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Joyner SZ250DI Owner's Manual

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Owner's Manual
SZ250DI

Parts Manual

READ THIS MANUAL CAREFULLY
IT CONTAINS IMPORTANT SAFETY INFORMATION.
MINIMUM
16
RECOMMENDED
OPERATOR AGE:
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for off-road use only.
USA only:
It does not confirm to federal motor vehicle safety standards, and operation on
public streets, roads, or highways is illegal
0

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Summary of Contents for Joyner SZ250DI

  • Page 1: Parts Manual

    Owner’s Manual SZ250DI Parts Manual READ THIS MANUAL CAREFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION. MINIMUM RECOMMENDED OPERATOR AGE: FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for off-road use only. USA only: It does not confirm to federal motor vehicle safety standards, and operation on...
  • Page 2 SZ50DI Limited Warranty The warranty policy applies to those cases where the new seller vehicle is unloaded from its shipping container, set up and delivered by authorized dealer, and under normal use and service is found to have defects in parts or workmanship under the following terms and conditions.

  • Page 3: Table Of Contents

    CONTENTS OWNER’S MANUAL ......................4 FOREWORD........................4 A FEW WORDS ABOUT SAFETY ................. 5 IMPORTANT SAFETY INFORMATION................6 SAFETY LABELS ......................8 ARE YOU READY TO DRIVE?..................9 IS YOUR VEHICLE READY TO DRIVE? ..............11 SAFE DRINING PRECAUTIONS................. 13 SPECIFICATIONS ....................... 15 OPERATION ........................
  • Page 4 ATTACH FRONT SHOCK .................... 69 ATTACH FRONT TIRE....................70 ATTACH LOOKUM....................... 71 ATTACH REAR SHOCK ....................72 ATTACH TRAILING ARM ..................... 73 ATTACH SEAT AND SAFT BELT ................. 75 ATTACH THE RADIATOR.................... 76...

  • Page 5: Owner's Manual

    OWNER’S MANUAL FOREWORD Thank you for choosing our Go-art. We hope you will have fun with it. Before you start operate the Go-Kart, please read through this Owner’s Manual carefully as it contains important safety and maintenance information. Failure to follow the warnings contained in this manual can result in serious injuries.

  • Page 6: A Few Words About Safety

    A FEW WORDS ABOUT SAFETY In order to keep everyone safe, you must take 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 7: Important Safety Information

    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 8 Never run your Go- Kart indoors. The exhaust from the engine contains a tasteless, odorless and poisonous gas called carbon monoxide. Keep away from moving parts of the Go-Kart The operator of the Go-Kart should never place their hands or other parts of their body near any moving part of the Go-Kart.

  • Page 9: Safety Labels

    SAFETY LABELS 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 are considered permanent parts of the Go-Kart. If a label comes off or becomes hard to read, contact your dealer for warning labels replacements.

  • Page 10: Are You Ready To Drive

    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 11 Driving pants with knee and hip pads, a driving jersey with padded elbows, ■ and a chest/shoulder protector. Drive Training Developing your driving skills is an on-going process. Even if you have derived other Go-Karts, take time to become familiar with how this Go-Kart works and handles.

  • Page 12: Is Your Vehicle Ready To Drive

    IS YOUR VEHICLE READY TO DRIVE? Before each drive, it is important to inspect your Go-Kart and make sure any problems you find are corrected. A pre-drive inspection is a must, not only for safety, but because having a breakdown, or even a flat tire, can be a major inconvenience.
  • Page 13 Throttle ■ Check the free play and adjust if needed. Press the throttle to make sure it moves smoothly without sticking, and snaps back automatically when it is released. Brakes ■ Press the rear brake pedal several times, check for proper brake pedal free play.

  • Page 14: Safe Drining Precautions

    SAFE DRINING 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. Operating this Go-Kart on paved surfaces may seriously affect handling and control of the Go-Kart, and may cause the vehicle to go out of control.
  • Page 15 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. Operating this Go-Kart at excessive speeds increases your changes of losing control of the Go-Kart, which can result in an accident. Always drive at a speed that is proper for your Go-Kart, the terrain, visibility and other operating conditions, and your experience.

