Joyner Dirt Devil SZ250DS 2006 Owner'S Manual And Parts Manual Download Page 3 | Manualshive

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CONTENTS

OWNER’SMAUNUAL

1. FOREWORD.............................................................................................  4
2.    A FEW WORDS ABOUT SAFETY.........................................................  5
3.    IMPORTANT SAFETY INFORMATION.................................................

6

4.    SAFETY LABELS..................................................................................  8
5.    ARE YOU READY TO DRIVE................................................................  9
6.    IS YOUR VEHICLE READY TO DRIVE..................................................  11
7.SAFE DRIVING PRECAUTIONS................................................................  13
8.SPECIFICATIONS.......................................................................................  15
9.OPERATION................................................................................................  16
10.SERVICE INSTRUCTIONS.......................................................................  20
11. REPAIR.....................................................................................................  24
12. PERIODICAL CHECK AND SERVICES...................................................  25
13. WIRING DIAGRAM...................................................................................  26

PARTS MANUAL

.................................................................................... 27

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Summary of Contents for Dirt Devil SZ250DS 2006

Page 1: ......

Page 2: ...S during the 90 days warranty period please contact your nearest authorized dealer for repairs What is not covered under this warranty This warranty does not cover any seller vehicle that has been sub...

Page 3: ...AFETY INFORMATION 6 4 SAFETY LABELS 8 5 ARE YOU READY TO DRIVE 9 6 IS YOUR VEHICLE READY TO DRIVE 11 7 SAFE DRIVING PRECAUTIONS 13 8 SPECIFICATIONS 15 9 OPERATION 16 10 SERVICE INSTRUCTIONS 20 11 REPA...

Page 4: ...ant safety and maintenance information Failure to follow the warnings contained in this manual can result in serious injuries Be sure to follow the recommended maintenance schedule and service your ka...

Page 5: ...Kart You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels On the Go Kart Physical harm may result from failure to adhere to the...

Page 6: ...s Take Time to Learn Practice Even if you may have driven other Go Karts take time to become familiar with how this Go Kart works and handles Practice in a safe area until you build your skills and ge...

Page 7: ...e their hands or other parts of their body near any moving part of the Go Kart Failure to adhere to this warning will cause physical harm to your body Skidding or Sliding The terrain surface can be a...

Page 8: ...nformation 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 h...

Page 9: ...nd that you always wear an approved motorcycle helmet eye protection boots gloves long pants and long sleeved shirt or jacket whenever you drive Although complete protection is not possible wearing pr...

Page 10: ...o the Go Kart s controls and feel comfortable with its size and weight Age Recommendation It is strongly recommended that no one under the age of 16 be permitted to drive this Go Kart without adult su...

Page 11: ...fuel if needed Also make sure the fuel fill cap is securely fastened Check for leaks Tires Use a gauge to check the air pressure Adjust if needed Also look for signs of damages or excessive wear Nuts...

Page 12: ...ay Make sure there is no brake fluid leakage Engine Stop Button When engine is running press and hold the Engine Stop Button for two seconds Make sure engine stops Steering Wheel Check that the wheels...

Page 13: ...reet vehicles may have difficulty seeing and avoiding you which could lead to a collision In many states it is illegal to operate Go Karts on public streets roads and highways Keep Hands and Feet on C...

Page 14: ...obstructions like hidden rocks bumps or holes in time to react Never drive past the limit of visibility Maintain a safe distance between your Go Kart and other off road vehicles Always exercise cauti...

Page 15: ...GK DPR7EA 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...

Page 16: ...The right foot pedal is the throttle that controls the Go Kart speed As the engine speed increased above idle the clutch automatically engages and moves the vehicle forward To disengage the clutch at...

Page 17: ...d tension Lubricate if necessary g Check Throttle Check for smooth operation Assure throttle snaps back to idle h Check Engine Stop Button Perform engine stop button test Repair as necessary i Check a...

Page 18: ...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 a Pull seat adjustment handle upward to...

Page 19: ...unit can t move because of in the neutral pull back the lever to R so that the unit can move backward See Fig 5 b Loosen nut 1 and 2 Adjust nut 3 can adjust the mesh status inside the reverse gear bo...

Page 20: ...e vehicle at a slow more controllable speed Heel on the ramp of the main board when turning Keep your leg rely on the foot pedal you can feel the kart is stable because of the gravity is adjusted and...

Page 21: ...uitable 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 oil as us...

Page 22: ...screw unless the carburetor needs to be replaced Prepare a 50r w tachometer before adjustment a Warm up the engine 5 10min b Tighten the airscrew gentle Back out 2 3 8 turns counter clockwise c Connec...

Page 23: ...truction 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 storage as follows a Drain fuel tank and carburetor by allowing...

Page 24: ...m 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 25: ...s 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 26: ...WIRING DIAGRAM...

