Joyner Dirt Devil 250 2004 Owner'S Manual And Parts Manual Download Page 81

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PREPARATION INSTRUCTIONS FOR THE GO-CART

Packing situation for SZ250DL.

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Rear of packing

Summary of Contents for Dirt Devil 250 2004

Page 1: ......

Page 2: ......

Page 3: ...CONTENTS...

Page 4: ...nual can result in serious injuries Be sure to follow the recommended maintenance schedule and service your kart accordingly Preventive maintenance is extremely important to the longevity of your Go K...

Page 5: ...o Kart You must use your own good judgment You will find important safely information in a variety of forms including Safety Labels On the Go Kart Safety Messages Preceded by a safety alert symbol and...

Page 6: ...Only Your Go Kart is designed and manufactured for off road use only The tires are not made for pavement and the Go Kart does not have turn signals and other features required for use on public roads...

Page 7: ...e and don t let your friends drink and drive either Never run your Go Kart indoors The exhaust from the engine contains a tasteless odorless and poisonous gas called carbon monoxide Keep away from mov...

Page 8: ...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 ha...

Page 9: ...protection and other protective clothing You don t have any alcohol or drugs in your system Protective Apparel For your safety we strongly recommend that you always wear an approved motorcycle helmet...

Page 10: ...hest 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 handle...

Page 11: ...ause having a breakdown or even a flat tire can be a major inconvenience If your Go Kart has overturned or has been involved in a collision do not drive it until your Go Kart has been inspected by you...

Page 12: ...working properly 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...

Page 13: ...nce and to control of the Go Kart Removing hands or foot away from the controls can reduce your ability to react control of the kart When driving ofT road also remember to always obey local ofT road d...

Page 14: ...nd reasonable manner When driving always keep all four wheels on the ground Use Care on Unfamiliar or Rough Terrain Before driving in a new area always check the terrain thoroughly Don t drive fast on...

Page 15: ...6EIX 9 NGK Plug Gap 0 6 0 7mm Fuel type RQ90 unleaded Lubricate oil SAE 10W 30 CAPACITIES Maximum load Double Seats 400lbs Fuel Tank 16 0L Engine Oil 1000ml Coolant 1800ml Starting 5s Climbing 20 25 B...

Page 16: ...moves the vehicle forward To disengage the clutch at any time allow the throttle to return to the idle position See Fig 1 b Brake The brake is located on the left side of the kart See Fig 1 Applying p...

Page 17: ...e The pressure on both Front and Rear tire is 15kpa and 20kpa e Check Drive Chain Check for drive chain s condition and tension Lubricate if necessary f Check Throttle Check for smooth operation Assur...

Page 18: ...OPERATION Component locations Figure 3...

Page 19: ...e 4 a Pull seat adjustment handle upward to disengage seat slide b Move seat to desired position c Be sure seat adjustment handle snaps back into place and that seat is locked into position E Reverse...

Page 20: ...to the F position so that the unit can move forward pull back the lever to P so that the unit can Parking See Fig 6 b Adjust Nut 1 on the top of the reverse cable can adjust the mesh status inside re...

Page 21: ...turning to prevent the Go Kart from rolling over e To prevent vehicle from rolling over be sure to only turn the vehicle at a slow more controllable speed Heel on the ramp of the main board when turn...

Page 22: ...oil into suitable container b Replace fill plug and tighten securely Place kart in a level position c Refill crankcase approximately 1000 ml to top of filler neck with SAE 10W 30 oil Use same grade of...

Page 23: ...correct for most applications It s not necessary to disassemble the screw unless the carburetor needs to be replaced Prepare a 50r w tachometer before adjustment a Warm up the engine 5 l0min b Tighten...

Page 24: ...ingarm on frame c Tighten the 12 bolts Figure 12 J Storage Instruction In the event your kart is not to be operated for periods in excess of 30 days or at the end of each driving season prepare for st...