  • Page 16: Specifications

    SPECIFICATIONS DIMENSIONS Overall Length---------------------------------------------------------------------------------------98 in. (2500mm) Overall Width ---------------------------------------------------------------------------------------- 59 in. (1500mm) Overall Height --------------------------------------------------------------------------------------- 64 in. (1630mm) Wheelbase -------------------------------------------------------------------------------------------- 78 in. (1980mm) Front Track ------------------------------------------------------------------------------------------ 53 in. (1350mm) Rear Track -------------------------------------------------------------------------------------------60.6 (1540mm) Ground Clearance ----------------------------------------------------------------------------------- 11.8 in. (300mm) ENGINE Type ------------------------------------------------------------------------------------------ Liquid-cooled.

  • Page 17: Operation

    OPERATION A．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.
  • Page 18 Figure 2 WARNING LEVER OF MODE FOR LIGHT SIGNLE STEERING Figure 3 B．Pre-Drive Inspection Perform this pre-drive inspection everyday before driving vehicle. If not performed, serious damage to the vehicle or personal injury may result. d. Check for Engine Oil Level. Check for leaks, add oil if required. e.

  • Page 19: Component Locations

    Component locations RADIATOR STEERIHNG WHEEL SAFTY BELT FUEL TANK FLAG POLE BRACKET BRAKE PEDAL THROTTLE PEDAL...
  • Page 20 C．Passengers The vehicle allows for two riders only. Combine maximum weight of driver And the passenger should not exceed 180kg or 400Ibs. D．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 21: Service Instruction

    Never engage the shift lever when the Go-kart is in motion Only engage the shift lever when the Go-kart is at a full stop Give a slight throttle and loosen throttle, then engage shift from neutral to shift. The shift lever must be on neutral and pull parking lever when leave the Go-kart F．Parking Adjustment Press down the reverse lever to the “F”...
  • Page 22 proper lubrication of internal parts and prevent costly repairs due to excessive wear. Never operate this Go-Kart when the provided seat is not securely fastened, to do so could result in a strong possibility of severe personal injury or loss of life. a.
  • Page 23 adjustment. a. Warm up the engine (5~10min) b. Tighten the airscrew gentle. Back out 2-3/8 turns counter clockwise. c. Connect the tachometer; adjust the throttle to limit the idle speed. The standard value is (1400RPM). d. Turn the airscrew counter slowly and observe the RPM of the engine, stop adjusting as the RPM reaches the top speed.
  • Page 24 J. Adjustment of Front and Rear Shock There are five adjustable positions on each shock. The default position is in the middle set by manufacture (See Fig.11) Use a round nut wrench as you adjust the shock, the tension of shock spring will increase as you screw to left, decrease as you screw to the right.

  • Page 25: Repair

    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.

  • Page 26: Periodical Check And Services

    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. Initial Time service Monthly Quarterly Yearly service Items (First week) Tire pressure/wear Brake performance Tightness of screws Air cleaner Carburetor...

  • Page 27: Wiring Diagram

    WIRING DIAGRAM...

  • Page 28: Parts Manual

    PARTS MANUAL 1、CRANKCASE ASSY. ENGLISH Q’ty 172MM-C-011100 CRANK CASE ASSY.L 172MM-C-011200 CRANK CASE ASSY.R 172MM-011001 SEAL 28X40X8 172MM-011002 SEAL RING.INNER OIL PIPE. 172MM-011004 STUD A.CYLINGDER 152MI-021005 LOCATING PIN Φ10x14 172MM-011005 STUD B.CYLINGDER 172MM-B-011006 SEAL WASHER.CRANK CASE 172MM-011400 INNER OIL PIPE ASSY 152MI-021019 BOLT M6X12 152MI-011017...
  • Page 29 1、CRANKCASE ASSY. ENGLISH Q’ty GB/T 9877-1988 FB33X35X5 OIL SEAL FB 33X35X5 GB/T 276-1994 6201 BEARING 6201 GB/T 276-1994 620-RS BEARING 6202-RS 172MM-B-068001 HOLLOW BOLT M14X1.5 CF188-068002 WASHER 14.4X22X1 CF188-068003 SPACE SPRING GB/T308-1989 3/8 STEEL BALL 152MI-130004 "O" RING FOR SEAL13.5X1.4 172MM-B-011300 ODOMETER SENSOR 172MM-B-011400...

  • Page 30: Side Cover Assy.l

    2、SIDE COVER ASSY.L ENGLISH Q’ty 172MM-B-012001 SIDE COVER.L 172MM-B-012002 AIR DAMPER GB/T818-2000 M6X12 SCREW 172MM-B-012005 BOLT 152MI-013008 BOLT 152MI-021005 LOCATING PIN Φ10x14 172MM-B-012003 SEAL WASHER.LEFT SIDE COVER 152MI-021018 BOLT...

