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Joyner Dirt Devil 250 2004 Owner's Manual And Parts Manual

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  • Page 3 CONTENTS...
  • Page 4 Beginners should drive this Go-Kart in a large open area to practice handle of this Go-Kart. Protective gear should be worn at all time when driving or riding in this Go-Kart. We hope you will have a pleasant experience with our products and thanks again for choosing Joyner.
  • Page 5 A FEW WORDS ABOUT SAFETY In order to keep everyone safe, you must lake responsibility for the safe operation of your Go- Kart. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.
  • Page 6 IMPORTANT SAFETY INFORMATION Your Go-Kart will provide you with many years of service and pleasure, providing you take responsibility for your own safety and understand the challenges you can meet while driving. There is much that you can do to protect yourself when you drive. You’ll find many helpful recommendations throughout this manual.
  • Page 7 IMPORTANT SAFETY INFORMATION Drive within Your Limits Pushing limits is another major cause of Go-Kart accidents. Never drive beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, fatigue, and inattention can significantly reduce your ability to make good judgments and driver safely. Don't Drink and drive Alcohol and driving don’t mix.
  • Page 8 SAFETYLABELS This section presents some of the most important information and recommendations to help you drive your Go-Kart safely. Please a few moments to read these pages. The labels be considered permanent pans of the Go-Kart. If a label comes off or becomes hard to read, contact your dealer for warning labels replacements.
  • Page 9 ARE YOU READY TO DRIVE Before each drive, you need to make sure you and your Go-Kart are both ready to drive. To help get you prepared, this section discusses how to evaluate your driving readiness, what items you should check on your Go-Kart, and adjustments to make for your comfort, convenience, or safety.
  • Page 10 ARE YOU READY TO DRIVE Additional Driving Gear In addition to a helmet and eye protection, we also recommend: ■ Sturdy off-road motorcycle boots to help protect your feet, ankles, and lower legs. ■ Off-road motorcycle gloves to help protect your hands. ■...
  • Page 11 ARE YOU READY TO DRIVE / IS YOUR VEHICLE READY TO DRIVE No Alcohol or Drugs Alcohol, drugs and Go-Karts don’t mix. Even a small amount of alcohol can impair your ability to operate a Go-Kart safely. Likewise, drugs - even if prescribed by a physician - can be dangerous while operating a Go-Kart.
  • Page 12 IS YOUR VEHICLE READY TO DRIVE ■ Pre-drive Inspection ■ Underbody & Exhaust System Check for and remove any dirt, vegetation or other debris that could be fire hazard or interfere with the proper operation of the Go-Kart. ■ Air Cleaner Housing Drain Tube Check for deposits in the drain tube.
  • Page 13 SAFE DRIVING PRECAUTIONS Off-Road Use Only You Go-Kart and its tires are designed and manufactured for off-road use only, not for pavement. Driving on pavement can affect handling and control. You should not drive your Go-Kart on pavement. When driving ofT-road, also remember to always obey local ofT-road driving laws and regulations. Obtain permission to drive on private property.
  • Page 14 SAFE DRIVING PRECAUTIONS Control Speed Driving at excessive speed increases the chance of an accident. In choosing a proper speed, you need to consider the capability of your Go-Kart, the terrain, visibility and other operating conditions, plus your own skills and experience. Use Care on Unfamiliar or Rough Terrain Before driving in a new area, always check the terrain thoroughly.