Page 27: ...omp 1 12 172MM 011005 Bolt B cylinder stud 1 13 172MM 011004 Bolt A cylinder stud 3 14 NTN TMB301 Bearing TMB301 1 15 172MM 011007 Bush fixing pin 1 16 172MM 011009 Seal 34X52X5 1 17 172MM 011001 Seal...

Page 28: ...e 1 4 172MM 012003 Bolt cover plate 2 5 152MI 012200 Cushion block comp 2 6 152MI 011007 Dowel pin 10X16 2 7 172MM 012008 Plug inspection 1 8 GB T818 2000 M5 X 8 Flat screw 4 9 172MM 012100 Clamp set...

Page 29: ...MM 013001 Guide oil level 1 12 172MM 013019 T joint breather 1 13 152MI 021008 Plug inspection 1 14 172MM 01303 Bolt M6X80 1 15 172MM 013028 O ring 18X3 55 1 16 152MI 021009 Drain plug M12x1 5 1 17 17...

Page 30: ...1015 Joint bolt M12x1 25 1 13 152MI 021013 Joint bolt C M8x25 1 14 152MI 021008 Cap top inspection 1 15 152MI 021016 Washer 8 3 16 152MI 021012 Washer 1 17 152MI 021014 Washer 12 2 18 152MI 021009 Sea...

Page 31: ...022601 Lower case thermostat 1 12 172MM 022400 Spark plug comp 1 13 152MI 021017 Bolt M6x25 2 14 172MM 022800 Gasket exhaust pipe 1 15 152MI 022600 Sensor water temp 1 16 GB T6191 1986 M6X18 D Cr Bol...

Page 32: ...Valve intake 1 5 172MM 022005 Valve exhaust 1 6 172MM 022002 Outer spring valve 2 7 172MM 022003 Inner spring valve 2 8 152MI 022005 Retainer valve spring 2 9 152MI 022001 Seat valve spring 2 10 152MI...

Page 33: ...003 Bolt spring holder 1 5 152MI 023002 Spring 1 6 152MI 023004 Gasket tensioned 1 7 172MM 023007 Hose water inlet 1 8 172MM 023009 Guard shield water pipe 1 9 QC T621 1999 B24 Clamp 2 10 152MI 023009...

Page 34: ...No P N ENGLISH Qty 1 172MM 022200 Chain camshaft driver 1 2 172MM 023200 Tensioner set chain 1 3 172MM 023001 Guide chain 1 4 GB96 85 6 D Zn Washer 1 5 GB T5781 2000 M6X12 D Zn Bolt M6x12 1...

Page 35: ...oil pick up 1 3 172MM 013008 Holder wire 1 4 172MM 031000 Rotor comp 1 5 172MM 032000 Coil assembly starter 1 6 GB T70 1 2000 M8X18 Screw inner hex head 3 7 172MM 040001 Nut M16x1 1 8 172MM 040002 Was...

Page 36: ...t 1 172MM 040009 Piston ring 2nd 1 2 172MM 042000 Oil ring set 1 3 172MM 040005 Piston 1 4 172MM 040007 Pin piston 1 5 152MI 040011 Joint oil passage 1 6 152MI 040010 Spring joint 1 7 152MI 040006 Cir...

Page 37: ...ce 1 4 172MM 051100 Movable drive face comp 1 5 172MM 051200 Weight rotor comp 6 6 172MM 051001 Cover drive face 1 7 172MM 051002 Ramp plate 1 8 GB3452 1 82 112X2 65 O ring 112x2 65 1 9 GB9074 14 88 M...

Page 38: ...8 172MM 052300 Driven face comp 1 9 172MM 052100 Movable driven face comp 1 10 172MM 052002 Guide pin 4 11 172MM 052001 Roller guide 4 12 172MM 052004 Spring clutch 1 13 172MM 052200 Seal collar 1 14...

Page 39: ...MM 060008 Final gear 1 9 172MM 060010 Bolt M8x38 3 10 172MM 060011 Bolt M8x28 2 11 152MI 060003 Thrust washer 14 1 12 172MM 060004 Thrust washer 14 1 13 152MI 060009 Washer 6 1 14 152MI 060010 Washer...

Page 40: ...070001 Sprocket oil pipe 1 6 152MI 073000 Chain oil pipe 1 7 152MI 071004 Inner rotor oil pump 1 8 152MI 071005 Outer rotor oil pump 1 9 152MI 070002 Separate plate comp A 1 10 152MI 072000 Separate p...

Page 41: ...p 1 4 172MM 080002 Gasket water pump cover 1 5 172MM 080001 Shaft water pump 1 6 152MI 013009 Bolt M6x40 2 7 152MI 021017 Bolt M6x25 2 8 GB T893 1 86 19 Circlip 1 9 152MI 080007 Washer 7 5x13x1 2 1 10...

