
4 Spax Screw
#8, 1-1/2 L
PN 12519

21
5 19 Part 19
Steering Column Shaft
PLYWOOD SHEET 2
Part 20
Steering Pinion
6M
PLYWOOD SHEET 1
:P
|ugu27s0,t150
Part 21
Steering Wheel
PLYWOOD SHEET 2

Assembling the steering shaft
INSTRUCTIONS
1. Press bushings into each side of part20. 6. Secure the parts usingscrews.
Note there are 2 bushings, 1 bushing per side. Use 2 screws on part20
7. Using a mallet, tap part21 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 eachbushingisflush.

3. Press bushings into each side of part21.
Note there are 2 bushings, 1 bushing per side..
19
20
8. Secure the parts usingscrews.

Use 2 screws on part21.
4. Hammer securely until the top of eachbushingisflush Total of 2 locations.
5. Using a mallet, tap part19 to part20.
Note The orientation of the parts.
19
20
|ugu27s0,t150
:P
6M
14 4 Steering Column Assembly

5 Steering Rack
Assembly
Introduction
Before beginning this assembly, be sure to pre-cut and sand
the gokartsteering rack.
|ugus52t,01510:38PM
150718 PLYFLY rev A_Steer rackA
15
Sheet 1
Parts 9-10
3/4 Plywood Sheet
Dead blow hammer
or mallet
Hammer
Screwdriver
9 10
Sheet 2
Parts 11-12 Electric driver
3/4 Plywood Sheet
12 11
Required hardware
4 Spax Screw
#8, 1-1/2 L
PN 12519

|ugus52t,01510:38PM
16 5 Steering Rack Assembly

Required wooden parts Assembling the steering rack
INSTRUCTIONS
1. Using amallet, tap parts9&10 into the slots on part11.
Part 9 Note the part orientation
Steering Rack Bracket
PLYWOOD SHEET 1 11 9 10
Part 10
Steering Rack Bracket
PLYWOOD SHEET 1
Part 11
Steering Rack
PLYWOOD SHEET 2
2. Secure parts9& 10 usingscrews.

Use 1 screw per part.
3. Using amallet, tap part12 into the tabconnections on
Part 12 parts 9&10.
Steering Rack Center Note the part 12 orientation the gear teeth should point in thesamedirection.
Bracket
PLYWOOD SHEET 2 12
4. Secure part12 to the assembly using screws.

Use 2 screws.
|ugus52t,01510:38PM

6 Fixed SteeringColumn
Assembly
Introduction
Before beginning this assembly, be
sure to pre-cut and sand parts13-18.
These6components are required to fully assemble
thegokartfixedsteeringcolumn.
150718 PLYFLY rev A_Steer fixedA

|ugus72t,015:06PM
18
Sheet 1
Parts 13
3/4 Plywood Sheet
Dead blow hammer
or mallet
Hammer
13 Required hardware
Sheet 2
Parts 14-18
3/4 Plywood Sheet
2 Small Tee Nut
Zinc Plated, 5/16-18
PN 12510
14 15 18
12 Spax Screw
#8, 1-1/2 L
PN 12519
16 17
|ugus72t,015:06PM

Required wooden parts Assembling the steering column
INSTRUCTIONS
1. Press teenuts into parts 15&18
Note the orientation of part 15.
Part 13
Steering Column Left
PLYWOOD SHEET 1
15
Note the orientation of part 18.
18
Part 14
Steering Column Right 2. Using ahammer, tap the teenut until the top isflush with
PLYWOOD SHEET 2 thewoodenpart.
3. Using a mallet, tap parts15,16,17,&18 into the
correspondingslots on part13.
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 part14 to the assembly so that the partmirrors

part13 exactly.
5. Using a mallet, tap part14 into the tab connections.
Part 18
6. Secure the parts usingscrews on each part.
Steering Pinion Mount

PLYWOOD SHEET 2 Use 1 screw per part, per side.
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.
|ugus72t,015:06PM
20 6 Fixed SteeringColumn Assembly

7 SteeringSpindle
Assemblies
Introduction
Before beginning this assembly, be sure to chisel
out and sand parts1-8. These 8 components
are required to fully assemble 2 steeringspindle.
Eachassembly contains 4parts.
|ugu27s0,t150
150718 PLYFLY rev A_Steer spindleA 6M
:P
21
Part 1
Sheet 1
Parts 3-4
3/4 Plywood Sheet
Parts 6-8 Dead blow hammer
or mallet
Hammer
Electric Driver
4 7 8 1 6
Sheet 2 Part 2
3/4 Plywood Sheet Part 5
Required hardware
2 Short Hex Bolt

Grade 5, 5/8-11, 6.5 L
PN 12503
6 LargeMetalBushing
Flanged, 3/4 OD, 5/8 ID
PN 12504
2 Small Tee Nut

PN 12510
150718 PLYFLY rev A_Steer spindleA
20 Spax Screw
#8, 1-1/2 L
PN 12519
|ugu27s0,t150
:P
6M
22 7 SteeringSpindle Assemblies
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
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
Part 8
6M

:P
|ugu27s0,t150
PLYWOOD SHEET 1

Assembling the left & right steering spindles
INSTRUCTIONS
1. Press bushings into parts 12,56, & 78 7. Using amallet, cap the parts 1, 3, 5 with part 7.
Note the orientation of part 1 & 2. 8. Using amallet, cap the parts 2, 4, 6 with part 8.
Note the location of the bushings.
7 8
1 2
Note Be sure to insert the bushing on the opposite side of the alignmentmark.
Parts 5 &6 are left and a right side biased.
9. Secure the parts usingscrews on each part.
Use 2 screws on part 5
5 6 Use 2 screws on part6
Use 4 screws on part7
Use 4 screws on part8
Total 20 locations, 20 screws.
10. Using ahammer, insert the 5/8 long bolt into each
steering spindle assembly.
Note the location of the bushings
Note the location of the bushings.
2. Using ahammer, tap thebushings until the top isflush

with thewoodenpart.
3. Using a mallet, tap parts1 into the outerslot on part5.
4. Using a mallet, tap parts2 into the outerslot on part6.
5. Using a mallet, tap parts3 into the innerslot on part5.
6. Using a mallet, tap parts4 into the innerslot on part6.
Note the location of the bushings. The bushing should face outwards.
Try to ensure 90
1 2
3 4
|ugu27s0,t150
:P
6M
5 6
24 7 SteeringSpindle Assemblies
8 Pedal Assemblies
Introduction
Before beginning this assembly, be sure to chisel out and sand
the gokartgas and brake pedals. Each assembly contains 3parts.
150718 PLYFLY rev A_Pedal |August7,20155:06PM
25
Sheet 1 Parts 34
3/4 Plywood Sheet Parts 36-39
Dead blow hammer
or mallet
38 39
Hammer
Electric Driver
36 37 34
Sheet 3
Parts 35
3/4 Plywood Sheet Required hardware
4 Plastic Bushing
Flanged, 1/4 ID, 3/8 OD
PN 12509
35
8 Spax Screw
#8, 1-1/2 L
PN 12519
26 8 Pedal Assemblies
Required wooden parts Assembling the gas & the brake pedals
INSTRUCTIONS
1. Insert and hammer into place the bushings into parts
Part 34 Part 36
Brake Pedal Part 37
PLYWOOD SHEET 1
Part 38
Part 39
Note the part orientation. The final 2 assemblies are mirror images of each other.
Part 35 38 39
Gas Pedal
PLYWOOD SHEET 3
36 37
Part 36
Pedal Side
PLYWOOD SHEET 1
2. Using a mallet, tap parts36&37 into the slots on part34.
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
PLYWOOD SHEET 1 36
37
Part 39
3. Secure parts 34,36&37 using screws.
Pedal Side Use 2 screws per part & per side.
PLYWOOD SHEET 1
4. Repeat step 2 using parts35,38&39.
Note part location and orientation of parts 36-37. Be sure to square the parts.
35
38
39
5. Secure parts35,38&39 using screws.

Use 2 screws per part & per side.