Page 25: ...end play See Fig 14 Tighten the nuts and put on the cotter Pin after replacing the wheels Figure 14 C Front Wheel Alignment a The front wheels should be toe in from 1 8 to 1 4 To check for alignment...

Page 26: ...m Initial service first week Monthly Quarterly Yearly Tire pressure wear I I Brake performance I I Tightness of screws I I Air cleaner C I Carburetor I A C Spark plug C A Drive chain I I C A L Brake o...

Page 27: ...WIRING DIAGRAM...

Page 28: ...ater 40 12 Pump comp oil 41 13 Electrical start propeller 42 14 Carburetor comp 43 15 Air cleaner comp 44 16 Radiator comp 45 BODY 1 Frame and fuel tank 46 2 Suspension arm assy 48 3 Steering assy and...

Page 29: ...M14x1 6 1 9 A06010007 O ring 13x28 1 10 SZ01010002 O ring 9 4x2 4 2 11 SZ01011003 Gasket cylinder head 1 12 SZ01012004 Washer 1 13 SZ01013005 Bolt M8x25 2 5 1 14 SZ01014006 Washer 12 2 15 SZ01015007...

Page 30: ...2 8 440602521 Bolt M6x25 2 9 SZ02013006 Nut M8 4 10 SZ02012005 Washer 8 4 11 440601221 Bolt M6x12 2 12 SZ02014007 Cover cam bearing 1 13 SZ02041007 Head cylinder 1 14 SZ02050007 Chain 1 15 SZ02120005...

Page 31: ...030005 Inlet hose clamp 1 33 170720000 Clamp 4 34 SZ02019002 Rubber tube 1 35 440601621 Bolt M6x16 2 36 SZ02201005 Thermostat lower case 1 37 SZ02220006 Constant temp valve assy 1 38 SZ02203007 Thermo...

Page 32: ...007 Gasket 1 7 SZ03033009 Cam Chain Tensioner 1 8 440601821 Bolt M16x18 2 9 SZ03002005 Spring 1 10 80080000 Washer 8 100HV 1 11 SZ03003006 Bolt hex 1 12 SZ03020005 Plate of tension Lower Chain Guide 1...

Page 33: ...nkcase assy L 1 9 SZ04060000 Rear pin 1 10 316004120 Bearing 6004 2Z P5 1 11 SZ04050009 Seal 27 42 7 1 12 740822000 Nut M8 1 13 SZ04050009 Rubber pin 2 14 316301100 Bearing 6301 P5 1 15 351420120 Bear...

Page 34: ...4 Crankcase comp No P N ENGLISH Qty 25 SZ04006000 O ring 9x1 7 2 26 SZ04080002 1 27 440601621 Bolt M6x16 3...

Page 35: ...1 7 SZ03101005 Union water outlet pipe 1 8 440606021 Bolt M6x60 2 9 SZ05002007 Gauge oil lever 1 10 440604021 Bolt M6x40 2 11 A06010007 O ring 13x2 8 1 12 SZ01008009 Plug M14x1 6 1 13 A03011005 O ring...

Page 36: ...6202000 Cushion block 2 4 SZ06201009 Cushion block seat 2 5 SZ06004000 Bolt 2 6 SZ06005001 Filter 1 7 SZ06101008 Seal 1 8 SZ06102009 Dust seal 1 9 SZ06002008 Backing plate l 10 SZ06120009 Cover plate...

Page 37: ...d 1 3 SZ07020009 Ring piston third 1 4 SZ07001008 Piston 1 5 SZ07003000 Clip piston pin 2 6 SZ07002009 Pin piston 1 7 SZ07100008 Crankshaft COMP 1 8 SZ07006003 Key woodruff 1 9 SZ07009006 Pin 2x11 5 1...

Page 38: ...p No P N ENGLISH Qty 1 SZ08100009 Move side of transmission Variator 1 2 SZ08001009 Collar of shaft Center Bushing 1 3 SZ08002000 Drive side of transmission Fan Plate 1 4 SZ07007004 Washer 1 5 SZ08003...