  • Page 15 SPECIFICATIONS DIMENSIONS Overall Length ………………………………………………………………………………………………. 102in. {2600mm) Overall Width …………………………………………………………………………………………………. 63in. (1600mro) Overall Height ………………………………………………………………………………………………… 65in. (1650mm) Wheelbase- …………………………………………………………………………………………………… 77in. (1950mm) Front Track …………………………………………………………………………………………………… 52in. (1330mm) Rear Thick ……………………………………………………………………………………………………. 53in. (1350mm) Ground Clearance …………………………………………………………………………………………… 5.2in. (130mm) ENGINE Type …………………………………………………………………………………………………………Liquid-cooled. 4- Slroke Bore x Stroke …………………………………………………………………………………………………...
  • Page 16 OPERATION Operation controls WARNING - Do not attempts to start or operate the engine until completely familiar with the location and use of each control necessary to operate this vehicle. The operator must know how to stop this machine before starting and driving it. a.
  • Page 17 d. Engine stop button Important - stop button test. Before driving this vehicle, test the Engine Stop Button to assure that it is operating properly. With the engine running, push and hold the Engine Stop Button for two seconds for the engine to shut down. B.
  • Page 18 OPERATION Component locations Figure 3...
  • Page 19 OPERATION Passengers The vehicle allows for two riders only. Combine maximum weight of driver and the passenger should not exceed 180kg or 400Ibs. Seat Adjustment The seat must always be securely fastened in the position which best affords the operator control of the foot pedals, steering wheel, and the remote stop button.
  • Page 20 OPERATION reverse gear box. Make sure the shift lever can be on the three positions (F, N, R) cleanly. Then tighten the nuts 1, 2. F. Parking Adjustment Press down the reverse lever to the ”F” position so that the unit can move forward, pull back the lever to “P”...
  • Page 21 OPERATION/SERVICE INSTRUCTIONS G. Starting And Operating Instructions Before starting the engine, be sure that the driver is sealed properly in the Go-Kart and tighten the seatbelt. Testing the Go-Kart in a open place at the beginning to learn how to start, turn and stop. Operate the Go-Kart slowly until you are familiar with it.
  • Page 22 SERVICE INSTRUCTIONS B. Engine Lubrication You must change the oil in the crankcase after the first 5 hours of operating of your new engine (See Fig. 9) and after 10 hours of use thereafter. This will insure proper lubrication of internal parts and prevent costly repairs due to excessive wear.
  • Page 23 SERVICE INSTRUCTIONS D. Spark Plug Remove the spark plug and inspect it each time you change the oil. (Use a spark plug wrench) The electrodes should be kept clean and free of carbon. The presence of carbon or excess oil will greatly reduce proper engine performance. If possible, check the spark plug gap (area between electrodes) using a wire feeler gauge.
  • Page 24 SERVICE INSTRUCTIONS Chain Lubrication To increase chain life, it should be lubricated with a spray on type chain lubricant. Chain Adjustment (See Check the chain adjustment after first two hours of use. Readjust if it has more than 1/2” flex. Figure 12) Loosen 12 Bolts Insert the special tools into the holes.
  • Page 25 REPAIR A. Front Wheel Replacement Do not disassemble the castle nuts when you replace the front wheels. It is only necessary to tighten the nuts so that the wheel turns freely on the axle with minimum end play . (See Fig. 13) Tighten the nuts after replacing the wheels. Figure 13 B.
  • Page 26 PERIODICAL CHECK AND SERVICES The maintenance intervals in the following table are based upon average driving conditions. Driving in unusually dusty areas, require more frequent servicing. Monthly Quarterly Yearly Time of service Initial service Item (first week) Tire pressure/wear Brake performance Tightness of screws Air cleaner Carburetor...
  • Page 27 WIRING DIAGRAM...

