Explorer 150 Visual Assembly Guide
OK, Let's get started!
First, we have to unpack your buggy from its crate.

Your buggy will arrive like this.

Remove front & rear J-bolts & U-bolts with a 17mm wrench.

Roll the buggy out the back of the shipping crate.

Remove all of the zip ties that hold the contents in. Then remove all of the contents slowly and place them in a place where they will not be in the way or get scratched.

CONTENTS:

  • 1 buggy
  • 2 seats
  • 1 rear rack
  • 2 large rollcage side rails with blinkers and mirrors attached
  • 2 small rollcage side rails
  • 1 rollcage top H-bar
  • 1 box containing:
    • 1 bag of bolts
    • 1 bag of plastic end caps for rails
    • 1 tool kit
    • 1 steering wheel
    • 1 owner's manual
    • 1 extra fuel valve
    • 1 breather hose for the gas cap
Install the seats first.

Install seats first. Turn seat upside down and slide the rails all the way toward the back of the seat.

Place the seat in the buggy and make sure the front tabs hook onto the front of the rails.

Find the silver-colored bolts & the gold nuts

Insert the silver bolt downward into the hole.

Screw on the nut.

Tighten bolt & nut with a 12mm and 13mm wrench.
GREAT JOB! Now let's install the luggage rack & gas tank.

Now find the 2 small gold-colored bolts & nuts.

Get the rear rack, place it on the rear of the buggy, & have some one hold it.

Find the rear rack brackets & raise them up to the rack holes so both holes align.

Put a bolt in & hand-tighten it.

NOTE: Do not tighten bolts at this point.

Lower the rack backwards to a vertical position (straight up & down).

Place something in the middle of the rack so you do not scratch the rack on the large bolt sticking up (chain tensioner bolt).

Remove fuel lines noting which line goes where.

Find fuel nipple on the side of the carburator & remove the clear plastic cap from nipple and install the larger of the 2 black hoses.

Find black vacuum "T" and install the smaller black hose.

Now take the rear rack assembly & place it back into its correct position.

Find black plastic caps & insert on the end of rack bars

Find longer gold colored bolts with the funny-looking washers.

Install bolt through the hole lifting the rear rack up a little bit to align the bolt with the hole in the rack bar. Be careful not to over tighten!

Don't forget to tighten the bolts on the rack brackets!
YOU'RE DOING GREAT! LOOKS AWESOME!
Let's install the rollcage next.

Now locate the left side roll bar. This is the longest bar with the mirror and blinker attached to it.

Find the large black plastic cap & unscrew the bolt out of the end of the roll bar. Then place the cap on the end of the bar. Have someone hold the other end while you install the front of the bar the same way you did the rack.

Repeat this procedure for the rear. Then repeat the same procedure for the right side of the buggy.

Locate the top bar that looks like an "H". The bend goes to the rear.

Install bolts & caps as done previously on left & right roll bars & rear rack.

Locate left & right side small roll bars and install like you did the others.
GREAT! Now install the steering wheel.

Now install the steering wheel. Make sure the wheels are straight & attach the steering wheel with the small silver-colored screws provided.
YES!!! A COUPLE MORE THINGS LEFT!

Now locate all of your connectors & plug them in. Two up front and three in the rear.

Find the fuel valve & re-connect the fuel and vacuum lines. The fuel line is the bigger of the 2 and goes onto the nipple closest to the tank. Put fuel in the tank, then remove the smaller line at the black tee. Pull it out & suck on it for 30 seconds. NOTE: Make sure the line you are sucking on is the bottom line on the valve!

Finally, even though your Explorer buggy is shipped from the factory with oil in the crankcase, double-check your engine for proper oil level using the dipstick on the engine oil filler plug.

Also go through all the nuts and bolts and ensure that they are tight. Sometimes they come loose during the trip from China.

WARNING:Running the engine without the crankcase being properly filled voids your warranty!
Congradulations!!!
You're finished. Ride to your hearts content.
DRIVE SAFE!!
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The first one is to check out our tech support menu in the main menu above. There you will find our unique visual assembly guides that portray with detailed photographs (and, as time permits, web video) detailing the step-by-step process of taking a buggy out of the crate and making it ready to drive. As of this time, we have assembly guides for several buggies, as well as one showing how to install our high-performance GY6 intake and exhaust system kit on a Magnum 150 buggy.

The second one is to call us and one of our technicians will be happy to assist you with your problem. Beware of buggy dealers who claim that they have "certified technicians" because, when it comes to these types of vehicles, no such certifications exist! Our technical folks who take your calls get their hands dirty working on these machines daily and know them inside and out, so you can be confident that you can and will get the assistance you need.

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Why go to all this trouble? So that when you buy one of our buggies, you know you are getting a proven vehicle that you can count on for years of reliable service and enjoyment.

If, after checking out our information here at AwesomeBuggy.com, you are still unsure or confused as to which buggy to buy and are needing some more input so that you can make a better-informed decision, we recommend the gang over at the BuggyNews.com forum. BuggyNews.com is a non-commercial (meaning they have nothing to sell and therefore can be counted on to give you the straight skinny with no axes to grind or ulterior motives). They are a great source of recommendations on various buggies and buggy dealers as well as a fund of general information on all things "buggy."