Step 1: Install the Lower and Upper Bumper Support Bars
- Take the lower bumper support bar and insert it into the frame tubes, pushing it a couple of inches in so it won’t easily fall out during the next steps.
- 1.1: Add the upper bumper support bar by holding each side up to the frame tabs near the spindle C’s.
- 1.2: Install the bolts to fully secure the upper bumper support to the frame tabs.
Step 2: Attach and Align the Plastic Support Clamp
- Take the plastic clamp, split it, and attach it over both the upper and lower bumper supports.
- 2.1: Orient the clamp so the elongated hole is at the bottom and the smaller round hole is on the top support.
- 2.2: Check the alignment of the upper and lower support bars using the clamp as a guide. From a side view, ensure the clamp runs straight up and down, not angled inward or outward.
- 2.3: Once aligned, use a sharpie to mark the hole locations on the lower bumper bar, visible through the frame hole, for drilling reference.
Step 3: Drill and Secure the Lower Support Bar
- Drill holes into the lower support bar using a ¼” (6mm) drill bit on each side, based on your marked positions.
- 3.1: After drilling one side, insert a bolt through the hole to hold the bar in place while drilling the other side, preventing accidental movement.
- 3.2: Install the hardware: Insert the bolt downward through the frame hole (head sitting slightly inside the hole) and secure with a nylock nut on the bottom.
- 3.3: Repeat for the opposite side to fully secure the lower support bar.
Assembling and Installing Front Bumper
Step 4: Assemble the Front Bumper Mounts
- Take the two black drop-down bumper mounts and their hardware from the bag. Hold each mount up to the molded bumper nut serts on the back face of the bumper, using the middle hole as the standard setting.
- 4.1: Partially screw in all eight bolts (four per mount) before fully tightening any, to avoid difficulty aligning the remaining screws.
- 4.2: Once all bolts are started, fully tighten them to secure both mounts to the bumper.
Step 5: Install the Front Bumper onto the Kart
- Lift the upper bumper support to give the black mounts room to set onto the metal bars.
- 5.1: Position the mounts onto the bars, then apply downward pressure on the upper support while pulling the plastic bumper backward to set it into place.
- Pro Tip: If the bumper is pushed all the way in, it will be loose and drag the ground as a safety feature to deter hitting competitors on the track. If it loosens during a race, expect a placement penalty off-track.
Step 6: Secure the Bumper with Hook Clamps
- Take the metal hook clamp set and place it onto the top bar, allowing the bottom to rest underneath the lower bar.
- 6.1: Raise the lever latch on the clamp to expand it, then position the hooks above and below the bars.
- 6.2: Push down the lever to secure the nose hook clamps.
- Pro Tip: If there’s little resistance when pressing the lever, remove the clamp, adjust the tension nut on the bottom to tighten it to your preference (tight enough to stay secure but not so tight that it requires a screwdriver to release), then reattach.