  • Page 31: Right Cover Assy

    3、RIGHT COVER ASSY ENGLISH Q’ty 172MM-013013 AIR PIPE.CYLINDER HEAD COVER 172MM-013100 BREATH PIPE.RIGHT SIDE COVER 172MM-013015 BREATH PIPE.AIR FILTER 172MM-013016 CLAMP.BREATH PIPE 172MM-013002 SIDE COVER.R 172MM-013008 PRESS PLATE.CABLE 172MM-013012 SEAL WASHER.RIGHT SIDE COVER 172MM-013007 CAP.OIL FILTER 152MI-013100 OIL FILTER CORE 172MM-013006 SPRING 172MM-013001...
  • Page 32 3、RIGHT COVER ASSY ENGLISH Q’ty QC/T621-1999-A12 CLAMP 10 172MM-013010 BREATH FAUCET 172MM-013009 WATER OUTLET FAUCET 152MI-013009 BOLT M6X40 172MM-013026 PROTECTION PIPE 152MI-071007 BOLT M6X28 1P52MI-011018 BOLT M6X70...

  • Page 33: Cylingder Head Caseing Assy

    4、CYLINGDER HEAD CASEING ASSY ENGLISH Q’ty 172MM-021009 CLAMP.OIL PIPE 172MM-021001 COVER.CYLINDER HEAD 172MM-021006 STOP PLATE 152MI-021011 SEAL WASHER. 172MM-021100 AXIS.SWING ARM.INLET 172MM-021200 AXIS.SWING ARM.OUTLET 172MM-021400 OIL PIPE ENGINE.OUTER 152MI-021001 RUBBER RING.OIL PIPE 172MM-021431 MOUNT.OIL PIPE 152MI-021003 SHOCK ABSORB RUBBER STRIP 152MI-021004 REAMED BOLT A M8X25 152MI-021015...
  • Page 34 4、CYLINGDER HEAD CASEING ASSY ENGLISH Q’ty 152MI-021018 BOLT M6X55 172MM-021404 SHOCK ABSORB SLEEVE 172MM-021002 BREATH PIPE FAUCET 172MM-021300 MOUNT.AIR FILTER 172MM-021008 BLOCKING...

  • Page 35: Cylingder Head Assy

    5、CYLINGDER HEAD ASSY ENGLISH Q’ty 172MM-022100 CYLINDER HEAD 172MM-022700 FLANGE.EXHAUST 152MI-022014 BEARING COVE.CAM AXIS 172MM-022008 NUT.EXHAUST 172MM-022010 SEAL WASNER.CYLINDER HEAD 172MM-022900 CARBURETOR SEAT UNIT 172MM-022500 CLAMP UNIT.AIR INLET PIPE 152MI-022810 THERMOSTAT 152MI-022803 THERMOSTAT SHELL.UPPER 152MI-022021 RUBBER PIPE1.CARBURETOR 172MM-022601 THERMOSTAT SHELL.LOWER 172MM-022400 SPARK PLUG 152MI-022017...
  • Page 36 5、 CYLINGDER HEAD ASSY ENGLISH Q’ty QC/T621-1999-A6.5 STEEL RING CLAMP 152MI-090005 BOLT M6X16 152MI-023008 BOLT M6X18 152MI-022017 BREATHE PIPE.CARBURETOR GB/T848-85-6-D·Cr SMALL WASHER 152MI-022021 SCREW BLOCKAGE...

  • Page 37: Cylinger Body Assy

    6、CYLINGER BODY ASSY ENGLISH Q’ty 172MM-023100 CYLINDER 172MM-023002 SEAL WASHER.CYLINDER 152MI-023300 TENSIONER UNIT 152MI-023307 BOLT.SPRING SEAT 152MI-023306 SPRING.TENSION 152MI-023004 SEAL WASHER.TENSIONER 172MM-023007 RUBBER PIPE.WATER INLET 172MM-023009 JACKET.WATER PIPE QC/T621-1999-B24 STEEL BAND CLAMP 152MI-023305 WASHER 8.5 GB/T848-85-6-D·ZN SMALL WASHER 152MI-021005 LOCATION PIN Φ10X14 152MI-023008 BOLT M6X18 152MI-080013...

