Joyner JNSZ250DN Owner'S Manual Download

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ENGINE OIL PUMP ASSY

No. P/N

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

PUMP.INNER

151MI-071005 ROTOR.OIL

PUMP.OUTTER

151MI-070002

SPACER PLATE A.OIL PUMP

151MI-072000

SPACER PLATE B.OIL PUMP

GB878-85-M3X12 SCREW

151MI-071006

LOCATION PIN 4X6.5

GB894.1-86-10 RETAINER

RING.AXIS

151MI-021019 BOLT

M6X12

151MI-070003 BOLT

M6X28

Summary of Contents for JNSZ250DN

Page 1: ...FETY INFORMATION MINIMUM RECOMMENDED OPERATOR AGE JNSZ250DN 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...

Page 2: ...0DN during the 90 days warranty period please contact the nearest authorized dealer for repairs What is not covered under this warranty This warranty does not cover any seller vehicle that has been su...

Page 3: ...5 5 CYLINGDER HEAD ASSY 37 6 CYLINGER BODY ASSY 39 7 TIMING CHAIN 40 8 MAGNETOR ASSY 41 9 ADMISSION MACHANISM 42 10 CRANK LINK LEVER PISTON 43 11 SPEED CHANGER 44 12 CLUTCH ASSY 45 13 GEARBOX COVER AS...

Page 4: ...ARATION ATTACH INSTRUCTION 73 ATTACH BATTERY 73 ATTACH PROTECTIVE BARS 75 ATTACH REAR SHOCK 76 ATTACH TRAILING ARM 77 ATTACH FRONT SHOCK 78 ATTACH FRONT TIRE 79 ATTACH SEAT AND SAFT BELT 80 ATTACH THE...

Page 5: ...important 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...

Page 6: ...o 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 and...

Page 7: ...Time to Learn Practice Even if you have derived 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 accustom...

Page 8: ...er 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 factor affecti...

Page 9: ...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...

Page 10: ...Go kartisatafullstop Giveaslightthrottleandreleasethrottle thenengageshift Onlyshiftfromneutral TheshiftlevermustbeinneutralandparkingleverpulledwhenleavingtheGo kart WARNING Donotshiftwhenpushingthro...

Page 11: ...though complete protection is not possible wearing 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 Pr...

Page 12: ...round when the Go cat will turn over Age Recommendation It is strongly recommended that no one under the age of 16 be permitted this Go Kart without adult supervision A child driving a Go Kart that is...

Page 13: ...get on the Go Kart Engine Oil Check the oil level and add oil if needed Check for leaks Fuel Check the fuel level and add fuel if needed Also make sure the fuel fill cap is securely fastened Check fo...

Page 14: ...e pedal several times check for proper brake pedal free play Make sure there is no brake fluid leakage Steering Wheel Check that the wheels turn properly as you turn the steering wheel Cable Check the...

Page 15: ...ing 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 Kart on public streets roads or highways ca...

Page 16: ...d be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the Go Kart Never drive past the limit of visibility Maintain a safe distance betw...

Page 17: ...9 NGK Plug gap 0 6 0 7mm Fuel type RQ90 unleaded Lubricate oil SAE 10W 30 CAPACITIES Maximum load 400Ibs Fuel tank 16 0L Engine oil 1000ml Gear oil 1000ml Coolant 1800ml Starting 5s Climbing 20 25 Bat...

Page 18: ...bly is working smoothly and returns to idle when released Do not operate if pedal or engine throttles linkage fail to return to idle If unable to correct the problem through lubrication adjustment or...

Page 19: ...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 a Check for Engine Oil Level Check...

Page 20: ...operly Check and tighten as necessary all other fasteners to specified condition i Check Roll Cage Bar Ensure all protective roll cage bar are in place before operating the Go Kart j Check Brake Light...

Page 21: ...20 STEERING WHEEL RADIATOR SAFETY BELT m Component locations FUEL TANK MUFFLER BATTERY WATER TANK...

Page 22: ...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 Before attempting to adjust the seat ensure...

Page 23: ...nd tighten the seat belt b Testing the Go Kart in an open place at the beginning to learn how to start turn and stop c Operate the Go Kart slowly until you are familiar with it d The turning radius of...

Page 24: ...ing up the front end and drain 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 S...

Page 25: ...en 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 1500RPM d Turn the airscrew slowly and observe...

Page 26: ...nch as you adjust the rear shock the tension of shock spring will increase as you screw to right decrease as you screw to left See Fig 15 K Storage Instruction In the event your kart is not to be oper...

Page 27: ...plug c Do not save or store gasoline over winter Using old gasoline which has deteriorated from storage will cause hard starting and affect engine performance Do not drain fuel while engine is hot Be...

