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Joyner JNSZ150DS, Owner'S Manual, Page: 1 / 74

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Owner’s manual       

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 public streets, 

roads, or highways is illegal

 

 

 

                             

JNSZ150DS 

 
 
 
 
 

Summary of Contents for JNSZ150DS

Page 1: ...FETYINFORMATION 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 stan...

Page 2: ...50DS 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...

Page 3: ...ASSY 1 28 4 CRANKCASE ASSY 2 29 5 CRANKSHAFT CON ROD PISTON ASSY 31 6 CAMSHAFT ASSY 32 7 LEFT COVER ASSY 33 8 FAN COVER AND SHROUD ASSY 34 9 OIL PUMP ASSY 35 10 DRIVEN PULLEY AND CLUTCH SUBASSY 36 11...

Page 4: ...3 ATTACH BATTERY 65 ATTACH PROTECTIVE BARS 66 ATTACH REAR SHOCK 66 ATTACH TRAILING ARM 67 ATTACH BRAKE PIPE 67 ATTACH FRONT SHOCK 68 ATTACH FRONT TIRE 69 DEALER PRE DELIVERY INSPECTION 70...

Page 5: ...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 Kart...

Page 6: ...Go 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 Safety Messages Preceded by a safety alert symbol an...

Page 7: ...ross Take Time to Learn Practice Even if you have driven other Go Kart take time to become familiar with how this Go Kart works and handles Practice in a safe area until you build your skills and get...

Page 8: ...r 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 major...

Page 9: ...formation and recommendations to help you drive your Go Kart safely Please take a few moments to read these pages The labels be considered permanent parts of the Go Kart If a label comes off or become...

Page 10: ...proper gear can reduce the chance of injury when you drive The following suggestions will help you choose the proper driving gear Helmets and Eyes Protection Your helmet is your most important piece...

Page 11: ...mendation It is strongly recommended that no one under the age of 8 be permitted this Go Kart without adult supervision A child under 8 driving a Go Kart that is not recommended for his her age could...

Page 12: ...on Check the following items before you get on the Go Kart Engine Oil Check the level and add oil if needed Check for leaks Coolant Check the coolant and add coolant if need Check for the leaks Fuel C...

Page 13: ...moves smoothly without sticking and snaps back automatically when it is released Brakes Press the brake pedal several times check for proper brake pedal free play Make sure there is no brake fluid lea...

Page 14: ...s of street 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 Operating this Go...

Page 15: ...Go Kart overturning or going out of control Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the Go Kart Never drive p...

Page 16: ...park Plug A7RTC Plug gap 0 6 0 8mm Fuel type RQ90 Lubrication oil SAE 15W 40 CAPACITIES Maximum load 120kg Fuel tank 8L Engine oil 900ml Starting 15s Climbing 20 25 Battery 12V9Ah Head Light 12V 18 18...

Page 17: ...problem through lubrication adjustment or replacement of worn parts contact your dealer for assistance b Brake The left foot pedal is the brake See Fig 1 Applying pressure to the pedal draws the brake...

Page 18: ...s 12psi 7 Check Throttle Check for smooth operation Assure throttle snaps back to idle 8 Check Engine Stop key Perform engine stop key test Repair as necessary 9 Check all Nuts Bolts and fasteners Che...

Page 19: ...to R so that the unit can move backward See Fig 4 Figure 4 i Starting And Operating Instructions a Before starting the engine be sure that the driver is seated properly in the Go Kart and tighten the...

Page 20: ...filter See Fig 8 Figure 7 Figure 8 c Check the air cleaner filter if the filter is dusty please replace with a new one B Engine Lubrication Engine oil replacement You must change the oil in the crankc...

Page 21: ...replace engine oil Replace engine oil as above b Check the engine oil level recharge if necessary from d as above C Spark Plug a Remove the spark plug and inspect it each time you change the oil Use...

Page 22: ...e off the dirt and oil around controls Wipe off any spilled fuel and oil Keep the engine clean of foreign object and be sure to check that air intake fan is free of debris for proper cooling F Kart Lu...

Page 23: ...Tighten the nuts and put on the cotter Pin after replacing the wheels Figure 15 C Front Wheel Alignment a Put the vehicle on level plate firmly b The toe in front wheels should be 0 4 0 6 inches To c...

Page 24: ...6 Exhaust I I 7 Transmission oil I R Ignition 10 Air cleaner C I 11 Throttle cable I A L I R A 12 Fuel tank cover I I R 15 Fuel hose and joints I I I R Control system 16 Wire and plugs I 18 Brake flu...

Page 25: ...24 WIRING DIAGRAM...

Page 26: ...25 PARTS MANUAL 1 CYLINDER HEAD ASSY...

Page 27: ...26 1 CYLINDER HEAD ASSY...