Page 39: ...9 SZ09420005 Clutch retracting spring Arm spring 3 10 SZ09430006 Clutch block assy 3 11 SZ09005004 Washer 1 12 SZ09403006 Rubber block cushion 3 13 SZ09420005 Drive disc assy l 14 SZ09007006 Nut l 15...

Page 40: ...ip external l 8 SZl 0006007 Gear drive 1 9 SZl 0005006 Thrust washer 1 10 316203100 Bearing 6203 P5 1 11 SZl0210003 Gasket of cover 1 12 SZl0008009 Pin dowel 10x16x6 4 2 13 SZl0300004 Tube breather ru...

Page 41: ...6 1 7 SZ11005007 Cover water pump 1 8 SZ11004006 Gasket water pump cover 1 9 SZ11008000 Pin 8x14x6 4 2 10 SZ11002004 Gose 1 11 SZ11200004 Bush 1 12 SZ11006008 Impeller of water pump 1 13 SZ11007009 Wa...

Page 42: ...5 SZ12105009 Rotor oil pump outer 1 6 SZl2102006 Body oil pump 1 7 SZ12I01005 Shaft oil pump 1 8 SZl2100004 Pump assy oil 1 9 SZl 2020005 Front back plate 1 10 440602821 Bolt M6x28 2 11 SZl2030006 Ch...

Page 43: ...3 10 SZ13003007 Roller 3 11 SZ13033000 Plug 3 12 SZ 13031008 Clutch body 1 13 SZ 13030007 One way clutch assy 1 14 SZ15100007 Flywheel assy 1 15 440503021 Bolt hex M5x30 3 16 SZ15200008 Stator assy 1...

Page 44: ...14 Carburetor comp No P N ENGLISH Qty 1 SZ16000007 Carburetor COMP 1...

Page 45: ...No P N ENGLISH Qty 1 SZ17000008 Air cleaner assy 1 2 SZ17000132 Bracket 1 3 SZ17000110 Fixing bolt 3 4 SZ17000143 Breather hose 1 5 170720000 Clamp 7 2 15 Air cleaner comp...

Page 46: ...2 Radiator inlet 1 9 SZ19601007 Water inlet body 1 10 SZ19620008 Radiator cap 1 11 161320000 Clamp 13 4 12 SZ19003003 Hose of radiator inlet 1 13 SZ19604000 Hose of heat inlet 1 14 SZ19602008 Sub hose...

Page 47: ...tective bar top 2 8 D250 11 771 Foam set 2 9 D250 11 702 Protective bar rear 1 10 444 10 65 Bolt flange M10X65 2 11 222 10 Washer 10 2 12 D250 11 001 Round rubber seat 2 13 D250 11 058 Round washer 44...

Page 48: ...omp fuel filler Gas Cap 1 21 D250 11 804 Tank comp fuel 1 22 D250 11 003 Rubber cushion 1 23 D250 11 903 Valve assembly fuel petcock 1 24 D250 11 060 Tube comp fuel 1 25 D250 11 802 Rear cargo rack 1...

Page 49: ...0 Pin cotter 2 10 330 12 Nut castle M12x1 25 2 11 555 12 Washer lock 12 2 12 222 12 Washer flat 12 2 13 D250 02 001 Dust cover moire 2 14 D250 02 802 Support strut and spindle R 1 15 D250 02 901 Unive...

Page 50: ...N ARM ASSY No P N ENGLISH Qty 24 440 12 245 Bolt washer M12x245 2 25 D250 11 905 Cushion assy FR 2 26 440 12 65 Bolt washer M12x1 5x65 4 27 D250 02 801 Support strut and spindle L 1 28 D250 02 804 Low...