  • Page 38: Timing Chain

    7、TIMING CHAIN ENGLISH Q’ty 172MM-022200 CHAIN UNIT 172MM-023200 TENSION PLATE 172MM-023001 CHAIN GUIDE PLATE GB96-85-6-D·Zn BIG WASHER GB/T5781-2000-M6X12-D·Zn BOLT...

  • Page 39: Magnetor Assy

    8、MAGNETOR ASSY ENGLISH Q’ty 172MM-094000 FREE-WHEELING CLUTCH 172MM-033000 TRIGGER COIL 172MM-013008 CABLE PRESS BAND 172MM-031000 FREE-WHEELING 172MM-032000 STATOR UNIT GB/T70.1-2000-M8X18 SOCKET HEAD SCREW 172MM-040001 NUT M16X1 172MM-040002 WASHER16.3X30X2 152MI-030002 BOLT M5X16 152MI-060002 BOLT M6X30...

  • Page 40: Admission Machanism

    9、ADMISSION MACHANISM ENGLISH Q’ty 152MI-022500 SEAL.VALVE ROD 172MM-022300 CAM UNIT 152MI-021007 SWING ARM 172MM-022001 INTAKE VALVE 172MM-022005 EXHAUST VALVE 172MM-022002 VALVE SPRINGL.OUTTER 172MM-022003 VALVE SPRINGL.INNER 152MI-022005 PAN.VALVE SPRING 152MI-022001 SEAT.VALVE SPRING 152MI-022006 CLAMP.VALVE NTN: 16002 BALL BEARING GB894.A-1-86-15 AXIS RETAINER RING 172MM-022310 CHAIN PULLY 172MM-022301...

  • Page 41: Crank Link Lever & Piston

    10、CRANK LINK LEVER & PISTON ENGLISH Q’ty 172MM-A-041000 CRANK LINK UNIT 172MM-040008 PISTON RING 172MM-040009 PISTON RING 172MM-042000 OIL RING 172MM-040005 PISTON 172MM-040007 PISTON PIN 152MI-040011 JOINT.OIL CHANNEL 152MI-040010 JOINT SPRING 152MI-040006 WOODRUFF KEY 172MM-040006 STOP RING.PISTON PIN GB/T119-2000-2X14...

  • Page 42: Speed Changer

    11、SPEED CHANGER. ENGLISH Q’ty 172MM-021007 NUT M14X1.5 172MM-021006 WASHER14.5X30.2 172MM-A-051005 DRIVE WHEEL PAN 172MM-A-051003 SLEEVE.DRIVE WHEEL PAN 172MM-A-051100 MOVABLE DRIVE PAN 172MM-A-051200 OFFCENTER ROLLER 172MM-A-051004 SLIDING BLOCK 172MM-A-051002 PUSH PAN...

  • Page 43: Clutch Assy

    12、CLUTCH ASSY ENGLISH Q’ty 172MM-052008 BOLT M12X1.25 172MM-A-052500 OUTTER WHEEL DISC 172MM-052005 THIN NUT M30X1 172MM-A-052400 DRIVE PAN UNIT 172MM-A-052200 DAMPING RUBBER BLOCK 172MM-A-052600 CLUTCH BLOCK 172MM-A-052006 RELEASE SPRING 172MM-A-052003 SIDE PAN GB/T896-1986-9 SPLIT WASHER 172MM-052310 NEEDLE BEARING GB/T893.1-1986-28 RETAINER RING.HOLE GB/T278-1989-1060902 BEARING 172MM-A-052300...

  • Page 44: Gearbox Cover Assy

    13、GEARBOX COVER ASSY ENGLISH Q’ty 172MM-C-060001 COVER.GEARBOX 172MM-C-060002 PAPER WASHER.GEARBOX 172MM-013005 BOLT M12X1.5.OIL OUTLET 152MI-021014 WASHER12 172MM-B-069000 SHIFT DISPLY SWITCH GB/T 276-1994 6202-RS BALL BEARING GB/T 276-1994 6201 BALL BEARING GB/T 276-1994 6203 BALL BEARING GB/T 276-1994 6305-RS BALL BEARING 172MM-B-011107 BOLT M8X48 172MM-B-011111...