  • Page 28: Table Of Contents

    CONTENTS ENGINE Page 1. Cover comp, cylinder head ………………………………………… 28 2. Head comp, cylinder ………………………………………………… 29 3. Cylinder comp ………………………………………………………… 31 4. Crankcase comp …………………………………………………….. 32 5. Cover comp, R.crankcase ………………………………………….. 34 6. Cover comp, L.crankcase ………………………………………….. 35 7. Piston ………………………………………………………………… 36 8.

  • Page 29: Cover Comp, Cylinder Head

    ENGLISH SZ01001002 Fuel pipe grommet SZ01002003 Hanger, oil pipe SZ01003004 Rubber cushion SZ01004005 Bolt, M8x25/ Φ1.5 SZ01005006 Pin, dowel SZ01006007 Cover, cylinder head SZ01007008 SZ01008009 Plug M14x1.6 A06010007 O-ring 13x28 SZ01010002 O-ring 9.4x2.4 SZ01011003 Gasket, cylinder head SZ01012004 Washer SZ01013005 Bolt, M8x25/ Φ2.5 SZ01014006 Washer 12...

  • Page 30: Head Comp, Cylinder

    2. Head comp, cylinder ENGLISH O’ ty SZ02006008 Cotter, valve SZ02005007 Retainer, valve spring SZ02004006 Spring, valve inner SZ02003005 Spring, valve outer SZ02060008 Seal, valve stem SZ02001003 Washer, valve spring SZ02042008 Guide, valve 440602521 Bolt M6x25 SZ02013006 Nut M8 SZ02012005 Washer 8 440601221 Bolt M6x12...
  • Page 31 2. Head comp, cylinder ENGLISH Q' ty SZ02002004 Valve, in SZ02011004 Gasket, cylinder head SZ01005006 Pin, dowel 243002650 O-ring 30x2.65 SZ02018001 Insulator washer, carburetor SZ02016009 O-ring 14.8x1.9 SZ02020004 Insulator comp SZ02030005 Inlet hose clamp 170720000 Clamp SZ02019002 Rubber tube 440601621 Bolt M6x16 SZ02201005 Thermostat lower case...

  • Page 32: Cylinder Comp

    3. Cylinder comp ENGLISH 152020000 Clamp SZ03007000 Hose water inlet SZ01005006 Pin, dowel 10x14x8.4 SZ03005008 Gasket, cylinder SZ03100004 Cylinder assy SZ03004007 Gasket SZ03033009 Cam Chain Tensioner 440601821 Bolt, M16x18 SZ03002005 Spring Washer 8-100HV 80080000 SZ03003006 Bolt, hex SZ03020005 Plate of tension (Lower Chain Guide) SZ03006009 Bolt, tension plate SZ03001004...

  • Page 33: Crankcase Comp

    4. Crankcase comp ENGLISH SZ04040008 Crankcase assy, R SZ04005009 Bolt cylinder stud M8x170 SZ04004008 Bolt cylinder stud M8x160 SZ04007001 Pin, dowel SZ04003007 Gasket, crankcase C06012009 O-ring 12.3x1.3 C06105002 O-ring 7.5x1.5 SZ04030007 Crankcase assy,L SZ04060000 Rear pin 316004120 Bearing 6004-2Z/P5 SZ04050009 Seal 27*42*7 740822000 Nut, M8...
  • Page 34 4. Crankcase comp ENGLISH SZ04006000 O-ring 9x1.7 SZ04080002 440601621 Bolt M6x16...

  • Page 35: Cover Comp, R.crankcase

    5. cover comp, R.crankcase ENGLISH SZ05007002 Tube, breather tube SZ05030008 Clamp assy 161320000 Clamp 13 SZ01005006 Pin, dowel 10x14x8.4 SZ05005000 Gasket, R, crankcase SZ05006001 Union, breather tube SZ03101005 Union, water outlet pipe 440606021 Bolt M6x60 SZ05002007 Gauge, oil lever 440604021 Bolt M6x40 A06010007 O-ring 13x2.8...

  • Page 36: Cover Comp, L.crankcase

    6. Cover comp, L. crankcase ENGLISH SZ06003009 Seal of rubber SZ06001007 Cover, L SZ06202000 Cushion block SZ06201009 Cushion block seat SZ06004000 Bolt SZ06005001 Filter SZ06101008 Seal SZ06102009 Dust seal SZ06002008 Backing plate SZ06120009 Cover plate, sub-assy SZ06100007 Cover plate, assy 590501421 Comp, screw M15x14 440601221...

  • Page 37: Piston

    7. Crankshaft / Piston ENGLISH SZ07005002 Ring, piston first SZ07004001 Ring, piston second SZ07020009 Ring, piston third SZ07001008 Piston SZ07003000 Clip, piston pin SZ07002009 Pin piston SZ07100008 Crankshaft COMP SZ07006003 Key, woodruff SZ07009006 Pin 2x11.5 SZ07010008 Spring SZ07011009 Oiln joint SZ07007004 Washer SZ07008005...

  • Page 38: Transmission Comp

    8. Transmission comp ENGLISH SZ08100009 Move side of transmission (Variator) SZ08001009 Collar of shaft (Center Bushing) SZ08002000 Drive side of transmission (Fan Plate) SZ07007004 Washer SZ08003001 Nut M14x1.5...