Page 28: ...ndplay See Fig 17 Tighten the nuts and put on the cotter Pin after replacing the wheels Figure 17 C Front Wheel Alignment a The front wheels should be toe in from 1 8 to 1 4 To check for alignment mea...

Page 29: ...rst 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 oil I Replace gearbox...

Page 30: ...temp erature sensor Rectifier regulator Fuse box G 3 M Ignition switc h OFF Start 1 2 3 Ignition coil t v C tC n v High beam switch ON blue Dipped beam switch green Turn signal switch R L yellow red R...

Page 31: ...21005 LOCATING PIN 10x14 4 7 172MM 011005 STUD B CYLINGDER 1 8 172MM B 011006 SEAL WASHER CRANK CASE 1 9 172MM 011400 INNER OIL PIPE ASSY 1 10 152MI 021019 BOLT M6X12 1 11 152MI 011017 BOLT M6X60 5 12...

Page 32: ...201 1 21 GB T 276 1994 620 RS BEARING 6202 RS 1 22 172MM B 068001 HOLLOW BOLT M14X1 5 1 23 CF188 068002 WASHER 14 4X22X1 1 24 CF188 068003 SPACER SPRING 1 25 GB T308 1989 3 8 STEEL BALL 1 152MI 130004...

Page 33: ...1 172MM B 012001 SIDE COVER L 1 2 172MM B 012002 AIR DAMPER 1 3 GB T818 2000 M6X12 SCREW 3 4 172MM B 012005 BOLT 7 5 152MI 013008 BOLT 2 6 152MI 021005 LOCATING PIN 10x14 2 7 172MM B 012003 SEAL WASH...

Page 34: ...MM 013012 SEAL WASHER RIGHT SIDE COVER 1 8 172MM 013007 CAP OIL FILTER 1 9 152MI 013100 OIL FILTER CORE 1 10 172MM 013006 SPRING 1 11 172MM 013001 METER ENGINE OIL 1 12 172MM 013019 3 WAY 1 13 152MI 0...

Page 35: ...LISH Q ty 22 QC T621 1999 A12 CLAMP 10 4 23 172MM 013010 BREATH FAUCET 1 24 172MM 013009 WATER OUTLET FAUCET 1 25 152MI 013009 BOLT M6X40 3 26 172MM 013026 PROTECTION PIPE 1 27 152MI 071007 BOLT M6X28...

Page 36: ...3 SHOCK ABSORBER RUBBER STRIP 1 11 152MI 021004 REAMED BOLT A M8X25 1 12 152MI 021015 REAMED BOLT M12X1 25 1 13 152MI 021013 REAMED BOLT M8X25 1 14 152MI 021008 REAMED BOLT A M8X28 1 15 152MI 021016 C...

Page 37: ...GDER HEAD CASEING ASSY No P N ENGLISH Q ty 26 152MI 021018 BOLT M6X55 1 27 172MM 021404 SHOCK ABSORBER SLEEVE 1 28 172MM 021002 BREATH PIPE FAUCET 1 29 172MM 021300 MOUNT AIR FILTER 1 30 172MM 021008...

Page 38: ...1 9 152MI 022803 THERMOSTAT SHELL UPPER 1 10 152MI 022021 RUBBER PIPE1 CARBURETOR 1 11 172MM 022601 THERMOSTAT SHELL LOWER 1 12 172MM 022400 SPARK PLUG 1 13 152MI 022017 BOLT M6X25 2 14 172MM 022800 S...

Page 39: ...P N ENGLISH Q ty 24 QC T621 1999 A6 5 STEEL RING CLAMP 2 25 152MI 090005 BOLT M6X16 2 26 152MI 023008 BOLT M6X18 1 27 152MI 022017 BREATHE PIPE CARBURETOR 1 28 GB T848 85 6 D Cr SMALL WASHER 1 29 152...

Page 40: ...SPRING SEAT 1 5 152MI 023306 SPRING TENSIONER 1 6 152MI 023004 SEAL WASHER TENSIONER 1 7 172MM 023007 RUBBER PIPE WATER INLET 1 8 172MM 023009 JACKET WATER PIPE 1 9 QC T621 1999 B24 STEEL BAND CLAMP 2...

Page 41: ...40 7 TIMING CHAIN No P N ENGLISH Q ty 1 172MM 022200 CHAIN UNIT 1 2 172MM 023200 TENSION PLATE 1 3 172MM 023001 CHAIN GUIDE PLATE 1 4 GB96 85 6 D Zn BIG WASHER 1 5 GB T5781 2000 M6X12 D Zn BOLT 1...