9 Frame Assembly
Introduction
Before beginning this assembly, be sure to chisel
out and sand parts40-55. These 11 components
and assemblies13 are required to fully assemble
thegokartframe.
150718 PLYFLY rev A_Frame |August7,20155:06PM
28
Plywood sheet reference
Sheet 1 Parts 40-43 Sheet 4 Part 47

3/4 Plywood Sheet Part 49 1/4 Plywood Sheet Part 50
41 40 43 42 49 50
47
Parts 44-46 Part 51

Sheet 2 Sheet 4
Part 48 Part 53-54
3/4 Plywood Sheet 1/4 Plywood Sheet
Part 52 Part 55
45 44 55
48 46 52 51 53 54

Recommended tools Required assemblies
Dead blow Hammer

or mallet
1
Steering rack
Assembly
Hammer Parts 9-12
Electric Driver
2
Screwdriver Fixed steering column
Assembly
Parts 13-18
Required hardware
1 Drawer Slide
Hardware included, 10 L 3
PN 12508
Steering column
Assembly
LargeMetalBushing Parts 19-21
Flanged, 3/4 OD, 5/8 ID
5 SINGLEWHEELKIT PN 12504
4 LIVEAXLEKIT PN 12504
10 Large Tee Nut

Zinc Plated, 3/8-16
PN 12545
10 Small Tee Nut

PN 12510
30 Spax Screw
#8, 1-1/2 L
PN 12519
3 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
Part 40
Frame Rail Inner Left
PLYWOOD SHEET 1 Part 48
Frame Rail Rear
PLYWOOD SHEET 2
Part 41
Frame Rail Inner Right
Frame Rail Engine Mount
PLYWOOD SHEET 1
Part 42
Frame Rail Outer Left
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
PLYWOOD SHEET 2
Part 46
Frame Rail Bracket

PLYWOOD SHEET 2
Part 47
Sprocket Guard
PLYWOOD SHEET 3

Assembling the frame
INSTRUCTIONS
1. To begin this assembly 5. Press the large tee nuts into
Start at Step 2 if you have a SINGLEWHEELKIT. Part 4243
Start at Step 4 if you have a LIVEAXLEKIT. Part 47
2. Press the bushing intopart40. Part50; on the opposite side of the smallteenut
Note the location of the bushing on part40. Install on the opposite side of the L. installation.
Note the location of 2 large tee nuts on part 42. Install on the same side of
40 theL.
1 2 42
3. Using a hammer, tap the bushing until the top isflush with
thewoodenpart. Note the location of 2 large tee nuts on part 43. Install on the same side of
theL.
4. Press the smallteenuts into
Part4041 43 1 2
Part49
Part50; be sure to follow installation pattern for the
correct engine model.
Note the location of the small tee nut on part40; install on the same side of Note the location of 2 large tee nust on part 47.
theL.
47 1 2
40
Note the location of the small tee nut on part 41. Install on the same side of
theL.
Note the location of 4 large tee nuts on part 50. Install on opposing side of the
41 1
small tee nut installion on part 50.
50 1 2
Note the location of 4 small tee nuts on part 49.
49
3 4
1 3 6. Using a hammer, tap the tee nuts until the top is flush with
the woodenpart.
2 4 Parts 4143, 47, 49 & 50.
Use 20 tee nuts; 10 small and 10 large.
Note the location of 4 small tee nuts on part 50 Total of 20 locations.

1 3 7. Screw in the fillesterheadmachinescrews into the
teenuts located parts40&41.
1 3
Tighten down until it stands flush with 3/8protrusion.
50
2.5 HP 50
4.0 HP
2 4
2 4
32 9 Frame Assembly
8. Press 2 bushings intopart 45. 16. E xtend the drawer slide until the last two holes on the
Note the location of the bushing on part 45 drawer slide are accessible from the underside through
the slot located on part44.
1 2
Note the location of the referenced slot on part 44.
9. Using a hammer, tap the bushings until the top isflush

with thewoodenpart.
10. Press 2 bushings intopart 44.
Note the location of the bushings on part 44
Mount 1 to the drawer slide.
1 2 Note the correct assembly
11. Using a hammer, tap the bushings until the top isflush
with thewoodenpart. 17. Secure 1 using screws.
12. Install the drawer slide on part 44, by extending the slide Use the remaining screws included in the
to its furthest extended position. DrawerSlideKit.
13. Align the 4 screw holes on the drawer slide with holes 18. Using amallet, tap part40 into the tabconnections on
found in the recess on part44. the leftside of part44.
Note the location and position of the mounting holes. The drawer slide should fit Note the location and orientation of the teenut on part 40;
into the recessedpocket on part44. the letter L should face inward to the centerline of the gokart.
1 2 40 44
3 4
14. Secure the drawer slide to part44 using screws.

Use a screwdriver and the screws provided in the
SlideDrawerKit. 19. Using amallet, tap part41 into the tabconnections on the
leftside of part44.
Use 4 screws
Note the letter L should face part41, away from the centerline of thegokart.
Total 4 locations
15. Test the drawer slide fit by moving the 41
slidebackandforth.
Be sure there are no interferences between any
screwhead and the slide.

20. Repeat steps 18 and 19 using 25. Secure part44 to the assembly using screws.
Part42 There is a purposeful gap in alignment to allow part51
Part43 to sit flush with the assembly.
Note the letter L should face part41, away from the centerline of thegokart. Use 12 screws.
26. Flip the assembly right side up again.
27. Using a mallet, tap part46 into place.
43 Note the orientation and position the tabs on part 46.
46
42
21. Using amallet, tap 2 into the tabconnections in the

center of part44.
Note the orientation and location of the assembly.
28. Using a mallet, tap part47 into the center slot of part46.
Note the orientation and position of part 47.
22. Using a mallet, tap part45 slots into the tabconnections

of gokartfront-end (parts4043).
Note the correct orientation for part45; the bushings face(down) part44.
45
47 46
29. Secure parts46 to part47 using screws.

Use 2 screws.
23. Secure part45 using screws.

Use 12 screws.
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
30. Using a mallet, tap part48 into the 5 connectiontabs. 34. Using a mallet, tap part49 into place.
Note the orientation and position of cutout tabs, it should face upward. Note the orientation and position of part 49.
Toensure alignment of all 5 tab connections; prior to using a mallet, tack 1 corner of
part48 with a screw that is not tightened down all the way.
49
48
31. Secure part48 to the assembly using screws on the

rearface, left and right side faces.
Use 12 screws.
Note the orientation and position of part 52.
Use 8 screws.
36. Flip assembly over allowing 2 to hang off table or
sawhorses.
37. Install the 3 mounted bearings
Note the orientation, location and position of each mounted bearing.
52
1
2
3

Use 2 screws.

39. Secure part51 to the assembly using 21 screws.
40. Flip assembly right side up.
41. Lay part50, with the small tee nuts facing upwards, into
place.
Note the orientation and position of tee nut pattern on part 50.
50
42. Secure part50 to the assembly using washers &

hexheadcap screw.
Use 4 washers
Use 4 hexheadcap screw.
Total 4 locations.
Note the orientation and position of the hex hed bolts; tee-nuts should face up.
36 9 Frame Assembly
10 Putting the gokart
together
Introduction
Before beginning this final assembly, be sure to have
assemblies17 completed. These 8assemblies are required to
fully assemble thegokart.
This chapter contains 10individual procedural parts to
successfully complete the full gokartassembly.
t2,0155:08PM
150718 PLYFLY rev A_GoKart |Augus7
37
Overview of the recommended tools Overview of the required hardware
PART 1
Dead blow Hammer

1 Sprocket
or mallet
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
1 Drive Shaft
ElectricDriver Steel, Keyed, 5/8 D, 33 L
LIVE AXLE KIT 10 WHEELS PN 12581
1 Drive Shaft
Allen Wrench Steel, Keyed, 5/8 D, 36 L
or ratcheting Allen wrench
1 Brake Disc
PN 12532
Metric Allen Wrench
included with mounted bearing
1 Brake Disc Hub

PN 12533
Socket Wrench
1 Long Hex Bolt
Axle Grade 5, 5/8-11, 11 L
SINGLEWHEELKIT 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 buttonsocketheadcapscrews PN 12520
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 Key
3/16 square, 1L
PN 12539
PART 2
1 Brake Caliper
PN 12531
1 Short Aluminum Spacer

1/2 OD, 1/4 ID, 7/8 L
PN 12547
t2,0155:08PM
38 10 Putting the gokart together

Overview of the required hardware Overview of the required hardware
1 Long Aluminum Spacer 6 Zip Tie

1/2 OD, 1/4 ID, 11/16 L 10lb Nylon, White, 7/8 D, 4 L
PN 12548 PN 12558
PART 7
2 Oversized Flat Washer
Zinc, M6
PN 12549 1 Gas Powered Engine Box 2
2.5 HP MODEL
2 Socket Head Cap Screw

Black oxide, M6, 55mm L 1 Gas Powered Engine
PN 12550 Box 2
4.0 HP MODEL
PART 3
1 Clutch
1 Nylon Spacer #35 Chain, 11 Tooth Pulley for 5/8 D
3/4OD, 3/8ID, 11/4L 2.5HPMODEL PN 12576
PN 12546
4 Flat Washer 1 Clutch

