Assembly Instructions for the ODES 800cc Sand Rail.

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Assembly Instructions for the ODES 800cc Sand Rail.
Assembly Instructions for the ODES 800cc Sand Rail. When you first get your Sand Rail it will look like the above picture. You will have the main crate as well as a secondary box that contains more parts needed to build your go kart. The next step is to remove all of the lower crate bolts that hold the top of the crate frame to the bottom. There should be 8 total bolts as well as 4 bolts on the top that the radiator mounts to. The above picture shows removing the radiator from the top of the frame crate. Then remove the top of the crate and your sand rail will look like the above picture. You need to remove everything out of the crate at this point and lay out so you know where everything is for the assembly process. Now that you have removed everything from the inside of the crate your sand rail will look like the above picture. The next step will be to lift up the go kart and remove the bottom frame. Preferably with a forklift. To remove the sand rail from the crate you will need to remove the 4 straps on the front and back that are holding the sand rail frame to the bottom of the crate. You will then locate the steering wheel and slide the end of the steering rod into the rod connector already attached on the utv and then screw in the holding screw at the base of the steering rod you just connected. You will need to remove this screw first before attaching the drive rods. Then attach the top of the steering column to the frame column support slider and position the steering wheel in the position that you want it to be in. Your steering wheel should now look like the above picture. You will then attach the top roll cage. Take out the existing bolts in the frame and then set the top of the roll cage into the connecting spots and put the bolts back though. You will also have two side connecting rods to attach as well to the bottom of the frame as well as to the top of the roll cage. The picture shows above the top roll cage mounting onto the main frame. You want to grab your longer bolts for this section as well as the half moon spacers, put a space on each side of the frame bar and the put your bolt through and attach your locking nut. The next step will be to attach the radiator to the back of the frame, it will go in the position as you see above. Next you will attach the roof with 4 different bolts. This requires to grab the silver 1/3 inch spacer and place it in between the bottom of the roof and the roof mounting tabs attached to the roll cage. You will have 4 bolts for this. You will attach the window next. The bottom black tab is already installed on the hood, simply slide in the window under the black slit. To secure the top of the window you will need to do a couple of things. First grab the inset spacer and place it inside the rubber inside the window. Then place the led light through the spacer, through the window and through the mounting tab and then secure the nut to the bottom of the led bolt to secure all 3 pieces. The window will now look like the above picture. You will then attach the gas tank to the back of the frame on the 4 mounting tabs. Grab 4 bolts with locking nuts and secure the gas can down in the position shown above. You will have a gas line on the gas tank to attach to the fuel filter attached to the bottom of the gas tank and another gas line attached to the motor you will put onto the other side of the fuel filter. The radiator hose will also attach to the overflow tank as well. Connect the fuel pump connector to the fuel line harness connector by the motor. The next step will be to attach the fin section. To do this grab the round top screws and attach the right and left side fin first. Then use the rubber and attach it in between the rear fin and the bottom rear fender that the lights are attached to. Then you will bolt the two fenders together. The rubber is used to cut down on any vibrations. This is how the tail section will look when it is done. Next you will attach the front hubs and spindles. So use the existing bolts already in place on the a-­‐arms and spindle to attach the two. The passenger side will look like the above picture when completed. Next you will install the rear swing arms, the above picture shows the left side when attached. Attach the shock also to the bottom of the swingarm and then place the cv joint through the swingarm and into the drive shaft. Your CV joints are labeled as to right left, front rear, once those are in you are going to attach you spindle, hub and brake the same way as you did on the front of the unit. Above you will see a cable. This is for your emergency brake. Attach this cable and adjust accordingly. Then mount your tires and test to make sure your brakes are working and stopping the sand rail from moving forward or backwards. Once adjusted, move to the next step. Next you will install the seats. Place them over the mounting holes and the attach the locking nuts to the bottom of the seat bolts which will be through the mounting tabs on the bottom of the frame. You will then attach the harness but first pull the harness through the seat. The left and right bottom side of the harness will mount in between where the bottom rear seat bolts and frame are. Your seats will then look like the above picture when installed. At this point you are done with the installation. Check all your bolts and fill your sand rail up with gas and go out for a test ride. Make sure you break you motor in accordingly. Half throttle for the first 15 miles and then you are good to romp and tear up the trails all you want. If you have any tech questions please contact your support rep at 866-­‐572-­‐8420 and ask to speak with our techs.