Page 28: ...27 2 CYLINDER ASSY...

Page 29: ...28 3 CRANKCASE ASSY 1...

Page 30: ...29 4 CRANKCASE ASSY 2...

Page 31: ...30 4 CRANKCASE ASSY 2...

Page 32: ...31 5 CRANKSHAFT CON ROD PISTON ASSY...

Page 33: ...32 6 CAMSHAFT ASSY...

Page 34: ...33 7 LEFT COVER ASSY...

Page 35: ...34 8 FAN COVER AND SHROUD ASSY...

Page 36: ...35 9 OIL PUMP ASSY...

Page 37: ...36 10 DRIVEN PULLEY AND CLUTCH SUBASSY...

Page 38: ...37 11 TRANSMISSION ASSY...

Page 39: ...38 12 ELECTRIC SYSTEM...

Page 40: ...39 13 ELECTRIC STARTER ASSY...

Page 41: ...40 14 DRIVE PULLEY SUBASSY...

Page 42: ...41 15 GOMP OF GY REVER SE GEAR ENGINE...

Page 43: ...42 15 GOMP OF GY REVER SE GEAR ENGINE...

Page 44: ...43 16 CARBURETOR...

Page 45: ...44 16 CARBURETOR...

Page 46: ...45 3 4 5 6 7 2 8 1 17 FRAME 14 18 19 9 11 10 12 13 21 20 16 15 17...

Page 47: ...00 01 35 CROSS PANHEAD SCREW M6X16 GB T818 2000 M6X16 35 RUBBER GASKET 6 34 SELF LOCKING FLANGE NUT M6 GB T6187 2000 M6 1 NETHER BOARD OF ELECTRICAL INSTALLATION D250 01 000 210A JD0900008 8 SELF LOCK...

Page 48: ...1 2000 M10X30 1 LEFT PROTECTIVE BAR DS150 01 02 01 00 4 FLANGE BOLT M12X1 25X60 GB5787 86 M12X1 25X60 4 NYLON BUSH D250 11 771 4 FLANGE NUT M12 GB6177 1 2000 M12 4 FLANGE BOLT M10X1 25X35 GB5787 86 M...

Page 49: ...24 25 26 1 OPTIONAL ALUMINUM ROOF RACK DS150 01 02 02 00 4 FLANGE NUT M10X1 25 GB T6177 2000 M10X1 25 4 RACK SPACER SLEEVE D1600 01 02 00 07 4 LOOP M10X1 25 D1600 08 01 00 06 18 PROTECTIVE BAR 4 FLAN...

Page 50: ...49 17 14 15 16 23 24 25 26 27 30 31 34 3536 37 38 39 40 42 43 44 20 3 2 19 18 41 1 28 29 33 32 19 FRONT SUSPENSION 4 5 9 8 7 6 10 11 8 13 12 22 21 45 48 47 46 49...

Page 51: ...5X30 4 1 STUB AXLE L DS250 02 00 00 03 2 BUSH 3 FRONT KNUCKLE JD0360008 2 BALL BEARING 6204 GB T276 1994 6204 2 BUSH 2 FRONT KNUCKLE JD0360007 12 KNURLED BOLT 2 HUB FRONT WHEEL JD0360200 EU 8 2 GB1387...

Page 52: ...3 64 65 66 87 88 89 90 91 92 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 47 48 49 50 51 52 53 54 19 FRONT SUSPENSION 2 FRACTION PLATE 1 DN250 04 01 00 03 2 FRACTION PLATE 2 DN250 04 01...

Page 53: ...4 16 17 18 19 21 22 23 27 28 26 24 20 4 3 2 1 15 25 29 30 31 16 41 42 38 37 43 44 45 46 49 50 52 53 54 55 56 57 58 59 60 61 65 64 66 67 70 76 75 74 73 72 71 68 69 20 CONTROL SYSTEM ASSEMBLY 51 40 39 3...

Page 54: ...03 10 1 BALL BEARING 20X42X12 D800 05 01 03 09 GB5787 1986 M10X1 25X75 FLANGE BOLT M10X1 25X75 2 1 BEARING COVER D800 05 01 03 05 GB5787 1986 M10X1 5X12 FLANGE BOLT M10X1 5X12 2 GB5787 1986 M6X25 FLAN...

Page 55: ...4 16 17 18 19 21 22 23 27 28 26 24 20 4 3 2 1 15 25 29 30 31 16 41 42 38 37 43 44 45 46 49 50 52 53 54 55 56 57 58 59 60 61 65 64 66 67 70 76 75 74 73 72 71 68 69 20 CONTROL SYSTEM ASSEMBLY 51 40 39 3...