5/16 ID, 7/8 OD #35 Chain, 12 Tooth Pulley for 3/4 D
PN 12516 4.0HPMODEL PN 12577
1 Roller Chain
1 Short Shoulder Screw
#35 Chain, 29-5/8 L
3/8D, 1L, 5/16-18
PN 12524
PN 12513
1 Master Chain Link

1 Long Shoulder Screw #35 Roller Chain connector
3/8D, 21/4L, 5/16-18 PN 12534
PN 12514
1 Part 56
Clutch Guard Side
PART 4 Engine Mounting Plate
PN 12005
2 Short Hex Bolt
Grade 5, 5/8-11, 6.5 L 1 Part 57
PN 12503 Clutch Guard Top
Top Cover
2 Lock Nut PN 12006
5/8 ID
1 Part 58
PN 12506
Clutch Guard Cover
Outside Cover
4 Flat Washer
PN 12007
5/8 ID, 13/8 OD
PN 12505 1 Control Cable
1/16 D, throttle & brake control cable
PART 5
PN 12525
1 Precision Rod
1/4 D, 18 L 1 Throttle cable clamp
PN 12507 PN 12537
PART 6
1 Extension Spring
t2,0155:08PM
1 Control Cable Black-Oxide, Precision

PN 12560
PN 12525
1 Throttle Return Clip

1 Red Throttle Cable 4.0HPMODEL
Brake conduit, 5 L PN 12561
PN 12527
8 Sheetmetal Screw
1 Green Throttle Cable Galvanized, #6
Gas conduit, 6 L PN 12551
PN 12528

Overview of the required hardware Overview of the required hardware
5 Button Socket Head Cap Screw 2 Undriven wheel

Zinc Plated, Steel, M8, 12mm L 10 D
TOTAL OF 5 PROVIDED PN 12515 LIVEAXLEKIT PN 12591
1 Hex head cap screw 1 Rear driven wheel

5/16-18, 1.25 L 12 D
4.0HPMODEL PN 12543 SINGLEWHEELKIT PN 12592
3 Undriven wheel
1 Hex Cap Screw 12 D
1/4-20, 1 L SINGLEWHEELKIT PN 12593
2.5HPMODEL PN 12554
1 Key
1 Flat Washer 3/16 square, 1L
5/16 ID, 7/8 OD PN 12539
PN 12516
PART 9
1 Fender washer
2 Fillister Head Screw
5/16 ID, 1-1/8 OD
5/16-18, 3/4 L
PN 12555
PN 12553
1 Lock washer 1 T-Handle

5/16 ID Quick Release Pin
PN 12542
1 Clutch Key
1 Flag
3/16, 1/2 L
Plyfly flag
PN 12557
PN 12535
2 Set Screw PART 10

Clutch
PN 12563 20 Spax Screw
1 #8, 1-1/2 L
1 Pan head PN 12519
M6, 12 mm L
4.0HPMODEL PN 12564
1 Green Elastic Cord
PART 8 3/16 OD, 18 L
PN 12517
Flat Washer
5/16 ID, 7/8 OD
2 LIVEAXLEKIT PN 12516
Note There are 2 types of buttonsocketheadcapscrews
2 Shaft Collar
5/8 ID size but are not. The easiest way to differentiate the
PN 12540 2 sizes, is by the number of screws provided.
2 Lock Nut
5/8"-11
PN 12506
1 Rear driven wheel

10D
3 Undriven wheel
10 D
2 Rear driven wheel

10D
LIVEAXLEKIT PN 12590
t2,0155:08PM

Overview of the required but not provided Overview of the required assemblies
Motor Oil Approximately 1 quart of 10W30 Motor Oil

2
Gas Regular unleaded gas. Fixed steering column
Assembly
PARTS 1318
3
Steering column
Overview of the required wooden parts Assembly
PARTS 1921
Part 53
Fairing Left 4
PLYWOOD SHEET 4
Seat
Assembly
Part 54 PARTS 2233
Fairing Right
PLYWOOD SHEET 4
5
Part 55 Gas Pedal
Fairing Front Assembly
PLYWOOD SHEET 4 PARTS 34, 3637
6
Brake Pedal
Assembly
PARTS 35, 3839
7
Left Spindle
Assembly
PARTS 1,3,5,7
8
Right Spindle
t2,0155:08PM
Assembly
PARTS 2,4,6,8
9
Frame
Assembly
PARTS 2128

Chapter 10 Required hardware
1
1 Sprocket
5/8 bore diameter
PART 60 Tooth, #35 Chain
PN 12522
Recommended tools
1 Drive Shaft
SINGLE WHEEL KIT PN 12580
Dead blow Hammer

or mallet
1 Drive Shaft
Allen Wrench
1 Drive Shaft
Socket Wrench
1 Brake Disc
PN 12532
ote There are 2 types of buttonsocketheadcapscrews

N
1 Brake Disc Hub
size but are not. The easiest way to differentiate the
PN 12533
2 sizes, is by the number of screws provided.
1 Long Hex Bolt

Axle Grade 5, 5/8-11, 11 L

Zinc Plated, Steel, 5/16-24, 1/2 L
4 Thin Nut
Grade 5, 5/16-24
PN 12520 150718 PLYFLY rev A_GoKart |Augus7
1 Key
3/16 square, 1L
PN 12539
t2,0155:08PM

Part 1 Install the rear axle 5. Insert the driveshaft by sliding it through
theoutermountedbearing located on part43 only.
INSTRUCTIONS
If there is too much resistance to insert the
1. Assemble the hub and brake disc using the driveshaft, temporarily loosen the mounting screws
buttonheadscrews and locknuts. so the mountedbearing is loose; or remove the
Use 4buttonheadscrews and 4 locknuts mountedbearing, slide the driveshaft and then
remount the mountedbearing.
Note orientation of the parts.
Rotate the bearing in its seat so that it is parallel to the
center frame rails.
6. Once the driveshaft is through the outer
mountedbearing, insert the brakedisc on the end.
Use the key to lock the brake disc to the driveshaft.
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 thebearings; as this will prevent
thedriveshaftinsertion.
3. Insert the driveshaft and bolts
7. Continue to slide the driveshaft through the assembly,
SINGLEWHEELKIT; continue to step 4. through the center mountedbearing, and then insert the
LIVEAXLEKIT; continue to step 5. sprocket on then end.
4. Insert the longhexbolt from the interior of the frame Use the key to lock the brake disc to the driveshaft.
through the bushing located on part40 and the SINGLEWHEELKIT is complete.
mountedbearing located on part42.
LIVEAXLEKIT continue to step 8.
If there is too much resistance to insert the
longhexbolt, temporarily loosen the mounting screws Note location and orientation of the bushing
so the mountedbearing is loose; or remove the
mountedbearing, slide the longhexbolt through and
then remount the mountedbearing.
Note location of the long hex bolt.
42 40
8. Continue to insert the driveshaft through the assembly

and through the final mountedbearing located on part42.
Note the drive shaft extends equal distances on both sides of the assembly.
t2,0155:08PM
9. Ensure all the hardware on mountedbearings are fully

tightened.

Chapter 10 Part 2 Install the brake caliper
2
The brakes will initially be installed and then adjusted.
INSTRUCTIONS
1. Insert the socketheadcapscrews with an oversizedflat
PART washer through the holes located on part43,
Use 1 socketheadcapscrew with
1oversizedflatwashers per location.
Recommended tools Total 2 locations
DESCRIPTION REFERENCE 2. Insert into the aluminumspacers on the opposite side of
part43.
Note the location and orientation of the brakecaliper. As well as the locations of
Dead blow Hammer the short spacer and the long spacer.
or mallet
43
Allen Wrench
Socket Wrench
Required hardware
1 Brake Caliper
PN 12531
3. Place brakecaliper into the cutout located at the rear of
part43 and insert the hardware.
1/2 OD, 1/4 ID, 7/8 L 4. Secure the brakecaliper in place, using
PN 12547 themetricAllenwrench provided.
Note the location and orientation of the brakecaliper.
1 Long Aluminum Spacer

1/2 OD, 1/4 ID, 11/16 L
PN 12548
2 Oversized Flat Washer 43

Zinc, M6
PN 12549

Black oxide, M6, 55mm L
PN 12550
t2,0155:08PM

Chapter 10 Part 3 Install the steering column assembly
3
INSTRUCTIONS
1. Position 3 , so that the gear aligns with those on 1 .
Be sure the gear alignment marks located on
PART parts20&12 line up.
Notethe orientation and alignment of the gear teeth
Recommended tools
DESCRIPTION REFERENCE 3
ElectricDriver
20
12
Allen Wrench
or ratcheting Allen wrench
2. Insert the shoulderscrews.
Insert the shortshoulderscrew through the bushing
located on part20 of 3 .
Insert the longshoulderscrew with the nylonspacer
through the teenut located on part21.
Required hardware
DESCRIPTION REFERENCE Total 2 locations, 2 shoulder screws.
Notethe orientation of the bolt; be sure thehead faces down
1 Nylon Spacer (towardtheground).
3/4OD, 3/8ID, 11/4L
PN 12546
4 Flat Washer
5/16 ID, 7/8 OD
PN 12516 21

3/8D, 1L, 5/16-18
PN 12513 3
1 Long Shoulder Screw

3/8D, 21/4L, 5/16-18
PN 12514
21
3. To secure, tighten both the shoulderscrews 3 .

