Your buggy will arrive like this.

First, remove the shipping bands and cardboard box from the crate.

Now that you know which side is the top, use a hoist, forklift, or a bunch of friends to carefully tip the crate and slowly lower it top-side-up to the ground.

WARNING: The Titan II buggy weighs 600+ pounds and, for safety reasons, this task should not be performed solo, even with a hoist.

Your buggy in its crate should now look like this.

Carefully cut the shipping bands and remove them

Remove the bolts from the bottom of the crate supports all the way around the crate.

Leave the top bolts in place so the supports can be lifted free along with the upper crate frame as one piece.

Remove the top and bottom bolts holding the rear-axle braces to the crate and the buggy's chassis on each side.

Remove the bolts holding the rear axle braces to the rear axles

Using the 8mm Allen-wrench provided in your buggy's tool bag, remove the Allen-head cap bolt holding the front brace of the crate to the buggy chassis.

NOTE: SAVE THESE BOLTS!!! You will need them to attach the rollcage later on.

Lift the crate top and vertical supports assembly free of the buggy and set it down somewhere out of the way.

NOTE: This step requires 2-3 people.

Remove and unwrap the contents of the buggy's interior, then set them aside in a place where they will not be in the way or get scratched.

Unstrap and remove the battery box. Set it and the hold-down strap aside with the other parts you've just removed.

NOTE: Do NOT lose the hold-down strap!

Unbolt the 4 anchors that hold the chassis to the crate.

CONTENTS:

• 1 buggy
• 2 Allen-head cap bolts you removed from the front crate-to-chassis brace
• 2 seats with seatbelts/shoulder harnesses attached
• 2 front wheel/tire aseemblies
• 2 rear wheel/tire/hub assemblies
• 2 rollcage side rails
• 2 rollcage crossbars with bolts and tube adaptors in each end
• 1 steering wheel with bolts & acorn nuts attached
• 1 cardboard box containing the battery kit
• 1 battery hold-down strap
• 1 tool kit in a bag
• 1 owner's manual

Unwrap the rear shock absorber.

Remove the pivot bolt in the free end of the shock.

Line up the free end of the shock with its mount on the frame, insert the bolt, thread on the nut and tighten.

Repeat this process on the other side.

Loosen and remove the front upper shock absorber pivot bolt

Align the upper end of the shock with it's mount on the chassis.

Insert the pivot bolt, thread the nut onto bolt, then tighten.

If you are having a hard time aligning the holes in order to insert the bolt, click here for additional instructions

Jack up one side of the buggy. An alternative to a jack is that 1 or 2 men with strong backs can lift one side of the buggy while another person can insert a jackstand or 2 (or a milk crate) under the buggy to hold it up.

Next, remove the 4 lugnuts & 8 washers from a front hub.

NOTE: Don't lose these!!!

Some Titans ship with uni-directional tires, others with bi-directional tires.

• Uni-directional tires have a chevron-style tread reminiscent of the rear tires on a farm tractor.
• Bi-directional tires have a tread that more closely resembles knobby tires for dirt motorcycles.

The tire shown at left has a bi-directional tread pattern.

If the tires for your Titan II are uni-directional, there is a correct side where they must be attached. Find the arrow on the tire sidewall. The arrow MUST point towards the front of the buggy.

Select the correct tire for the side you are working on.

If your tires are bi-directional, then you must determine whether the ground you will be traveling over most of the time will be soft sand or a harder surface, like packed dirt.

If you're going to drive most of the time on soft sand, then the arrow labeled, "soft" should point towards the front of the buggy. Otherwise, the "hard" arrow should point to the front.

Place the front wheel you have selected into the wheel lugs on the hub.

The washers on the front lugs need to be installed in a certain order as shown at left. The flat washer goes on first, then the lock washer, then screw on the lug nut. Repeat this with the other 3 lugs.

Cross-tighten the lugnuts.

Remove the cotter pin and castellated nut from the rear axle.

NOTE: Don't lose these, either!

Using the arrow in the tire sidewall, select the correct rear hub/wheel/tire assembly for the side you are working on.

Start the wheel hub onto the axle, then rotate the wheel to align the hub with the splines on the axle.

Slip the hub the rest of the way onto the axle.

Thread on the castellated nut, and tighten it, aligning the slots with the holes in the axle.

Insert the cotter pin through the slots and axle hole, then spread and bend the pin so it won't fall out.

Remove the jackstand(s) or milk crate and allow the buggy to rest on its wheels.

Now jack up the other side and repeat the process.

Remove the cotter pin and castellated nut from one of the tie-rod ends.