  • Page 45: Transmission Gear Assy

    14、TRANSMISSION GEAR ASSY ENGLISH Q’ty 172MM-B-067000 TRANSITION GEARS ASSY GB/T89431-1986 20 RTAINER RING 172MM-B-067000 TRANSITION GEAR 172MM-B-067001 TRANSITON GEAR-AXIS 172MM-B-060001 MAIN AXIS 172MM-B-062000 SECONDARY AXIS ASSY 172MM-B-062006 WASHER.15X28X2 172MM-B-062002 DRIVEN GEAR.HIGH SPEED NTN: K16X20X10 NEEDLE BEARING 172MM-B-062009 SLIDING SLEEVE.SHIFT 172MM-B-062001 SECONDARY AXIS 172MM-B-062007 WASHER 24X33X2...
  • Page 46 14、TRANSMISSION GEAR ASSY ENGLISH Q’ty CF188-061007 RETAINER RING.AXIS 25 172MM-C-063001 OUTPUT AXIS 172MM-C-063004 CHAIN PULLEY 172MM-C-063005 PRESS PLATE.CHAIN PULLEY 172MM-C-063009 BOTL M6X12 172MM-B-062008 WASHER 16X28X2...

  • Page 47: Gear Shift Machanism

    15、GEAR SHIFT MACHANISM ENGLISH Q’ty 172MM-B-066000 SHIFT DRUM ASSY 172MM-B-066002 SHIFT YOKE 172MM-B-066003 PIN.SHIFT YOKE 172MM-B-066004 SNAP RING.PIN.SHIFT YOKE 172MM-B-066001 SHIFT DRUM 172MM-B-066005 TOUCH CHIP.SPEED DISPLY CF188-065201 WASHER.DRIVEN SECTOR GEAR CF188-065203 DRIVEN SECTOR FEAR.SHIFT CF188-065204 WASHER 13.5X22X1 CF188-065202 DRIVEN SECTOR GEAR-AXIS.SHIFT CF188-065204 SPRING.DRIVEN SECTOR GEAR CF188-065206...

  • Page 48: Engine Oil Pump Assy

    16、ENGINE OIL PUMP ASSY ENGLISH Q’ty 151MI-071000 OIL PUMP ASSY 151MI-071002 OIL PUMP BODY 151MI-071003 OIL PUMP COVER 151MI-071001 OIL PUMP AXIS 151MI-071001 CHAIN PULLEY.OIL PUMP 151MI-073000 CHAIN OIL PUMP 151MI-071004 ROTOR.OIL PUMPL.INNER 151MI-071005 ROTOR.OIL PUMPL.OUTTER 151MI-070002 SPACER PLATE A.OIL PUMP 151MI-072000 SPACER PLATE B.OIL PUMP GB878-85-M3X12...

  • Page 49: Coolant Pump Assy

    17、COOLANT PUMP ASSY ENGLISH Q’ty 172MM-080004 IMPELLER.WATER PUMP 152MI-081000 WATER SEAL ASSY 172MM-080003 WATER PUMP COVER 172MM-080002 SEAL WASHER. COVER 172MM-080001 WATER PUMP AXIS 152MI-013009 BOLT M6X40 152MI-021017 BOLT M6X25 GB/T893.1-1986-19 RETAINER RING.HOLE 152MI-080007 WASHER.7.5X13X1.2 152MI-080011 WASHER.6X12X1 NTN: 6800 NEEDLE BEARING 172MM-080005 GREAS SEAL 10X20X5 152MI-080008...

  • Page 50: Electric Starter Assy

    18、ELECTRIC STARTER ASSY ENGLISH Q’ty 172MM-090001 AXIS.DUPLICATE GEAR 172MM-092000 DRIVEN GEAR COMP 172MM-091000 DUPLICATE GEAR COMP 172MM-090007 MOUNTING PLATE 172MM-093000 STARTER COMP 152MI-080013 BOLT M6X22 172MM-090008 BOLT M6X14...

  • Page 51: Carburetor Assy

    19、CARBURETOR ASSY ENGLISH Q’ty 172MM-100000 CARBURETOR ASSY...

  • Page 52: Frame And Fuel Tank

    20、FRAME AND FUEL TANK 20 FRAME AND FUEL TANK...
  • Page 53 20 FRAME AND FUEL TANK PART NO. DESCRIPTION Q'TY GB5787-1986 M12x1.5x60 FLANGE BOLT D250.11.886 NYLON BUSHING GB6177.1-2000 M12X1.5 FLANGE NUT DI250.01.05.04.00 PROTECTIVE BAR.CANDAL.R T U B E S E A T . N Y L O N D250.11.004 ? 32 D250.11.058 R-WASHER D250.11.001...