Required assemblies Total 2 locations.
1
t2,0155:08PM
Steering rack
Assembly
Parts 9-12
3
Steering Column
Assembly
PARTS 1921

Chapter 10 Part 4 Install the steering spindles
4
INSTRUCTIONS
1. Slide the steeringrack all the way to the right.
2. Insert 7 with the bolt facing out.
PART
Check that the bushings on 7 are completely seated 8
before installing.
Note the location and orientation of the assemblies.
Recommended tools
Hammer
7
Required hardware
3. Align the gear teeth of 7 with the gearalignmentmark
2 Short Hex Bolt located on the steeringrackassemblygear.
Grade 5, 5/8-11, 6.5 L Note the location and orientation of the alignment marks.
PN 12503
2 Lock Nut
5/8 ID
PN 12506 7
4 Fender Washer
3/4 OD, 5/8 ID
PN 12505
4. Insert the shorthexbolt with a washer, starting from the

bottom and insert through the bushings found on 7 and
Required assemblies then through the top of the frame.
DESCRIPTION REFERENCE Note the order of the hardware insertion.
7
Left Spindle
Assembly
PARTS 1,3,5,7
5. Using a hammer, tap into place.

6. Insert a washer over the shorthexbolt and secure it with
alocknut.
Note the order of the hardware insertion.
8
Right Spindle
Assembly
PARTS 2,4,6,8
t2,0155:08PM
7. Repeat steps 1 through 6 on the opposite side using 8 .

Chapter 10 Part 5 Install the gas & brake pedals
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
PART pointing towards the middle of the fixedsteeringcolumn.
Note the right and left pedals tabs, holes, and their position in the Assembly.
1 2
Recommended tools
Dead blow Hammer

or mallet
6 5
ElectricDriver
2. Position 5 on the right of the fixedsteeringcolumn.
3. Position 6 on the left of the fixedsteeringcolumn.
Note location and orientation of the assembly 5 & 6.
5 6
Required hardware
1 Precision Rod
1/4 D, 18 L
PN 12507
Required Assemblies
DESCRIPTION REFERENCE 4. Insert the precisionrod through the holes located in 5
and then through the holes located in 6 .
5 Note location of the precision rod.
Gas Pedal
Assembly
Parts 34, 36-37
6
Brake Pedal
Assembly
Parts 35, 38-39
t2,0155:08PM
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).

Chapter 10 Reference Assemblies
6
2
PART
Fixed steering
column
Assembly
Recommended tools PARTS 1318
Needle Nose Pliers

5
Gas Pedal
Assembly
Parts 34, 36-37
Allen Wrench
6
Brake Pedal
Assembly
Socket Wrench Parts 35, 38-39
9
Required Assemblies Frame
DESCRIPTION REFERENCE Assembly
PARTS 2128
1 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

t2,0155:08PM

Part 6 Install the gas & brake cables 4. Continue to run the redcable on the left side of
thegokart
INSTRUCTIONS
Through the cableties located on 9 ,
1. Loop 4 zipties through the holes located on 2 .
through the slots located on part40&43,
Loosely tighten the zipties, leaving a large loop so later,
thecables can slidethrougheasily. and into the brakecaliper assembly.
Note path of the red cable.
Note the locations of the zip ties.
2 43
41
1
2 3 9
4
2. Loop 2 zipties through the holes located 9 .

Loosely tighten the nyloncableties, leaving a large loop
so later, thecables can slidethrougheasily.
Note the locations of the zip ties.
1
9
5. Run the greencable on the right side of the gokart
Through the interior of 2 and then
through the cableties located on 2 and then
through the hole located on the right side of part17.
Note the location and direction of the greencable. Be sure to seat the
2 greencable in the notches located on part17 of 3 .
14 3
2 17 19
3. Run the redcable on the left side of the gokart
Through the interior of 2
through zipties located on part13 and then
through the hole located on the left side ofpart17.
Note the location and direction of the redcable. Be sure to seat the redcable in
the notches located on part19 of 3 .
13 3
t2,0155:08PM
2
17 19

6. Continue to run greencable on the right side of 11. Feed the brake controlcable through a washer into the
thegokart fitting located on the brake.
Through the cableties located on 9 , Note path of the brake control cable through the brake caliper.
through the slots located on part40&43,

and leave slack to secure to the engine later.
Note path of the red cable.
43
41
12. Secure the controlcable in place using a smallwrench or

pliers.
13. Test brakepedal to ensure proper movement of brake.
7. Secure the nyloncableties by tightening them.

8. Use the needle nose pliers to clip any excess
cabletiematerial.
9. Feed the brake controlcable through the hole located in
the 6 and into theredcable.
Note path of the brake control cable through the brake pedal.
10. Fish the brake controlcable through the redcable all the
way to the end.
t2,0155:08PM

Chapter 10 Required but not provided
7
Oil Type & Amount TYPE & AMOUNT
Gas Type TYPE

PART
Recommended tools Required hardware

DESCRIPTION IMAGE REFERENCE DESCRIPTION REFERENCE
Dead blow Hammer 1 Gas Powered Engine Box 2

or mallet 2.5 HP MODEL

Box 2
Metric Allen Wrench 4.0 HP MODEL
included with mounted bearing
1 Clutch
#35 Chain, 11 Tooth Pulley for 5/8 D
2.5HPMODEL PN 12576
Wrench
1 Clutch
#35 Chain, 12 Tooth Pulley for 3/4 D
4.0HPMODEL PN 12577
Socket Wrench 1 Roller Chain

#35 Chain, 29-5/8 L
PN 12524
1 Master Chain Link

Electric Driver #35 Roller Chain connector
PN 12534
1 Part 56
Clutch Guard Side
Note Be sure not to lose attached key, Engine Mounting Plate
setscrews and bolt to hold clutch in place. PN 12005
1 Part 57
Clutch Guard Top
Top Cover
Required assemblies PN 12006
1 Part 58
Clutch Guard Cover
Outside Cover
5 PN 12007
Gas Pedal
1 Control Cable
Assembly
Parts 34, 36-37
PN 12525
t2,0155:08PM
1 Throttle cable clamp

PN 12537
1 Extension Spring
9 Black-Oxide, Precision
PN 12560
Frame
Assembly
PARTS 2128
4.0HPMODEL
PN 12561

Required hardware Part 7 Install the engine and drive train
DESCRIPTION REFERENCE The engine arrives with nooil, no configuration is required.
8 Sheetmetal Screw INSTRUCTION

Galvanized, #6
1. Stand the engine on part50 located on 9 ,
PN 12551
aligningtheenginemountingholes to the teenut pattern
(installed previously) appropriate for the engine model.
Zinc Plated, Steel, M8, 12mm L Note the location of the engine mount.