Align the stud on the tie-rod end with the attachment point on the steering spindle and insert it into the hole.

Thread on the castellated nut and tighten it, aligning the slots with the holes in the stud, then insert the cotter pin and spread/bend it to keep it from falling out.

This is what is enclosed in the battery box you removed earlier.

• Empty motorcycle battery
• Container of battery acid with filler tube
• Battery cells caps (the long plastic strip)
• Rubber battery cushion
• Battery cover

Follow the enclosed directions to fill the battery with the battery acid.

Once that's done, place the rubber battery cushion in the battery tray. Sometimes the factory sends one that is too big for the tray. If this happens, cut the pad down to fit.

Carefully place the battery on the cushion in the tray.

Connect the battery cables to the battery using the terminal screws provided in the battery kit.

• The RED wire connects to the POSITIVE (+) terminal,
• The BLACK wire goes to the NEGATIVE (–) one.

NOTE: Do NOT reverse these connections, or you will burn up the electrical system and void your warranty.

Cap the battery with its cover.

Strap the battery into the tray using the hold-down strap.

Select either seat and remove the gold-colored nuts from its mounting bolts.

Before proceeding, tighten the silver-color nuts (see upper left of photo).

NOTE: Do NOT remove the silver-color nuts!

Place the seat in the buggy and use the seat adjustment rails to align the mounting bolts with the mounting tabs.

Thread the mounting nuts onto the bolts and tighten them.

Bolt each shoulder harness V-connector to its attachment point behind the seat.

Here is what your buggy should look like at this point.

Remove the acorn nuts from the steering sheel mounting screws. Line up the screws with the holes in the steering wheel mount.

NOTE: Ensure that your front wheels are aimed straight ahead before attaching the steering wheel

Thread the acorn nuts onto the steering wheel mounting screws and tighten them.

Here's what it looks like in place.

Use the enclosed 8mm Allen wrench to remove the rollcage mounting bolts and adaptors from the front and rear mounts

Select one of the long rollcage bars. To determine which side is which, the second mounting point towards the front should be towards the outside of buggy.

Insert the front of the bar into the front mount first, then insert the rear of the bar into the rear mount.

NOTE: Sometimes it takes a bit of jockeying the bar around to get it onto the mounts.

Insert the screws and thread the adaptor nuts onto them, but do not tighten at this time.

Insert the 8mm Allen-head cap bolts that you removed from the front crate support (remember them?) into the side bracket holes and start them into the threads on the frame. Again, do not tighten them all the way at this time.

NOTE: Sometimes it takes a bit of jockeying the bar around to get the holes to line up.

Insert the bolt into the rear rollcage bar, thread on the matching nut. As with the first 2 mounting points, do not tighten these yet either.

Take the the two rollcage crossbars and remove the end bolts and tubing adaptors using the 8mm Allen wrench from the tool kit.

Place the longer of the two between the holes at the rear of the rollcage.

Line up the holes, then insert the rollcage bolt and adaptor through the roll cage and thread it into the end of the crossbar.

Repeat this process for the other end of the rear crossbar, and then do the same thing with the short crossbar using holes at the front of the rollcage

Your Titan ships from the factory with NO coolant in the cooling system. If anything, it is shipped with water only. BEFORE operating your buggy, you MUST:

1. Go buy a bottle of automotive antifreeze from your local auto parts or department store.
2. Remove the radiator cap from the radiator.
3. Disconnect the lower radiator hose from the radiator and allow the water to drain from both the hose and radiator.
4. Re-attach the lower radiator hose to radiator.
5. Fill the cooling system with the same ratio of antifreeze to water that you would use in your full-size automobile. This ratio will vary according to the region/climate in which you live.
6. Now bleed the air from the cooling system. Do this by:

1. Leave the cap OFF the radiator
2. Start the engine
3. After the engine warms and the thermostat opens, an air bubble will surface in the radiator and the coolant level will go down.
4. Top off the cooling system so that the coolant level is at the bottom of the radiator filler neck.
5. Replace the radiator cap on the radiator.
6. Now fill the coolant overflow tank about 1/4 full with coolant.

WARNING: Running the engine without the cooling system being properly filled voids your warranty!

Finally, even though your Titan 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!

The final step is installing the Titan's sunshade. Lay out the sumshade over the rollcage with the Velcro fasteners facing down. If things aren't lined up properly with the rollcage crossbars, you have the sunshade backwards. Starting with the front rollcage crossbar and workign towards the back of the buggy, fasten the Velcro fasteners around the rollcage bars.

When you are done, your sunshade should look like this.

Your Titan is now completely assembled and ready to run. Put some gas in the tank and fire that puppy up!