Page 42: ...72MM 033000 TRIGGER COIL 1 3 172MM 013008 CABLE PRESS BAND 1 4 172MM 031000 FREE WHEELING 1 5 172MM 032000 STATOR UNIT 1 6 GB T70 1 2000 M8X18 SOCKET HEAD SCREW 3 7 172MM 040001 NUT M16X1 1 8 172MM 04...

Page 43: ...INTAKE VALVE 1 5 172MM 022005 EXHAUST VALVE 1 6 172MM 022002 VALVE SPRINGL OUTTER 2 7 172MM 022003 VALVE SPRINGL INNER 2 8 152MI 022005 PAN VALVE SPRING 2 9 152MI 022001 SEAT VALVE SPRING 2 10 152MI 0...

Page 44: ...MM 040008 PISTON RING 1 172MM 040009 PISTON RING 1 2 172MM 042000 OIL RING 1 3 172MM 040005 PISTON 1 4 172MM 040007 PISTON PIN 1 5 152MI 040011 JOINT OIL CHANNEL 1 6 152MI 040010 JOINT SPRING 1 7 152M...

Page 45: ...X1 5 1 2 172MM 021006 WASHER14 5X30 2 1 3 172MM A 051005 DRIVE WHEEL PAN 1 4 172MM A 051003 SLEEVE DRIVE WHEEL PAN 1 5 172MM A 051100 MOVABLE DRIVE PAN 1 6 172MM A 051200 OFFCENTER ROLLER 6 7 172MM A...

Page 46: ...IDE PAN 1 9 GB T896 1986 9 SPLIT WASHER 3 10 172MM 052310 NEEDLE BEARING 1 11 GB T893 1 1986 28 RETAINER RING HOLE 1 12 GB T278 1989 1060902 BEARING 1 13 172MM A 052300 DRIVEN PAN UNIT 1 14 172MM A 05...

Page 47: ...GB T 276 1994 6305 RS BALL BEARING 1 10 172MM B 011107 BOLT M8X48 3 11 172MM B 011111 BOLT M8X30 5 12 1P52MI A 011007 BOLT M8X55 2 13 CF188 332004 O RING 19X2 5 1 14 CF188 332003 BOLT OIL INLET 1 15...

Page 48: ...5X28X2 2 8 172MM B 062002 DRIVEN GEAR HIGH SPEED 1 9 NTN K16X20X10 NEEDLE BEARING 2 10 172MM B 062009 SLIDING SLEEVE SHIFT 1 11 172MM B 062001 SECONDARY AXIS 1 12 172MM B 062007 WASHER 24X33X2 2 13 GB...

Page 49: ...P N ENGLISH Q ty 21 CF188 061007 RETAINER RING AXIS 25 1 22 172MM C 063001 OUTPUT AXIS 1 23 172MM C 063004 CHAIN PULLEY 2 24 172MM C 063005 PRESS PLATE CHAIN PULLEY 1 25 172MM C 063009 BOTL M6X12 1 26...

Page 50: ...HER DRIVEN SECTOR GEAR 1 8 CF188 065203 DRIVEN SECTOR FEAR SHIFT 1 9 CF188 065204 WASHER 13 5X22X1 1 10 CF188 065202 DRIVEN SECTOR GEAR AXIS SHIFT 1 11 CF188 065204 SPRING DRIVEN SECTOR GEAR 1 12 CF18...

Page 51: ...71001 CHAIN PULLEY OIL PUMP 1 6 151MI 073000 CHAIN OIL PUMP 1 7 151MI 071004 ROTOR OIL PUMP INNER 1 8 151MI 071005 ROTOR OIL PUMP OUTTER 1 9 151MI 070002 SPACER PLATE A OIL PUMP 1 10 151MI 072000 SPAC...

Page 52: ...080002 SEAL WASHER COVER 1 5 172MM 080001 WATER PUMP AXIS 1 6 152MI 013009 BOLT M6X40 2 7 152MI 021017 BOLT M6X25 2 8 GB T893 1 1986 19 RETAINER RING HOLE 1 9 152MI 080007 WASHER 7 5X13X1 2 1 10 152M...

Page 53: ...GLISH Q ty 1 172MM 090001 AXIS DUPLICATE GEAR 1 2 172MM 092000 DRIVEN GEAR COMP 1 3 172MM 091000 DUPLICATE GEAR COMP 1 4 172MM 090007 MOUNTING PLATE 1 5 172MM 093000 STARTER COMP 1 6 152MI 080013 BOLT...

Page 54: ...53 19 CARBURETOR ASSY No P N ENGLISH Q ty 1 172MM 100000 CARBURETOR ASSY 1...