  • Page 39: Clutch Comp

    9. Clutch comp ENGLISH SZ09030002 Bearing 812440000 Circlip 24 SZ09140003 Bearing SZ09100000 Pulley, inner SZ09020001 Seal, oil SZ09200001 Pulley, outer 850640000 Circlip 6 SZ09401004 Back plate SZ09420005 Clutch retracting spring (Arm spring) SZ09430006 Clutch block assy SZ09005004 Washer SZ09403006 Rubber block, cushion SZ09420005 Drive disc assy SZ09007006...

  • Page 40: Reduction Comp

    10. Reduction comp ENGLISH SZ10001002 Shaft of clutch 316204100 Bearing 6204/P5 SZ10003004 Washer 14 SZl0100002 Counter shaft assy 351420120 Bearing HK1414/P5 SZl0004005 Output shaft 832010000 Circlip, external SZl 0006007 Gear, drive SZl 0005006 Thrust washer 316203100 Bearing 6203/P5 SZl0210003 Gasket of cover SZl0008009 Pin dowel 10x16x6.4 SZl0300004...

  • Page 41: Pump Comp, Water

    11. Pump comp, water ENGLISH 440603221 Bolt M6x32 440602221 Bolt M6x22 SZ11001003 Cable clamp 152020000 Clamp 20 SZ11010003 Bolt M6x10 SZ11011004 Washer 6 SZ11005007 Cover, water pump SZ11004006 Gasket, water pump cover SZ11008000 Pin 8x14x6.4 SZ11002004 Gose SZ11200004 Bush SZ11006008 Impeller of water pump SZ11007009 Washer 5...

  • Page 42: Pump Comp. Oil

    12 pump comp. ,oil ENGLISH 580301222 Screw SZ12103007 Cover, oil pump gear SZl2106000 Pin, dowel SZl2104008 Rotor, oil pump inner SZ12105009 Rotor, oil pump outer SZl2102006 Body, oil pump SZ12I01005 Shaft, oil pump SZl2100004 Pump assy, oil SZl 2020005 Front back, plate 440602821 Bolt M6x28 SZl2030006...

  • Page 43: Electrical Start Propeller

    13. Electrical start propeller ENGLISH Q t y SZ14000005 Motor, starter SZ13001005 Gear, reduction SZ 13002006 Shaft, reduction gea 440601421 Bolt M6x14 SZ13004008 Hold plate SZ13020006 Gear 500601421 Bolt hex M6x14 SZ13006000 Spring SZ13005009 SZ13003007 Roller SZ13033000 Plug SZ 13031008 Clutch body SZ 13030007 One-way clutch assy...

  • Page 44: Carburetor Comp

    14. Carburetor comp ENGLISH SZ16000007 Carburetor COMP •...

  • Page 45: Air Cleaner Comp

    15. Air cleaner comp ENGLISH SZ17000008 Air cleaner assy SZ17000132 Bracket SZ17000110 Fixing bolt SZ17000143 Breather hose 170720000 Clamp 7...

  • Page 46: Radiator Comp

    16. Radiator comp ENGLISH SZ19100001 Radiator assy 241401800 O-ring 14x1.8 SZ19500005 Water tension sensor SZ19001001 Outlet hose 152020000 Hose clamp SZ19200002 Fan assy SZ19400004 Fan motor assy SZ19002002 Radiator inlet SZ19601007 Water inlet body SZ19620008 Radiator cap 161320000 Clamp 13 SZ19003003 Hose of radiator inlet SZ19604000...

  • Page 47: Frame And Fuel Tank

    1. FRAME AND FUEL TANK ENGLISH D250.11.886 Bumper, front 333.10 Nut, flange M10 444.10.40 Bolt, flange Ml0X40 D250.11.889 Defense to dump, top 444.10.30 Bolt, hex M10x30 D250.11.701 Protective bar, front D250.11.803 Protective bar, top D250.11.771 Foam set D250.11.702 Protective bar, rear 444.10.65 Bolt, flange M10X65 Washer Φ10...
  • Page 48 1. FRAME AND FUEL TANK ENGLISH D250.11.920 Cap comp fuel filler (Gas Cap) D250.11.804 Tank comp. fuel D250.11.003 Rubber cushion D250.11.903 Valve assembly, fuel petcock D250.11.060 Tube comp. fuel D250.11.802 Rear cargo rack 444.8.20 Bolt, flange M8x20 333.8 Nut, flange lock M8...