Page 51: ...er M8x35 2 9 333 8 Nut flange lock M8 5 10 D250 03 901 Steering knuckle 1 11 D250 03 902 Steering gear 1 12 D250 03 006 Nylon cover R 1 13 D250 03 007 Bracket steering gear 2 14 D250 03 008 Nylon cove...

Page 52: ...10 801 Throttle pedal comp 2 30 D250 10 003 Spring 2 31 333 8 Nut M8 4 32 D250 10 904 Cable throttle 1 33 444 6 30 Bolt washer M6x30 2 34 333 6 Nut flange lock M6 2 35 222 10 Washer flat 10 2 36 D250...

Page 53: ...04 901 Electric ass y 1 8 440 12 60 Bolt washer M12x1 5x60 2 9 D250 04 802 Fixed rod rear engine 1 10 440 10 50 Bolt washer M10x1 25x50 1 11 440 14 240 Bolt washer M14x1 5x240 1 12 222 14 Washer flat...

Page 54: ...16 Washer lock 16 2 6 330 16 Nut M16x1 5 2 7 330 12 Nut flange lock M12x1 5 2 8 D250 05 005 Bush swing arm 2 9 D250 05 006 Spacer swing arm 2 10 444 12 65 Bolt washer M12x1 5x65 2 11 D250 05 002 Clam...

Page 55: ...olt M10x1 25x30 8 10 330 30 Nut wheel M30x1 5 4 11 D250 06 006 Spacer 2 12 999 38 62 8 Seal axle carrier 38x62x8 2 13 770 62 Circlip 62 4 14 D250 06 007 Compart spacer 2 15 D250 06 004 Eccentricity tr...

Page 56: ...ty 24 D250 06 003 Mounting brake 1 25 D250 06 008 Limit bolt 1 26 444 8 15 Bolt M8x15 12 27 555 8 Washer lock 8 12 28 222 8 Washer flat 8 12 29 D250 06 013 Disc IT brake 1 30 D250 06 009 Big sprocket...

Page 57: ...2 8 D250 07 902 Switch box 1 9 D250 07 911 Function display 2 1 10 D250 07 906 Function display 1 1 11 D250 07 001 Panel 1 12 D250 07 908 Button engine 1 13 D250 07 909 Ignition switch 1 14 D250 07 90...

Page 58: ...2 9 D250 08 906 Ball reverse gear 4 10 D250 08 801 Long drive lever 1 11 330 10 Nut flange lock M10x1 25 1 12 D250 08 003 Sway arm right angle 1 13 D250 08 016 Shaft 1 14 D250 08 802 Short drive lever...

Page 59: ...09 903 Standby water tank 1 6 D250 09 004 Water pipe for tank 1 7 D250 09 904 Cover for add water 1 8 D250 09 908 Cooling pipe 1 9 333 10 Nut M10 2 10 222 10 Washer flat 10 2 11 444 10 Bolt M10x25 2...

Page 60: ...10 REVERSE GEAR...

Page 61: ...17 666 204 Bearing 6204 1 18 770 47 Circlip 47 1 19 777 20 Circlip 20 1 20 D250 08 111 Shaft seat 1 21 D250 08 112 Prick gear 1 22 D250 08 113 Compart spacer 1 23 D250 08 114 Joint spacer 1 24 D250 08...

Page 62: ...ector board shaft 1 46 D250 08 123 Sector board 1 47 D250 08 124 Compart spacer 1 48 333 10 Nut M10 1 49 333 8 Nut M8 4 50 444 8 35 Screw M8x35 4 51 D250 08 125 Reverse gear box 1 52 424 6 12 Bolt M6x...

Page 63: ...al exhaust pipe 1 2 D250 11 888 Exhaust pipe 1 3 444 8 35 Bolt M8x35 1 4 D250 11 041 Mounting exhaust pipe 2 5 444 8 12 Bolt M8x12 2 6 D250 11 880 Mounting exhaust pipe 1 7 D250 11 887 Front exhaust p...

