Trailmaster Challenger 300 cable.
- 75" Overall Length
- 1/4" Barrel End
- 3/8" Disc End
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I was asked by a friend who had just purchase a new Trailmaster 300 to help get it started. Brand new and won’t start…. hmmm. He figured as a professional race engineer I would be the logical candidate. That part of the puzzle wasn’t so bad. Coil connectors had protective coating that inhibited contact…mind you it was “clear coated" so you couldn’t see it. The plug wire coming out of the coil also had a bad connection. Ok, now it starts and runs with a bit of prompting. Seems to have a fueling issue as well… yep, the “gravity” feed line is running uphill and is pinched at the tank. Ooops… the throttle cable mount and position sleeve is broken at the carburetor too. This is causing inconsistent throttle application. Looking at the other end of the cable at the throttle pedal, I am amazed at the throttle stop piece of work… A bent bolt through a welded washer. WOW! Oh and the throttle connection to the pedal was a "coat hanger size" piece of bend rod that was holding its weld by a thread. All in all, with this setup… if the “throttle position” bent bolt mechanism gets loose and turns a little, the throttle could very easily stick WIDE OPEN…. Also discovered along the way that the hose clamp holding the carb to the intake was stripped and wouldn’t tighten causing a significant air leak. This was just a cheap component that was replaced with a proper hose clamp.
Now it starts and runs great! I also re-engineered and the entire throttle stop system and cable system. Fabricated new components, made it simple to adjust and took out the “full throttle stuck” piece out of the puzzle. Pretty cool actually.
Last piece was the exhaust outlet pointed directly at the frame on the rear of the kart. Simple adjustment?? Not really, the pipe was over bent in production and with the pickup points for the exhaust, that was how it fit. I removed the pipe, and with be help of a hydraulic tube bender, reformed the exhaust to exit between two frame tubes with a clear shot out the back of the kart.
The guys at GoPowerSports are great… the Trailmaster 300 needs some re-design at the factory and a bit more quality control up front. 5 stars for the guys at GoPowerSports but a 1 star for the product itself.