  • Page 49: Suspension Arm Assy

    2. SUSPENSION ARM ASSY ENGLISH 330. 10 Nut, flange lock M10x1.25 555. 10 Washer, lock Φ10 Washer, flat Φ10 222. 10 D250. 02. 805 Dust cap D250. 02. 002 Bush, upper suspension arm D250. 02. 003 Spacer, upper suspension arm 440.
  • Page 50 2. SUSPENSION ARM ASSY ENGLISH 440.12.245 Bolt-washer M12x245 D250.11.905 Cushion assy, FR 440.12.65 Bolt-washer M12x1.5x65 D250.02.801 Support strut and spindle, L D250.02.804 Lower arm...

  • Page 51: Steering Assy And Brake

    3. STEERING ASSY AND BRAKE ENGLISH D250.03.802 Cover, steering bolt 330.12 Nut. M12x1.5 D250.03.801 Steering wheel D250. 03. 905 Assorted on-off assembly 777.17 Circlp Φ17 D250.03.002 Nylon cover D250.03.001 Steering shaft 444.8.35 Bolt-washer M8x35 333.8 Nut, flange lock M8 D250.03.901 Steering knuckle D250.03.902 Steering gear...
  • Page 52 3. STEERING ASSY AND BRAKE ENGLISH 4406010 Bolt-washer M6x10 D250.03.011 Tie rod, R D250.03.904 Rod end, R D250.10.007 Axle, throttle pedal D250.04.002 Bush, pedal D250.10.801 Throttle pedal comp. D250.10.003 Spring 333.8 Nut. M8 D250.10.904 Cable, throttle 444.6.30 Bolt-washer M6x30 333.6 Nut, flange lock M6 222.10 Washer, flat Φ10...

  • Page 53: Engine Rack

    4. ENGINE RACK ENGLISH D250.04.801 Engine rack 333.10 Nut, flange lock M10 D250.04.001 Con'rod D250.04.002 Bush, con'rod 444.10.45 Bolt-washer M10x45 433 4.10 Bolt-vaulted M4x10 D250. 04.901 Electric ass'y 440.12.60 Bolt-washer M12x1.5x60 D250.04.802 Fixed rod, rear engine 440.10.50 Bolt-washer M10x1.25x50 440.14.240 Bolt-washer M14x1.5x240 222.14 Washer, flat Φ14...

  • Page 54: Rear Swing Arm

    5. REAR SWING ARM ENGLISH 440.16.185 Bolt M16x185 D250.05.003 Spacer, swing arm D250.05.004 Bush, swing arm D250.05.801 RR swing arm comp, under 555.16 Washer, lock Φ16 330.16 Nut. M16x1.5 330.12 Nut, flange lock M12x1.5 D250.05.005 Bush, swing arm D250.05.006 Spacer, swing arm 444.12.65 Bolt-washer M12x1.5x65 D250.05.002...

  • Page 55: Rear Housing

    6. REAR HOUSING ENGLISH D250.02.010 Hub cover, rear wheel 888.3.40 Cotter pin, shaft, 3x40 330.16 Nut, M16x1.5 D250.06.011 Adjusting washer Φ18 330.10 Nut, wheel, M10x1.25 555.10 Washer, lock Φ10 Washer, flat Φ10 222.10 D250.06.002 Hub, rear D250.06.014 Bolt, M10x1.25x30 330.30 Nut, wheel, M30x1.5 D250.06.006 Spacer...
  • Page 56 6. REAR HOUSING ENGLISH D250.06.003 Mounting, brake D250.06.008 Limit bolt 444.8.15 Bolt, M8x15 555.8 Washer, lock Φ8 Washer, flat Φ8 222.8 D250.06.013 Disc brake D250.06.009 Big sprocket wheel D250.08.904 Chain...

  • Page 57: Electrical Assembly

    7. ELECTRICAL ASSEMBLY ENGLISH D250. 07.900 Turning signal, front N6. 200 Nylon clamp, 6x200 D250.07.901 Headlight (35/25w) D250.07.903 Tail lamp D250.07.801 Harness, wiring D250.07.802 Battery (12v, 9Ah) D250.07.904 Turning signal, rear D250.07.902 Switch box D250.07.911 Function display 2 D250. 07.906 Function display 1 D250.