  • Page 54: Suspension Arm Assy

    21、SUSPENSION ARM ASSY 21 SUSPENSION ARM ASSY...

  • Page 55: Suspension Arm Assy

    21 SUSPENSION ARM ASSY Q'TY PART NO. DESCRIPTION DS250.02.02.00.00 LOWER A-ARM.R DS250.02.00.00.04 UNIVERSAL JOIN.R DI250.04.01.01.00 FRONT BRAKE CALIPER.R DS250.02.00.00.02 KNUCKLE.R GB5787-1986 M12x1.5x85 FLANGE BOLT M12x1.5x85 SEAL,LOWER A-ARM30*40*10 JD2682000 JD0268001 BUSH.LOWER A-ARM.FR DS250.02.00.00.01 SPACER.LOWER A-ARM GB6177.1-2000 M12X1.5 FLANGE NUT M12X1.5 GB3632-83 16 SPRING WASHER 16 GB6172.1-2000 M16X1.75 THIN NUT M16X1.75...

  • Page 56: Steering Assy

    22、STEERING ASSY 22 STEERING ASSY...
  • Page 57 22 STEERING ASSY Q'TY PART NO. DESCRIPTION GB70-85 M4x16 SOCKET HEAD SCREW M4x16 DI250.03.01.00.01 PLASTIC COVER.STEERING WHEEL DI250.03.01.00.02 RUBBER COVER.STEERING WHEEL GB819-85 M6x20 CRUCIFORM SLOT SUNK SCREW M6x20 DI250.03.00.00.02 RUBBER WASHER DI250.03.01.00.03 STEERING WHEEL D250.03.905 COMBINED SWITCH GB822-2000 M6X20 CRUCIFORM SLOT PANHEAD SCREW M6X20 GB6177.1-2000 M6 FLANGE NUT M6 DS250.03.01.00.00...

  • Page 58: Engine Rack

    23、ENGINE RACK 23 ENGINE RACK 25 26...
  • Page 59 23 ENGINE RACK Q'TY PART NO. DESCRIPTION GB6177.1-2000 M10X1.25 FLANG NUT M10X1.25 D650.04.01.00.01 ENGINE RUBBER BUMPER DI250.08.01.00.00 ENGINE MOUNT.REAR GB6177.1-2000 M12X1.5 FLANG NUT M12X1.5 DI250.08.00.00.01 SPACER.ENGINE GB5787-1986 M10X1.25X20 FLANG BOLT M10X1.25X20 GB5787-1986 M12X1.5X115 FLANG BOLT M12X1.5X115 DI250.08.02.00.00 ENGINE RACK GB6170-86 M12 NUT M12 GB5785-86 M12X1.5X80 BOLT M12X1.5X80...

  • Page 60: Engine Rack

    24、ENGINE RACK 24 TRAILING ARM ASSY...
  • Page 61 24 TRAINLING ARM ASSY Q'TY PART NO. DESCRIPTION DI250.09.02.00.00 TRAILING ARM.R DI250.07.01.00.01 BRIDLE.BOOT DI250.07.01.00.02 INNER BOOT DI250.07.01.00.03 BRIDLE.BOOT DI250.07.01.00.04 OUTER BOOT DI250.07.01.00.00 HALF AXLE GB9877.1-1988 FB32X47X8 SEAL FB 32X47X8 GB/T5787-86 6005 BALL BEARING 6005 GB6177.1-2000 M8X15 FLANG NUT M8X15 GB/T93-1987 8 SPRING WASHER 8 DI250.04.03.02.00 BRAKE CALIPER.HAND BRAKE.L...

  • Page 62: Middle Axis Assy

    25、MIDDLE AXIS ASSY 25 MIDDLE AXIS ASSY...
  • Page 63 25 MIDDLE AXIS ASSY PART NO. DESCRIPTION Q'TY DI250.07.00.00.01 SPRING CIR CLIP GB894.1-86 26 CIRCLIP FOR AXIS 26 DI250.07.00.00.03 SLEEVE.MID AXIS RETAINE RING RETAINER RING SN206.1 SEAL.BEARING BLOCK SN206.2 BEARING BLOCK.UPPER GREASE CUP GREASE CUP.BEARING BLOCK GB/T93-1987 10 SPRING WASHER 10 SCREW BOLT M10X80 SCREW BOLT TWO-ROW BALL BEARING...