50
5/16-18, 1.25 L
4.0HPMODEL PN 12543
1 Hex Cap Screw

1/4-20, 1 L
2.5HPMODEL PN 12554
1 Flat Washer
5/16 ID, 7/8 OD
PN 12516 9
1 Fender washer Note the location of the tee nut bolting pattern on part 50.
5/16 ID, 1-1/8 OD 1 3
PN 12555
1 3
1 Lock washer 50
2.5 HP 50
5/16 ID 4.0 HP
2 4
1 Clutch Key
2 4
3/16, 1/2 L
PN 12557
2 Set Screw Note the direction and orientation of the engine within the go-kart.
Clutch
PN 12563
1 Pan head
M6, 12 mm L
4.0HPMODEL PN 12564
2. For next installation step:

2.5HPMODEL continue to step 3.
t2,0155:08PM

3. Remove the 2 bolts holding the throttle linkage; to be able 8. Slide part56 into the space located on the engine side.
to secure the engine to part50. Note the location of slot.
Remove 2 bolts.
Note the location of the 2 throttle linkage bolts. 56
2
9. Secure part 56, using M8screws.
Use 3 screws.
4. Using a socket wrench secure theenginebolts to part50. Total of 3 locations.
Use 4 bolts. Note the locations of the 3 screws.
5. For next installation step:
4.0HPMODEL continue to step 8. 1 3
6. Secure the throttlelinkage back into place using thebolts.
Use 2 bolts. 2
7. Install the extensionspring, by hooking one end
through thehole located on thethrottlelinkage. Then
using pliers, stretch the extensionspring and hook it
through thesecondhole on the opposite side of the 10. Slide the clutch over the engine crank shaft.
throttlelinkage. Be sure the setscrewson the clutch are backedout
Note the location of the extension spring. enough to be able to slide the clutch over
thecrankshaft.
Be sure the smallsprocket is facing toward the engine
and the set screws are facing away from the engine.
1 Be sure to align the keyway on the clutch with the
keywayonthe driveshaft.
Note the orientation of clutch; the small sprocket should face the engine.
t2,0155:08PM
2

11. Insert 1/2 clutchkey through the center of the clutch. 15. Connect the chain by sliding the posts of the masterlink
12. Using an Allen wrench tighten the set screws. into the holes located at the ends of the chain.
Note the order of the assembled hardware.
2 set screws.
Total of 2 screws.
Note the locations of the 3 set screws.
1
16. Add the masterlinkplate.
13. Using a wrench, tighten the hex head cap screw

assembled with a lockwasher and a fenderwasher to
secure the clutch.
Tighten hexheadcapscrew until the lock washer is
compressed.
If necessary, pull the starter cord to prevent the
crankshaft from rotating while tightening. 17. Secure the masterlink, using the retainingclip; snapping
Note the order of the assembled hardware. it into place.
18. Tension the chain.

Slide the engine forward until chain is taut.
19. Secure the engine in place using the bolts located on
part50.
14. Slide the chain, over both sprockets.
20. Test the rear wheel drive by spinning the driveshaft.
Be sure to align the clutchsprocket with the

driveshaftsprocket vertically. Be sure the shaft can spin freely with the chain.
21. For instructions on how to install the throttlecontrolcable
t2,0155:08PM

22. Secure the greencable loosely in the 26. Secure the greencable loosely in the clamp.
throttlecontrollinkage. Note the location of the green cable.
Note the location of the green cable.
23. Feed the throttlecontrolcable through the hole 27. Feed the throttlecontrolcable through the hole located
located on the throttlecontrollinkage and then into the on the throttlelinkage.
greencable. Note the locations of the throttle control cable.
Note the location of the green cable.
2
24. For the next installation instruction, continue to step 32.
25. Thread the greencable into the right side of the engine.
28. Install the extension spring, by hooking one end to the
Note the location of the green cable. hole located on the throttlelinkage.
Note the location of the extension spring.
t2,0155:08PM

29. Using pliers, hook the other end of the extensionspring to 32. Continue to feed the throttlecontrolcable all the way
the throttlereturnclip. through to 5 .
Note the location of the extension spring. Note the location of the throttle control cable.
33. Secure the throttlecontrolcable using the

throttlecableclamp at the bottom of 5 .
Be sure the controlcable is taut, before tightening the
throttleclamp.
34. Secure the green cable fully at the start location of the
30. Secure the throttlereturnclip to the engine using a screw. throttlelinkage.
Use 1 M6 screw. 35. Test the gas pedal to ensure proper movement of throttle.
Total 1 location 36. Place part57 over part56.
Note the location of the throttlereturnclip. Note the location part 57.
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 part57 to part56, using sheet metal screws.

Use 4 sheet metal screws.
38. Place part 58.
Note the location part 58.
58
!
57
39. Secure part58 to part57, using sheet metal screws.

t2,0155:08PM
Use 4 sheet metal screws.


Chapter 10 Part 8 Install the wheel assemblies
8
INSTRUCTIONS
1. Mount the undriven wheels (the wheels with bearings)
bysliding them over the axles.
PART SINGLEWHEELKIT continue to step 2.
LIVEAXLEKIT continue to step 4.
Recommended tools 2. Mount 3 undriven wheels.

DESCRIPTION REFERENCE 2 located on the front axles.
1 located on the back, left axle.
Socket Wrench
3. SINGLEWHEELKIT continue to step 5.
4. Mount 2 undriven wheels.
2 located on the front axles.
Wrench
5. Secure the undriven wheels using lock nuts.
Hint To keep the wheels from rotating, place a
largeslottedscrewdriver into the heads of the front axle bolts.
Required hardware 6. Slide the shaft collar over drive shaft.

DESCRIPTION REFERENCE SINGLEWHEELKIT continue to step 7.
Flat Washer LIVEAXLEKIT continue to step 9.
5/16 ID, 7/8 OD
7. Install 1 shaft collar.
2 LIVEAXLEKIT PN 12516 1 on the back, right drive shaft.
2 Shaft Collar 8. SINGLEWHEELKIT continue to step 10.
5/8 ID 9. Install 2 shaft collars.
PN 12540
2 located on the rear drive shaft.
2 Lock Nut Total of 2 locations.
5/8"-11
10. Secure the shaft collar using an Allen wrench.
PN 12506
11. Mount the driven wheel (the wheels with the fixed hub)
1 Rear driven wheel bysliding them over the drive shaft.
10D
Use the key to lock the drivenwheel to the driveshaft.
SINGLEWHEELKIT continue to step 12.
3 Undriven wheel LIVEAXLEKIT continue to step 14.
10 D
SINGLEWHEELKIT PN 12591 12. Mount 1 driven wheel.
1 located on the back, right drive shaft.
2 Rear driven wheel
10D Total of 1 location.
LIVEAXLEKIT PN 12590 13. SINGLEWHEELKIT continue to step 15.
2 Undriven wheel 14. Mount 2 driven wheels.
10 D Use the key to lock the drivenwheel to the driveshaft.
LIVEAXLEKIT PN 12591
2 located on the rear drive shaft.
t2,0155:08PM
1 Rear driven wheel Total of 2 locations.

12 D
15. Secure the driven wheel to the drive shaft using
thesetscrews.
3 Undriven wheel Be sure the setscrew aligns with the keyway.
12 D
16. Secure the axle to the driven wheel using the shaftcollar.
Use a socket wrench to tighten the locknut; while
1 Key holding the locknut on alternate side with wrench.
3/16 square, 1L
PN 12539

Chapter 10 Part 9 Install the seat assembly
9
INSTRUCTIONS
1. Place the Fillister head screws into the parts41&42
located on 9 .
PART Note the location of the Fillister head screws.
41
Dead blow Hammer

or mallet
Required hardware
2. Secure the Fillister head screws to be flush with the
wooden surface of part41.
5/16-18, 3/4 L
3. Position 4 at the forwardmostposition.
PN 12553 Align the side slots located on 4 to the screwheads
located on parts41&42.
4. Slide 4 backwards into position so that the pins slide all
1 T-Handle the way through slots.
Quick Release Pin 5. To secure 4 in place, insert the T-handle, pinside,
PN 12542 through part41 located on the right side of the gokart.
6. Insert the flag through holes located on the back right
side of SeatAssembly and the gokart frame.
1 Flag Note the location of the flag holes.
Plyfly flag
PN 12535
Required assemblies
4
Seat
Assembly
PARTS2233
9
Frame
Assembly
t2,0155:08PM
PARTS 2128

Chapter 10 Part 10 Install the fairings
10
INSTRUCTIONS
1. Place the front tab of part53 into the slot located on
part40.
STEP Note the location of the tab on part40.
Dead blow Hammer

or mallet 2. Using the mallet, tap part53 into the recess.
3. Secure part53 to the assembly usingscrews.
Use 7 screws.
Electric Driver
4. Repeat steps 1 through 3 on the opposite side using
part54.
5. Thread the green elastic cord, from the top through left
hole located in part16 of 2 .
Required hardware Note the part16
20 Spax Screw
1 #8, 1-1/2 L
PN 12519
6. Tie an overhand knot on the bottom side.
1 Green Elastic Cord 7. Thread the green elastic cord, from the top through right
3/16 OD, 18 L side hole located in part16 of 2 .
PN 12517 Note the location of part16.
16
Part 53
Fairing Left
PLYWOOD SHEET 4
8. Pull green elastic cord tight and tie overhand knot on
theunderside.
9. Align part55 to the front of 2 .
Part 54
Fairing Right Note the location of the orientation of part55.
PLYWOOD SHEET 4
2
t2,0155:08PM
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 thefairings; reverse woodenparts5355 (so the
10. Screw part55 to the assembly using 6screws.
unfinished side is facing outward and ready to receivepaint). For more Use 6 screws.
information on Visual reference of the plywood sheets, see page 61.
Total of 6 locations
FINISHED!! TIME TO RIDE!!