Page 42: ...1 172MM 090001 Shaft gear compound 1 2 172MM 092000 Driven gear comp 1 3 172MM 091000 Gear compound 1 4 172MM 090007 Holder 1 5 172M 093000 Starting motor comp 1 6 152MI 080013 Bolt M6x22 2 7 172MM 0...

Page 43: ...No P N ENGLISH Qty 1 172MM 100000 Carburetor assy 1...

Page 44: ...washer 2 14 D250 11 004 Tube seat 32 2 15 DS250 01 05 00 00 Protective Bar Right 1 16 DS250 11 01 00 10 Rear cargo rack 1 17 DS250 01 01 02 11 Battery box 1 18 444 5 20 Bolt flange M8x20 4 19 555 5 N...

Page 45: ...02 Front shock 2 7 444 12 45 Bolt flange M12x1 5x45 8 8 444 10 60 Bolt flange M10x1 25x60 4 9 JD0110004 Rubber upper arm 4 10 333 10 Nut flange M10x1 25 4 11 DS250 02 02 00 00 Upper arm 2 12 333 16 N...

Page 46: ...0mm 2 16 333 10 Nut castle M10x1 25 2 17 888 2 30 Pin cotter 2 18 D250 03 003 Washer 2 19 0250 03 004 Washer 1 20 D250 03 006 Nylon cover R 1 21 D250 03 007 Bracket steering gear 2 22 D250 03 008 Nylo...

Page 47: ...0x1 25x210 1 6 DS250 02 00 00 02 Cushion blocking 4 7 DS250 02 00 00 03 Fixed rod front engine 1 8 DS250 02 00 00 04 Fixed rod rear engine 1 9 DS250 02 00 00 01 Engine rack 1 10 444 10 55 Bolt flange...

Page 48: ...ge lock M12x1 5 2 8 D250 05 005 Bushing swing arm 2 9 D250 05 006 Spacer swing arm 2 10 444 12 65 Bolt washer M12x1 5x65 2 11 D250 05 002 Clamp piece prejudicial tray 2 12 444 8 30 Bolt flange M8x30 8...

Page 49: ...38 62 8 Seal axle carrier 2 13 770 62 Circlip 62mm 4 14 D250 06 007 Compart spacer 2 15 D250 06 004 Eccentricity tray 2 16 666 206 Bearing 4 17 999 45 65 8 Seal axle carrier 2 18 D250 06 010 Sensor s...

Page 50: ...Turning signal Rear 2 8 DS250 10 00 00 02 Panel 1 9 D250 07 911 Function display 2 1 10 D250 07 906 Function display 1 1 11 DS250 10 00 00 05 Horn button 1 12 D250 07 909 Ignition switch 1 13 D250 07...

Page 51: ...6 D250 08 990 Sensor 1 7 JD1082101 Handgrip 1 S DS250 07 00 00 03 Lever reverse gear 1 9 REV 35 Spring 1 10 REV 36 Sliding 1 11 444 8 55 Nut hex M8x55 2 12 444 4 16 Bolt M6x16 1 13 555 4 Washer lock 4...

Page 52: ...andby water tank 1 6 D250 09 004 Water pipe for tank 1 7 D250 09 904 Cover for add water 1 8 D250 09 008 Cooling pipe 1 9 333 10 Nut M10 2 10 222 10 Washer flat 10mm 2 11 444 10 Bolt M10x25 2 12 31300...

Page 53: ......

Page 54: ...66 204 Bearing 6204 1 31 770 47 Circlip 47 1 32 999 28 47 8 D Seal axle carrier 28x47x8 1 33 DS250 07 01 00 23 Gasket for out 1 34 DS250 07 01 00 22 Shaft seat for out 1 35 444 6 12 Screw philips head...

Page 55: ...1 3 444 8 30 Bolt flange M8x30 2 4 333 8 Nut lock M8 8 5 DS250 11 01 00 12 Exhaust pipe Canister 1 6 D250 11 880 Mounting exhaust pipe 1 7 444 8 20 Bolt flange M8x20 2 8 444 8 45 Bolt flange M8x45 2...

Page 56: ...arning 1 2 D250 02 004 China warning 1 3 D250 12 005 Luggage carrier warning 1 4 D250 12 003 Safety belt warnlng 2 5 D250 12 002 Colligate warning 1 6 D250 12 006 Shift reverse gear 1 7 D250 12 007 Ag...

Page 57: ...eal FB 25x40x7 2 9 D250 02 007 Spacer FR hub outer 2 10 555 16 Lock washer front axle 16mm 2 11 888 4 40 Cotter pin 4x40 2 12 330 16 Nut front axle M16x1 5 2 13 222 16 Washer front axle 16mm 2 14 D250...

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