  • Page 64: Electrical Assy

    26、ELECTRICAL ASSY 26 ELECTRICAL ASSEMBLY...

  • Page 65: Electrical Assembly

    26 ELECTRICAL ASSEMBLY PART NO. DESCRIPTION Q'TY D250.07.900 TURNING SINGLE.FR D250.07.907 SPEED METER D250.07.915 VOLTAGE REGULATOR DS250.10.00.00.02 FACE PLATE D250..07.909 IGNITION SWITCH DS250.10.00.00.05 BUTTON.HORN DI250.10.02.00.00 FUNCTION DISPLAY 3# DI250.10.03.00.00 FUNCTION DISPLAY 4# DI250.10.04.00.00 FLASHER D250.07.912 RELAY.STRAT HEADLIGNT(35/25W) GB6177.1-2000 M12X1.5 D250.07.903 TRAIL LAMP D250.07.913 HORN...

  • Page 66: Seat And Mud Guard

    27、SEAT AND MUD GUARD 27 SEAT AND MUD GUARD...
  • Page 67 27 SEAT AND MUD GUARD PART NO. DESCRIPTION Q'TY DS250.08.01.00.03 SEAT COMP.R DS250.08.01.00.02 SEAT COMP.L GB6177.1-2000 M10X1.25 FLANG NUT M10X1.25 D250.11.005A SAFTY BELT DI250.11.01.00.07 SEAT ADJUSTER.R DI250.11.01.00.06 SEAT ADJUSTER.L 444.6.20 SCREW.PHILIPS HEAD M6X20 D250.11.058 RUBBER WASHER 6 GB6177.1-2000 M6 FLANG NUT.LOCK M6 D250.11.005A MUD GUARD DS250.11.01.00.05...

  • Page 68: Preparation Attach Instruction

    PREPARATION ATTACH INSTRUCTION ATTACH BATTERY 1、 REMOVE BATTERY FROM GO-KART REMOVE THE BOLT AND THE REMOVE THE BATTERY CAP REMOVE THE RUBBER CUSHION 2、 REMOVE ALL OF PLUGS BY SCREWDRIVER PUT OUT SEAL CAP FIX OVERFALL TUBER 3、 ILL THE ELECTROLYTE AS BELOW a) Pull the seal cap out of the plastic bottle b) Turn over the seal cap 180 degree, fix it on the outlet of plastic bottle...
  • Page 69 b) Cut the inlet of plastic bottle c) Fill the battery with electrolyte to upper lever by inserting every inlet of the battery 4、 Put the battery into the box on go-kart. 5、 Connect the wire to battery as below picture; red to “+”, black to “-”. RED WIRE BLACK WIRE 6、...

  • Page 70: Attach Front Shock

    ATTACH FRONT SHOCK FRONT SHOCK FRAME TIE ROD 1- Remove pin, nut, adjust cushion from the bolt on the tie rod. 2- Insert the tie rod into the hole on the front wheel axle. 3- Tighten the nut, insert the pin, then lock the pin. 4- Put the upper hole of the front shock into the groove on the frame.

  • Page 71: Attach Front Tire

    ATTACH FRONT TIRE The hub to fix the front tire is packed as below: 1- Remove four nuts, four spring washers, four plain washers on the hub. 2- Fix the rim on the hub. 3- Insert the washers, spring washers through bolt on the hub. Tighten four nuts. Notice: Direction marked on the tire must correspond to the vehicle forward...

  • Page 72: Attach Lookum

    ATTACH LOOKUM 1、 2、 3、 4、...

  • Page 73: Attach Rear Shock

    ATTACH REAR SHOCK a) Remove the bolt and the nut b) Attach the rear shock as below picture:...

  • Page 74: Attach Trailing Arm

    ATTACH TRAILING ARM 1、...
  • Page 75 2、...

  • Page 76: Attach Seat And Saft Belt

    ATTACH SEAT AND SAFT BELT FIX SAFTY BELT FIX SEAT FIX SEAT FIX SAFTY BELT...

  • Page 77: Attach The Radiator

    ATTACH THE RADIATOR 1- Attach the radiator as below pictures. 2- Connect wire from fan motor to main wire. 3- Arrange the main and reserve coolant rubber tube as below picture. CONNECT WIRE END FROM MAIN WIRE TO FAN MOTOR...

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