150718 PLYFLY rev A_EM |August7,20155:06PM
Master List
11
60
Visual reference of the plywood sheets Visual reference of the plywood sheets
Sheet 1 Sheet 3
41 40 43 42 38 49 3 39 22
50
35
23
36 13
9 37 4 34 7 8 1 10 6 20 24 26 27 25
47
Parts 1, 3-4 Parts 20

Parts 36-43 Parts 22-23 Parts 35
Parts 6-10 Parts 24 Parts 50
Parts 49 Parts 25-27 Part 47
Part 13 Parts 34
Sheet 2 Sheet 4
12 11 14 15 45 18 2 44 31
16 21
5 48 46 52 19 17 29 28 30
Parts 2, 5 Parts 20-21

Parts 28-33
Parts 11-12 Parts 44-46 Parts 52 Parts 53-55
Parts 51
Parts 14-18 Parts 48
Note If you received a 1/4 plywood sheet that is finished on one side and you
intend to paint the Plyfly gokart seat or fairings; reverse woodenparts2833 and
parts5355 (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 wooden parts List of the wooden parts
DESCRIPTION reference image DESCRIPTION reference image
Part 1 Part 9
Steering Spindle Outer Spacer Steering rack Bracket
PLYWOOD SHEET 1 PLYWOOD SHEET 1
Part 2 Part 10
Steering Spindle Outer Spacer Steering rack Bracket
Part 11
Steering rack
Part 3 PLYWOOD SHEET 2
PLYWOOD SHEET 1
Part 4 Part 12
Steering Spindle Inner Spacer Steering rack Center Bracket
Part 5 Part 13
Steering Spindle Bottom Left Steering column Left
Part 6 Part 14
Steering Spindle Bottom Right Steering column Right
Part 15
Part 7
Steering column Top
PLYWOOD SHEET 2
PLYWOOD SHEET 1 150718 PLYFLY rev A_EM |August7,20155:06PM
Part 8 Part 16
Steering Spindle Top Steering column Phone Mount
62 11 Master List
Part 17 Part 25
Steering column Bracket Seat Crossbar
Part 18 Part 26
Steering Pinion Mount Seat Crossbar
Part 19 Part 27
Steering column Shaft Seat Crossbar Bracket
Part 20 Part 28
Steering Pinion Seat Bolster Left
Part 21 Part 29
Steering Wheel Seat Bolster Right
Part 22 Part 30
Seat Side Left Seat Thigh Bolster Left
Part 23
Part 31
Seat Side Right
Seat Thigh Bolster Right
gas tank side
PLYWOOD SHEET 4
PLYWOOD SHEET 3
Part 24 Part 32
Seat Crossbar Seat Back

Part 41
Frame Rail Inner Right
Seat Bottom
PLYWOOD SHEET 4
Part 42
Frame Rail Outer Left
Brake Pedal
PLYWOOD SHEET 1
Part 43
Frame Rail Outer Right
Gas Pedal
PLYWOOD SHEET 3
Part 36 Part 44
Pedal Side Frontend Bottom
Part 37 Part 45
Pedal Side Frontend Top
Part 38 Part 46
Pedal Side Frame Rail Bracket
Part 39 Part 47
Pedal Side Sprocket Guard
PLYWOOD SHEET 1 PLYWOOD SHEET 3 150718 PLYFLY rev A_EM |August7,20155:06PM
Part 40
Frame Rail Inner Left
Frame Rail Rear
PLYWOOD SHEET 2
64 11 Master List
List of the wooden parts
DESCRIPTION reference image
Part 49
Frame Rail Engine Mount
PLYWOOD SHEET 1
Part 50
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
PLYWOOD SHEET 4

List of the wooden assemblies List of the wooden assemblies
1 6
Steering rack Brake Pedal
Assembly Assembly
Parts 9-12 Parts 35, 38-39
2 7
Fixed steering column Left Spindle
Assembly Assembly
Parts 13-18 Parts 1,3,5,7
3 8
Steering column Right Spindle
Assembly Assembly
Parts 19-21 Parts 2,4,6,8
4 9
Seat Frame
Assembly Assembly
Parts 22-33 Parts 21-28
5
Gas Pedal
Assembly
Parts 34, 36-37
Note If you received a 1/4 plywood sheet that is finished on one side and you
intend to paint the Plyfly gokart seat or fairings; reverse woodenparts2833 and
parts5355 (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.
66 11 Master List
List of the tools needed List of the tools needed
DESCRIPTION REFERENCE IMAGE DESCRIPTION REFERENCE IMAGE
Chisel Screwdriver
Allen Wrench
Hammer
or ratcheting allen wrench
Dead blow Hammer Metric Allen Wrench

or mallet included with mountedbearing
Sandpaper Socket Wrench
Orbital Sander
Wrench
(optional)
Jigsaw or
Needle Nose Pliers
Reciprocating Saw
(optional)
Electric Driver
Impact Driver
(optional)

List of loose contents 2.5 HP 4.0 HP 4.0 HP 4.0 HP 4.0 HP
KIT DESCRIPTION 10 WHEELS 10 WHEELS 12 WHEELS 10 WHEELS 12 WHEELS
12576 Clutch
#35 Chain, 11 Tooth Pulley for 5/8 D 1
2.5HPMODEL
12577 Clutch
#35 Chain, 12 Tooth Pulley for 3/4 D 1 1 1 1
4.0HPMODEL
12522 Sprocket
#35 Chain, 60 Tooth, 5/8 D bore 1 1 1 1 1
12524 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
12005
Clutch Guard Side 1 1 1 1 1
Part 57
12006 Clutch Guard Top 1 1 1 1 1
Top Cover
Part 58
12007 Clutch Guard Cover 1 1 1 1 1
Outside Cover
12525 Control Cable

1/16 D, throttle & brake control cable 2 2 2 2 2
12527 Red Throttle Cable
Brake conduit, 5 L 1 1 1 1 1
12528 Green Throttle Cable
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

12502 Long Hex Bolt

Grade 5, 5/8-11, 11 L 1 1 1
SINGLEWHEELKIT
12503 Short Hex Bolt

Grade 5, 5/8-11, 6.5 L 4 4 4 4 4
68 11 Master List
List of loose contents 2.5 HP 4.0 HP 4.0 HP 4.0 HP 4.0 HP
12507 Precision Rod

1/4 D, 18 L 1 1 1 1 1
12580 Drive Shaft
Steel, Keyed, 5/8 D, 18 L 1 1 1
SINGLE WHEEL KIT
12581 Drive Shaft

Steel, Keyed, 5/8 D, 33 L 1
LIVE AXLE KIT 10 WHEELS
12582 Drive Shaft

Steel, Keyed, 5/8 D, 36 L 1
LIVE AXLE KIT 12 WHEELS
12508 Drawer Slide

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
12590 10 D Wheels
Rear driven wheel 1 1 2
12591 10 D Wheels
Undriven wheel 3 3 2
12592 12 D Wheels
Rear driven wheel
1 2
12593 12 D Wheels
Undriven wheel
3 2
12535 Flatworks Flag
Plyfly safety flag 1 1 1 1 1

List of the packaged contents 2.5 HP 4.0 HP 4.0 HP 4.0 HP 4.0 HP
12504 LargeMetalBushing
Flanged, 3/4 OD, 5/8 ID 11 11 11 10 10
12505 Flat Washer
5/8 ID, 13/8 OD 4 4 4 4 4
12506 Lock Nut
5/8 ID 5 5 5 4 4
12509 Plastic Bushing
Flanged, 1/4 ID, 3/8 OD 4 4 4 4 4
12510 Small Tee Nut
Zinc Plated, 5/16-18 12 12 12 12 12
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
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
12520 Thin Nut
Grade 5, 5/16-24 4 4 4 4 4
12537 Throttle Cable Clamp 1 1 1 1 1

12538 Small Metal Bushing
Flanged 3/8 ID, 1/4 L 4 4 4 4 4
12539 Key
3/16 square, 1L 3 3 3 4 4
12540 Shaft Collar
5/8 ID 1 1 1 2 4
12542 T-Handle Pin
Quick Release Pin 1 1 1 1 1

5/16-18, 1.25 L 8 8 8 8 8
4.0HPMODEL

Black Oxide Alloy Steel, 3/8-16, 1.25 L 6 6 6 6 6
12545 Large Tee Nut
Zinc Plated, 3/8-16 6 6 6 6 6
70 11 Master List
List of the packaged contents 2.5 HP 4.0 HP 4.0 HP 4.0 HP 4.0 HP
12546 Nylon Spacer