  • Page 58: Shift Lever And Parking Lever Assy

    8. SHIFT LEVER AND PARKING LEVER ASS'Y ENGLISH D250. 08.908 Lever, reverse gear 666.GE12E Sliding bearing GE12E D250.08.004 Spring D250.08.005 Bush 888.2.30 Pin.cotter D250.08.009 Cover, reverse gear lever 330.10 Nut, R M10x1.25 330.10.L Nut, L M10x1.25 D250.08.906 Ball, reverse gear D250.08.801 Long drive lever 330.10...

  • Page 59: Radiator Assy

    9. RADIATOR ASSY ENGLISH D250.09.901 Water tank D250.09.902 Fanner D250.09.001 Water pipe for enter D250.09.002 Water pipe for out D250.09.903 Standby water tank D250.09.004 Water pipe for tank D250.09.904 Cover for add water D250.09.908 Cooling pipe 333.10 Nut, M10 Washer, flat Φ10 222.10 444.10 Bolt, M10x25...

  • Page 60: Reverse Gear

    10. REVERSE GEAR...
  • Page 61 10. REVERSE GEAR ENGLISH Q’ty 333.24 Nut, M24 444.6.16 Bolt, M6x16 555.6 Washer lock Φ6 222.6 Washer Φ6 D250.08.100 Shaft seat D250.08.101 Gasket head cover D250.08.102 Small shaft D250.08.103 Washer D250.08.103 Prick gear D250.08.104 Compart spacer D250.08.105 Joint spacer D250.08.106 Poker D250.08.107 Shaft...
  • Page 62 10. REVERSE GEAR ENGLISH 444.6.18 Screw M6x18 D250.08.909 Sensor 330.12 Nut, M12 333.6 Nut, M6 D250.08.122 Sector board shaft D250.08.123 Sector board D250.08.124 Compart spacer 333.10 Nut, M10 333.8 Nut, M8 444.8.35 Screw, M8x35 D250.08.125 Reverse gear box 424.6.12 Bolt, M6x12 D250.08.126 Left shaft D250.08.910...

  • Page 63: Exhaust

    11. EXHAUST ENGLISH D250.11.037 Seal, exhaust pipe D250.11.888 Exhaust pipe 444.8.35 Bolt, M8x35 D250.11.041 Mounting, exhaust pipe 444.8.12 Bolt, M8x12 D250.11.880 Mounting, exhaust pipe D250.11.887 Front exhaust pipe 333.8 Nut, M8...

  • Page 64: Label

    12. LABEL ENGLISH D250.12.008 Long-hair warning D250.02.002 Colligate warning D250.12.003 Safety belt warning D250.12.005 Luggage carrier warning D250.12.004 Chain warning D250.12.006 Shift reverse gear warning D250.12.007 Hand indication D250.12.001 Age warning...

  • Page 65: Seat And Safety Belt

    13. SEAT AND SAFETY BELT ENGLISH D250.11.601 Belt, safety D250.11.904 Seat comp 444.10.25 Bolt, flange M10x25 333.10 Nut, flange lock M10 D250.11.003 Seat cushion board 422.6.20 Screw-washer, M6x20 333.6 Nut, flange lock M6 D250.11.602 Seat adjuster...

  • Page 66: Fender

    14. FENDER ENGLISH D250.11.005 Mudguard, left front D250.11.006 Mudguard, right front D250.11.007 Mudguard, left rear D250.11.008 Mudguard, right rear D250.11.051 Support, mudguard #1 D250.11.052 Support, mudguard #2 D250.11.053 Support, mudguard #3 D250.11.054 Support, mudguard #4 444.8.30 Bolt, flange M8X30 333.8 Nut, flange lock M8 333.6 Nut, flange lock M6...

  • Page 67: Front, Rear Wheel

    15. FRONT, REAR WHEEL ENGLISH 999.28.47.7 Seal, FB 28x47x7 666.204 Bearing, inner 6204 D250.02.006 Spacer, FR hub inter D250.11.062 Bolt, tire M10x1.25x25 D250.02.004 Hub, FR, wheel D250.02.005 Spacer, FR hub 666.203 Bearing, outer 6203 999.25.40.7 Seal, FB 25x40x7 D250.02.007 Spacer, FR hub outer 555.16 Lock washer 888.4.40...