Page 56: ...DS150 04 02 00 00 1 THROTTLE PEDAL DS150 04 00 00 01 1 CABLE THROTTLE DS150 04 04 00 00 PLAIN WASHER 8 GB T95 1985 8 1 DS150 05 04 01 00 SHIFT CABLE 1 GB6177 1 2000 M6X15 FLANGE NUT M6X15 2 GB T91 200...

Page 57: ...56 9 10 11 12 14 15 17 18 19 20 5 6 7 8 16 21 22 23 24 25 26 27 28 32 34 33 35 31 4 1 13 30 29 2 3 21 REAR SUSPENSION 38 37 36 39...

Page 58: ...1 2000 M12X1 5 FLANGE NUT M12X1 5 4 FLANGE BOLT M12X1 5X60 GB5787 1986 M12X1 5X60 DS150 09 02 00 00 SHOCK ABSORBER REAR 2 4 GB2673 1986 M6 20 SUNK SCREW M6X20 DI250 04 01 00 04 DISC REAR BRAKE 4 2 2 D...

Page 59: ...2000 M12X1 5 FLANGE NUT M12X1 5 1 2 3 5 6 8 9 10 14 15 13 16 11 12 GB T9877 1988 FB38X62X8 GREASE SEAL FB 38X62X8 2 2 BEARING BLOCK DN250 07 00 00 06 GB T9877 1988 FB35X55X8 GREASE SEAL FB 35X55X8 2 6...

Page 60: ...FIXED MOUNT 1 DS150 07 03 00 00 ENGINE ASSEMBLY 1 CAPPED NUT EXHAUST PIPE 2 DS150 05 03 00 02 EXHAUST ELBOW PIPE 1 DS150 05 03 00 01 19 23 ENGINE SYSTEM ASSEMBLY 36 32 31 24 25 26 27 28 30 29 23 10 1...

Page 61: ...B5787 86 M6X20 1 FIXED BAR OF AIR FILTER DS150 01 04 00 02 1 AIR FILTER DS150 05 02 01 00 DS150 05 02 01 01 AIR CLEANER FILTER 1 N650 08 05 00 01 HOSE CLAMP 6 DS150 05 02 00 04 1 8 FUEL PIPE 2 DS150 0...

Page 62: ...FULL THREAD BOLT M12X1 75X100 2 GB6170 2000 M12X1 75 NUT M12X1 75 2 DS150 05 02 02 01 MOUNTING CARBURETOR 1 DS150 05 02 02 00 CARBURETOR 1 DS150 05 02 01 01 MOUNTING AIR FILTER 1 1 FLANGE BOLT M10X1...

Page 63: ...JD1910003 4 STEEL BUSH WATER TANK JD1910002 1 RUBBER BUSH FULE TANK JD1135001 1 DS150 05 02 00 01 4 FLEXIBLE FUEL PIPE 2 RUBBER BAND S250 11 003 2 SUPPORT FUEL TANK DI250 05 02 00 01 2 1 3 20 19 18 17...

Page 64: ...TAGE REGULATOR 1 DI250 10 05 00 00 IGNITION COIL 1 DS150 10 04 00 00 CDI 1 D250 07 912 RELAY 1 DS150 10 01 01 00 FUSE BOX 1 HORN DS150 10 08 00 00 1 BATTERY D250 07 802 PLASTIC TAP D650 08 05 00 06 2...

Page 65: ...1 01 00 00 SEAT 2 8 SELF LOCKING FLANGE NUT M8 GB T6187 2000 M8 5 6 7 4 6 7 8 DS150 11 08 00 00 COWL 1 DS150 11 03 00 00 COWL PROTECTIVE BAR 1 series DS150 11 10 00 00 COWL SHOCK ABSORBER 2 pairs DS15...

Page 66: ...the battery into the box on go kart STEP 3 Connect the wire to battery as below picture red to black to STEP 4 Fix the battery cap rubber cushion and tighten both bolts and nuts Notice Before use new...

Page 67: ...66 ATTACH PROTECTIVE BARS 1 2 ATTACH REAR SHOCK a Remove the bolt and the nut b Attach the rear shock as below pictures...

Page 68: ...67 ATTACH TRAILING ARM 1 2 ATTACH BRAKE PIPE Front Rear...

Page 69: ...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 5 Insert the bolt th...

Page 70: ...ed 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...

Page 71: ...70 DEALER PRE DELIVERY INSPECTION...

Page 72: ...ts _______I have been shown the VIN number for each machine and they match this form and all paperwork received _______I understand that I have only 72 hours to notify the seller of any issues to the...

Page 73: ...le for failure to deliver or for delay in delivering the Vehicle or other product where such failure or delay is due in whole or in part to any cause beyond Seller s control or without Seller s fault...

Page 74: ...le or product or fails to comply with this contract Seller may keep any cash deposit as liquidated damages to the extent not prohibited by law The deposit may also be used to reimburse Seller for any...

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