3/4 OD, 3/8 ID, 11/4 L 1 1 1 1 1
1/2 OD, 1/4 ID, 7/8 L 1 1 1 1 1
12548 Long Aluminum Spacer
1/2 OD, 1/4 ID, 11/16 L 1 1 1 1 1
12549 Oversized Flat Washer
Zinc, M6 2 2 2 2 2
Black oxide, M6, 55mm L 2 2 2 2 2
12551 Sheetmetal Screw
Galvanized, #6 8 8 8 8 8
5/16-18, 3/4 L 2 2 2 2 2
12558 Zip Tie
10lb Nylon, White, 7/8 D, 4 L 6 6 6 6 6
Zinc Plated, Steel, 5/16-24, 1/2 L 4 4 4 4 4
12560 Extension Spring
Black-Oxide, Precision 1 1 1 1 1
12554 Hex Cap Screw
1/4-20, 1 L 1
2.5HPMODEL
12555 Fender washer

5/16 ID, 1-1/8 OD 1 1 1 1 1
12556 Lock washer
5/16 ID 1 1 1 1 1
12557 Clutch Key
3/16, 1/2 L 1 1 1 1 1
4.0HPMODEL
1 1 1 1
12562 Button Head Cap Screw

5/16-24, 3/4 L
1 1 1 1
12563 Set Screw
Clutch 2 2 2 2 2
12564 Pan head
M6, 12 mm L 1 1 1 1
4.0HPMODEL

150718 PLYFLY rev A_Legal August
| 5,201510:38PM
Legal
12
72
Legal
Assumption of Risk, Waiver and Release of Liabilities and Indemnity 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
Agreement
Released Parties, I, for myself and for anyone acting on my behalf, further
I, the undersigned, on behalf of myself, (and, if applicable, my minor agree to hold harmless, defend, and indemnify the Protected and Released
Parties from any such claims, suits, actions, liabilities, losses, damages,
child or ward listed below), as well as my spouse, heirs, estate, insurers
fees, costs or expenses.
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 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
operate (whether via a test drive prior to purchase or otherwise) the go discretion, to administer emergency first aid, CPR, and use an AED, and
kart equipment of The Flatworks, LLC, a Rhode Island Limited Liability to secure emergency medical care or transportation (i.e., EMS). I agree to
Company (hereinafter Flatworks), at its premises and facilities located assume all costs of such emergency medical care and transportation.
at 11 Waites Wharf, Newport, Rhode Island or at any other locale, and for 7. I acknowledge that this Agreement constitutes the entire agreement
other good and valuable consideration, do hereby covenant and agree as by and among me and the Protected and Released Parties pertaining
follows: to the subject matter hereof and supersedes all prior agreements and
understandings pertaining thereto, and agree that this Agreement may not
1. I fully understand and acknowledge that I, like all potential customers of be changed, modified or amended in whole or in part except in writing,
Flatworks and others desiring to test drive or otherwise use and operate signed by all of the parties hereto.
its go-kart equipment, as a condition of such use and operation, must first: 8. I agree that this Agreement and the rights of the parties hereunder shall
a) read, understand, and agree to this Assumption of Risk, Waiver and be interpreted in accordance with the laws of the State of Rhode Island,
Release of Liabilities and Indemnity Agreement (the Agreement); and b) as broadly and inclusively as permitted under such laws, and all rights and
read, understand, adhere to, and abide by the safety rules and instructions remedies shall be governed by such laws without regard to principles of
of Flatworks related to the use and operation of its go-kart equipment. conflict of laws. I further agree that if any portion of this Agreement is held
2. I fully understand and acknowledge that: a) using and operating a invalid, the balance shall, notwithstanding, continue in full legal force and
motorized go-kart is an inherently dangerous activity and that participation effect.
in this activity involves risks of damage to or loss of my property or the 9. I agree that if any disputes or controversies shall arise from this Agreement
property of others and risks of bodily injury to me or others, including or otherwise in connection with my use and operation of Flatworks go-kart
injuries such as bruises, lacerations, sprains, fractures and, in extreme equipment, my participation in any related activities, or my presence on
cases, disability, paralysis and death; b) such dangers and risks may be the premises and facilities of the Protected and Released Parties, I shall
caused, in whole or in part, by my own actions or inactions, the actions first engage in good faith efforts to mediate such dispute. Should the
or inactions of others, the condition of the go-kart equipment and the issue not be resolved by mediation, I further agree that all such disputes or
condition and the layout of the facilities on which they are used, and/or controversies shall be submitted to binding arbitration in accordance with
the negligence of others, including the Protected and Released Parties (as the Commercial Arbitration Rules of the American Arbitration Association
defined below); and c) there may be other dangers and risks associated then in effect.
with this activity which at this time are unknown or that are not readily
foreseeable by me or others. 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
3. I fully understand and acknowledge the demands of this inherently understand all of its terms and conditions. I understand that I am giving up
dangerous and risky activity relative to my personal knowledge, experience, substantial legal rights, including rights that I may otherwise have to sue for
skills, aptitude and abilities, as well as my current physical and medical damages in the event of my death, or injury or loss occasioned by my use
condition and level of fitness, and nevertheless knowingly and voluntarily of the go-kart equipment of Flatworks. I acknowledge that I am signing
accept and assume such dangers and risks, and further assume full this Agreement freely and voluntarily, and intend by my signature, that this
responsibility for any and all liabilities, losses or damages, including Agreement constitute a complete and unconditional waiver, release, and
any direct or consequential damages, resulting from or related to my discharge of the Protected and Released Parties from any and all manner of
participation in this activity, including, but not limited to: any and all damage claims, suits, actions, liabilities, losses, damages, fees, costs or expenses
to or loss of my property or the property of others; personal injuries to me arising from or related to the inherent risks of this activity, to the greatest
or others of any type, including disability and death; and any legal fees, extent allowed by laws of the State of Rhode Island.
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).
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
5,201510:38PM
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
150718 PLYFLY rev A_Legal August
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
150718 PLYFLY rev A_Terms & Conditions
P2
1
3
0
M
8
1
:5
A
5,ugust|
Terms &
Conditions
13
74
THE FLATWORKS, LLC
Terms & Conditions of Purchase and Use
THE FOLLOWING TERMS AND CONDITIONS APPLY TO ALL PRODUCTS 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
DESIGNED, MANUFACTURED AND SOLD BY THE FLATWORKS,
Flatworks for any liabilities, losses or damages, including any direct or
LLC. THESE TERMS AND CONDITIONS INCLUDE PROVISION WHICH consequential damages, resulting from or related to his or her use of the
ALLOCATE THE RISKS ASSOCIATED WITH THE USE OF THE PRODUCTS Products, including, but not limited to: any and all damage to or loss of my
AND LIMIT MY LEGAL RIGHTS TO RECOVER DAMAGES IN THE EVENT 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
OF INJURY OR LOSS OCCASIONED BY SUCH USE, INCLUDING
expenses related to such damages and/or injuries, expressly including, but
DISCLAIMERS, EXCULPATORY PROVISIONS (ASSUMPTIONS OF not limited to, those alleged to be caused, in whole or in part, by equipment
RISK AND RELEASES), WAIVERS, INDEMNIFICATION PROVISIONS, malfunction from whatever cause, or any other negligence or fault of
LIMITATIONS OF LIABILITY, LIMITED WARRANTIES, A COVENANT NOT Flatworks, User, for himself or herself, and for anyone acting on his or her
TO SUE, AN ABBREVIATED LIMITATIONS PERIOD FOR CLAIMS, AND AN behalf, further agree to hold harmless, defend, and indemnify Flatworks
from any such claims, suits, actions, liabilities, losses, damages, fees, costs
ARBITRATION PROVISION. or expenses.
1. Definitions. As used herein, the following terms shall have the following 6. Limited Replacement Warranty. Flatworks warrants to any Original
meanings: Purchaser that the Products shall to be free from defects in materials and
a) Flatworks, shall mean The Flatworks, LLC, a Rhode Island Limited workmanship for a period of one-hundred eighty (180) days from the date of
Liability Company and any and all of its affiliates, subsidiaries, associates, purchase, provided that they have not been subject to apparent accident,
owners, members, officers, agents, employees, and volunteers, and its alteration, abuse, neglect or misuse. Flatworks sole liability under this
successors and assigns. 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. THE ABOVE STATED LIMITED WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE WARRANTIES
c) Products shall mean all products and related accessories designed,
manufactured and sold by Flatworks. OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
FLATWORKS NEITHER ASSUMES OR AUTHORIZES ANY OTHER
d) User shall mean the purchaser and/or the end user of any Product.
PERSON OR ENTITY TO ASSUME FOR IT, ANY OTHER LIABILITY
2. Acknowledgement of High Risk Activity. Products sold by Flatworks IN CONNECTION WITH THE DESIGN, MANUFACTURE OR SALE OF
include motorized go-karts and related accessories. User hereby ITS PRODUCTS, WHETHER FROM ITS WEBSITES, CATALOGS OR
acknowledges that: a) using and operating a motorized go-kart is an
inherently dangerous activity and that participation in this activity involves OTHERWISE. THE LIMITED WARRANTY SHALL NOT APPLY TO ANY
risks of damage to or loss of my property or the property of others and PRODUCT WHICH HAS BEEN SUBJECT TO ACCIDENT, NEGLECT,
risks of bodily injury to himself, herself, or others, including injuries such ALTERATION, ABUSE OR MISUSE.
as bruises, lacerations, sprains, fractures and, in extreme cases, disability,
paralysis and death; b) such dangers and risks may be caused, in whole 7. General Disclaimers. All Original Purchasers, as a condition of purchase,
or in part, by Users own actions or inactions, the actions or inactions of agree to be bound by the following terms and conditions:
others, the condition of the go-kart equipment and the condition and the a) Inspection Prior to Use. All Products must be inspected upon delivery
layout of the facilities on which they are used, and/or the negligence of for use to ensure that they have not been damaged in shipment or
others; and c) there may be other dangers and risks associated with this otherwise. If any Product is damaged, such Product should not be
activity which at this time are unknown or that are not readily foreseeable by used and should be promptly returned to Flatworks for inspection,
User or others. replacement or repair, as the case may be.
3. Assumption of Risk. User fully understands and acknowledges the b) Use of Products. Prior to the use and operation of any Product, the
dangers and risks involved with the use of the Products relative to his or her Original Purchaser must read, understand, adhere to, and abide by
personal knowledge, experience, skills, aptitude and abilities, as well as his any instructions, manuals, directions and safety rules related to the
or her physical and medical condition and level of fitness, and nevertheless Product, including, without limitation, those related to the assembly, use,
knowingly and voluntarily accepts and assumes such dangers and risks, operation, and maintenance of the Product. Flatworks shall have no
and further assumes full responsibility for any and all liabilities, losses or responsibility whatsoever for the misuse or unauthorized and improper
damages, including any direct or consequential damages, resulting from or use of its Products.
related to his or her use of the Products, including, but not limited to: any
c) Duty to Inform Others and Indemnification. Prior to allowing others to
and all damage to or loss of his or her property or the property of others;
use any Product, the Original Purchaser must require that such person
personal injuries to User or others of any type, including disability and
(or his or her legal guardian, if a minor) reads, understands and agrees to
death; and any legal fees, costs or other expenses related to such damages
adhere to and abide by these Terms and Conditions and any instructions,
and/or injuries, expressly including, but not limited to, those alleged to
manuals, directions and safety rules related to the Product. The Original
be caused, in whole or in part, by equipment malfunction from whatever
Purchaser further agrees, for himself or herself, and for anyone acting
cause, or any other negligence or fault of Flatworks.
on his or her behalf, to hold harmless, defend, and indemnify Flatworks
4. Release and Waiver of Liability, Covenant Not to Sue. Other than the from any claims, suits, actions, liabilities, losses, damages, fees, costs or
liability assumed under the limited warranty set forth herein below, which expenses arising out of such persons use of any Product.
liability is confined to the repair or replacement of its Products under limited
circumstances, User hereby waives, releases, discharges and covenants 8. Applicable Law. These Terms and Conditions and the rights of all affected
M
150718 PLYFLY rev A_Terms & Conditions
P0
3
1
25,ugust|
A
:5
1
8
not to sue Flatworks from liability for any and all claims, suits, demands, parties hereunder shall be interpreted in accordance with the laws of the
liabilities, losses or damages arising from or relating to his or her use of the State of Rhode Island, as broadly and inclusively as permitted under such
Products. This waiver, release, discharge and covenant not to sue applies, laws, and all rights and remedies shall be governed by such laws without
but is not limited to, any and all liabilities, losses or damages, including any regard to principles of conflict of laws. If any portion of these Terms
direct or consequential damages, resulting from or related to the use of and Conditions shall be held invalid, the balance shall, notwithstanding,
the Products, including, but not limited to: any and all damage to or loss of continue in full legal force and effect.
his or her property or the property of others; personal injuries to the User
9. Resolution of Disputes. Any dispute, claim or controversy arising out of or
or others of any type, including disability and death; and any legal fees,
in connection with the purchase or use of the Products shall be resolved
costs or other expenses related to such damages and/or injuries, expressly
by means of binding arbitration held within the State of Rhode Island
including, but not limited to, those alleged to be caused, in whole or in part,
in accordance with the Commercial Arbitration Rules of the American
by equipment malfunction from whatever cause, or any other negligence or
Arbitration Association then in effect. Any demand for arbitration must
fault of Flatworks.
be commenced within one (1) year after the dispute, claim or controversy
arises.