  • Page 68: Preparation Attach Instruction

    CONTENTS ----------------------------- PREPARATION ATTACH INSTRUCTION 1. ATTACH BATTERY ------------------------------------------------------------------------ 2. ATTACH FRONT BUMPER -------------------------------------------------------------- 3. ATTACH FRONT SHOCK ---------------------------------------------------------------- 4. ATTACH FRONT TIRE -------------------------------------------------------------------- 5. ATTACH FUEL TANK/ATTACH HEADLIGHT/ATTACH LEFT AND RIGHT REAR TURN SIGNALS ------------------------------------------------------------------------------- 6. ATTACH LOOKUM ------------------------------------------------------------------------- 7.

  • Page 69: Attach Battery

    ATTACH BATTERY Remove battery from Go-Kart Fill the electrolyte as below. Put the battery into the box on ATV. Connect the wire to battery as below picture; red to +; black and green to - Fix the metal cover, rubber cushion and tighten two bolts Notice;...

  • Page 70: Attach Front Bumper

    ATTACH FRONT BUMPER Front of bumper is as below picture. 3- Attach upper bumper to front bumper by inserting bolts. 1- Attach front of bumper to left front end of frame as picture, don’t tighten four nuts. Also for the right side. 4- Tighten all bolts and nuts on the bumper.

  • Page 71: Attach Front Shock

    ATTACH FRONT SHOCK The front shock in packing situation is as below picture about. Remove pin, nut, adjusted cushion from the bolt on the tie rod. Insert the bolt on the tie rod into the hole on the front wheel axle. Tighten the nut, insert the pin, then lock the pin.

  • Page 72: Attach Front Tire

    ATTACH FRONT TIRE 3- Insert the cushion, lock cushion through bolt The hub fixed the front tire in packing is as below; on the hub. Tighten four nuts. 1- Remove four nuts, four lock cushion, four cushion on the hub. Notice;...

  • Page 73: Attach Fuel Tank/Attach Headlight/Attach Left And Right Rear Turn Signals

    ATTACH FUEL TANK/ATTACHHEADLIGHT/ATTACH TURN SIGNAL Figure 1 Figure 2 Attach headlight Attach headlight as below pictures Attach left and right rear turn signals Attach the right rear turn signal as picture Connect wire to wire from main wire.

  • Page 74: Attach Lookum

    ATTACH MIRROR...

  • Page 75: Attach Rear Brake Lamp/Attach Rear Shock

    ATTACH REAR BRAKE LAMP/ATTACH REAR SHOCK 2- Connect wire of rear lamp to main wire as picture. Attach rear shock Remove the bolt Attach the rear shock as below picture. Tighten the bolt and nut. cushion...

  • Page 76: Attach Rear Tire

    ATTACH REAR TIRE 2- Remove the pin, nut, cushion 1- Remove the cover oh hub 3- Insert the hub of tire through the axle 4- Attach the cushion. Tighten the nut. Insert the pin and lock it. 5- cover the hub cover as pictures...

  • Page 77: Attach Seat

    ATTACH SEAT Figure 1 Figure 3 Figure 2 Figure 4...

  • Page 78: Attach Steering Wheel

    ATTACH STEERING WHEEL Remove the nut on the steering shaft Insert the switch Assy through the steering shaft along the groove on the frame Insert steering wheel through the shaft Adjust two front wheel to direct straight Tighten two nut on the switch Assy. forward by turning steering wheel.

  • Page 79: Attach The Radiator

    ATTACH THE RADIATOR Attach the radiator as below pictures. 3- Arrange the main and reserve coolant rubber Connect wire from fan motor to main tube as below pictures wire...

  • Page 80: Attach The Rear Tack

    ATTACH THE REAR RACK Insert four bolt between the rear rack and the frame. Tighten the four bolt and the nuts as the below picture...

  • Page 81: Preparation Instructions For The Go-Cart

    PREPARATION INSTRUCTIONS FOR THE GO-CART Packing situation for SZ250DL. Front of packing Rear of packing...

  • Page 82: The Whole Go-Kart Looks

    THE WHOLE GO-KART LOOKS Side Review Front review Upper Review Back Review...

This manual is also suitable for:

Sz50dl 2004

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