Page 64: ...arning 1 2 D250 02 002 Colligate warning 1 3 D250 12 003 Safety belt warning 2 4 D250 12 005 Luggage carrier warning 1 5 D250 12 004 Chain warning 1 6 D250 12 006 Shift reverse gear warning 1 7 D250 1...

Page 65: ...2 2 D250 11 904 Seat comp 2 3 444 10 25 Bolt flange M10x25 14 4 333 10 Nut flange lock M10 14 5 D250 11 003 Seat cushion board 2 6 422 6 20 Screw washer M6x20 12 7 333 6 Nut flange lock M6 12 8 D250 1...

Page 66: ...250 11 008 Mudguard right rear 1 5 D250 11 051 Support mudguard 1 2 6 D250 11 052 Support mudguard 2 2 7 D250 11 053 Support mudguard 3 2 8 D250 11 054 Support mudguard 4 2 9 444 8 30 Bolt flange M8X3...

Page 67: ...005 Spacer FR hub 2 7 666 203 Bearing outer 6203 2 8 999 25 40 7 Seal FB 25x40x7 2 9 D250 02 007 Spacer FR hub outer 2 10 555 16 Lock washer 2 11 888 4 40 Cotter pin 4x40 2 12 330 16 Nut front axle M...

Page 68: ...L TANK ATTACH HEADLIGHT ATTACH LEFT AND RIGHT REAR TURN SIGNALS 72 6 ATTACH LOOKUM 73 7 ATTACH REAR BRAKE LAMP ATTACH REAR SHOCK 74 8 ATTACH REAR TIRE 75 9 ATTACH SEAT 76 10 ATTACH STEERING WHEEL 77 1...

Page 69: ...rubber cushion and tighten two bolts Notice Before using new battery it need to notice follows 1 After the battery is filled electrolyte the new battery need to recharge as the Owner s manual said Ot...

Page 70: ...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 2 Attach upper bumper to t...

Page 71: ...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 5 Insert the bolt though the...

Page 72: ...uts four lock cushion four cushion on the hub 3 Insert the cushion lock cushion through bolt on the hub Tighten four nuts Notice Direction marked on the tire must correspond to the vehicle forward ATT...

Page 73: ...HEADLIGHT ATTACH TURN SIGNAL Figure 1 Figure 2 Attach headlight Attach headlight as below pictures Attach left and right rear turn signals 1 Attach the right rear turn signal as picture 2 Connect wire...

Page 74: ...ATTACH MIRROR...

Page 75: ...TTACH REAR BRAKE LAMP ATTACH REAR SHOCK 2 Connect wire of rear lamp to main wire as picture Attach rear shock Remove the bolt 1 Attach the rear shock as below picture 2 Tighten the bolt and nut cushio...

Page 76: ...REAR TIRE 1 Remove the cover oh hub 2 Remove the pin nut cushion 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 pic...

Page 77: ...ATTACH SEAT 1C Figure 2 Figure 1 Figure 3 Figure 4...

Page 78: ...over Insert the switch Assy through the steering shaft along the groove on the frame 1 Insert steering wheel through the shaft 2 Adjust two front wheel to direct straight forward by turning steering w...

Page 79: ...1 Attach the radiator as below pictures 2 Connect wire from fan motor to main wire ATTACH THE RADIATOR 3 Arrange the main and reserve coolant rubber tube as below pictures...

Page 80: ...ATTACH THE REAR RACK 1 Insert four bolt between the rear rack and the frame 2 Tighten the four bolt and the nuts as the below picture...

Page 81: ...PREPARATION INSTRUCTIONS FOR THE GO CART Packing situation for SZ250DL Front of packing Rear of packing...

Page 82: ...THE WHOLE GO KART LOOKS Front review Side Review Back Review Upper Review...

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Joyner Dirt Devil 250 2004, Owner'S Manual And Parts Manual

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Summary of Contents for Dirt Devil 250 2004

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