Plyfly Instructions V 10

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Plyfly Instructions V 10

Uploaded by

Copyright:

Available Formats

HOW TO BUILD

For Ages 12+

the Flatworks Crew,

Assembling the steering column 20

Assembling the left & right steering spindles 24

2 1 Exploring the kit

Box 3 hardware & wheels

PlyFly GoKart Instruction Guide 2015 Release 3

150718 PLYFLY rev A_CH 1 August

4 1 Exploring the kit

Plyfly Packaged Hardware Kit Sealed kit of gokart hardware 1 1 1 1 1

Clutch #35 Chain, 12 Tooth Pulley for 3/4 shaft 4.0HPModel 1 1 1 1

Short Hex Bolt Grade 5, 5/8-11, 6.5 L 4 4 4 4 4

10 D Wheels Undriven wheel 3 3 2

12 D Wheels Rear driven wheel 1 2

12 D Wheels Undriven wheel 3 2

PlyFly GoKart Instruction Guide 2015 Release 5

150718 PLYFLY rev A_CH 2 August

Reciprocating saw method

For more information on Whats in the kit?, see page 3.

PlyFly GoKart Instruction Guide 2015 Release 7

150718 PLYFLY rev A_Seat August

Sheet 3 Parts 22-23

PlyFly GoKart Instruction Guide 2015 Release 9

Seat Crossbar Bracket

you intend to paint the Plyfly gokart seat; reversethewoodenparts2833

(sotheunfinishedsideis outward facing and

3. Secure part 27 using 2 screws.

4. Using amallet, tap parts24,25,&26 into the

12. Secure part 33 using screws.

5. Secure parts 24,25,&26 by usingscrews.

PlyFly GoKart Instruction Guide 2015 Release 11

150718 PLYFLY rev A_Steer columnA

4 Small Metal Bushing

Required wooden parts

PlyFly GoKart Instruction Guide 2015 Release 13

2. Hammer securely until the top of eachbushingisflush.

8. Secure the parts usingscrews.

14 4 Steering Column Assembly

150718 PLYFLY rev A_Steer rackA

16 5 Steering Rack Assembly

2. Secure parts9& 10 usingscrews.

4. Secure part12 to the assembly using screws.

PlyFly GoKart Instruction Guide 2015 Release 17

150718 PLYFLY rev A_Steer fixedA

PlyFly GoKart Instruction Guide 2015 Release 19

Note the orientation of part 18.

4. Align part14 to the assembly so that the partmirrors

Steering Pinion Mount

20 6 Fixed SteeringColumn Assembly

2 Short Hex Bolt

2 Small Tee Nut

Steering Spindle Top

PlyFly GoKart Instruction Guide 2015 Release 23

Note the location of the bushings.

2. Using ahammer, tap thebushings until the top isflush

150718 PLYFLY rev A_Pedal |August7,20155:06PM

5. Secure parts35,38&39 using screws.

PlyFly GoKart Instruction Guide 2015 Release 27

150718 PLYFLY rev A_Frame |August7,20155:06PM

Sheet 1 Parts 40-43 Sheet 4 Part 47

Parts 44-46 Part 51

PlyFly GoKart Instruction Guide 2015 Release 29

HOW TO BUILD

Assembling the steering column 20

Assembling the left & right steering spindles 24

For more information on Whats in the kit?, see page 3.

150718 PLYFLY rev A_Pedal |August7,20155:06PM

150718 PLYFLY rev A_Frame |August7,20155:06PM

150718 PLYFLY rev A_Frame |August7,20155:06PM

ote There are 2 types of buttonsocketheadcapscrews