Page 55: ...54 20 FRAME FUEL TANK REDIATOR 45 20 FRAME FUEL TANK REDIATOR 1 43 2 3 4 5 6 7 8 9 10 13 14 11 12 15 16 17 18 19 21 20 33 22 23 24 25 26 27 28 29 30 31 32 34 35 36 37 38 39 41 40 42 44...

Page 56: ...M12X1 25X55 7 6 NYLON BUSHING D250 11 771 8 6 FLANGE NUT M12 GB6177 1 2000 M12 9 1 PROTECTIVE BAR R DN250 01 02 08 00 10 1 FLANGE BOLT M10X1 25X20 GB5787 86 M10X1 25X20 11 2 FLANGE NUT M10 GB6177 1 20...

Page 57: ...56 21 FRONT SUSPENSION 47 48 49 50 21 FRONT SUSPENSION 1 2 4 6 5 7 8 9 10 11 13 14 12 15 18 17 19 20 16 21 22 23 24 44 45 46 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 43 3 40...

Page 58: ...NGE BOLT M8X15 GB5787 86 M8X15 23 1 BRAKE CLIPPER 2 DN250 04 01 00 02 24 2 BUSHING 33 8 FRONT WHEEL DN250 02 00 00 03 25 2 GREASE SEAL FB47X28X7 GB9877 1 88 FB47X28X7 26 2 BALL BEARING 6204 GB T276 19...

Page 59: ...FT 53 54 55 56 57 58 59 60 66 67 68 69 22 STEERING THROTTLE BRAKE SHIFT 1 2 3 4 5 6 7 8 10 9 11 12 13 14 15 17 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 44 45 46 47 49 43 42 41 40 39 38...

Page 60: ...IVERSAL JOINT GB893 1 86 26 CIRCLIP FOR HOLE 26 DN250 03 03 00 01 SLEEVE STEERING COLUMN GB T276 1994 61902 BALL BEARING 61902 GB893 1 86 28 CIRCLIP FOR HOLE 28 SHAFT STEERING COLUMN GB6187 1 2000 M8...

Page 61: ...R 57 GB T95 1985 8 PLAIN WASHER 8 58 GB91 86 3x30 COTTER PIN 3x30 59 DN250 05 03 04 00 CABLE SHIFT 60 GB5787 86 M10X1 25X30 FLANGE BOLT M10x1 25x30 61 GB6177 1 2000 M10x1 25 FLANGE NUT M10x1 25 62 GB6...

Page 62: ...61 23 ENGINE RACK TRANSMISSION 23 ENGINE RACK TRANSMISSION 1 2 3 4 6 7 8 9 10 11 12 13 15 16 17 18 5 20 21 14 22 23 24 25 26 27 28 30 31 29 32 33 19...

Page 63: ...FLANGE NUT M12x1 5 16 GB5787 86 M8x30 FLANGE BOLT M8x30 17 DI250 07 00 00 02 CHAIN PULLEY 35 TOOTH 18 DN250 07 02 00 00 MID AXIS 19 20 GB6177 1 2000 M10x1 25 ENGINE BUMPER DS250 08 00 00 03 FLANGE BO...

Page 64: ...63 24 ENGINE ASSEMBLY 1 2 3 4 5 6 7 8 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 42 39 10 11 24 9 43 24 ENGINE ASSEMBLY CONNECT TO CCA...

Page 65: ...M8 FLANGE LOCK NUT M8 8 DN250 05 01 00 05 OVERFLOWING PIPE 9 DN250 05 01 00 01 WATER PIPE OUTLET ENGINE 10 DN250 05 01 00 02 WATER PIPE INLET ENGINE 11 GB5787 86 M6x20 FLANGE BOLT M6X20 12 D650 04 06...

Page 66: ...65 25 EXHAUST SHIFT 1 2 3 4 5 6 7 8 9 10 11 12 14 21 20 22 23 24 25 26 27 28 29 30 31 32 33 36 37 35 34 38 39 40 45 46 44 41 42 43 19 13 16 17 25 EXHAUST SHIFT PARKING BRAKE...

Page 67: ...CUP PARKING BRAKE 1 1 DN250 04 03 01 00 MAIN PISTON PARKING BRAKE 1 DN250 04 03 00 00 1 43 44 45 46 SLOTTED PIN 3X30 DN250 04 01 00 02 BRAKE CALIPER 2 PARKING BRAKE ASSY Q TY DESCRIPTION PART NO No EN...

Page 68: ...67 26 REAR SUSPENSION 38 39 40 41 1 2 5 4 3 9 8 7 6 10 11 12 14 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 37 36 35 34 33 26 REAR SUSPENSION...

Page 69: ...15 16 17 18 19 20 21 22 23 24 25 26 27 28 GB T95 1985 8 PLAIN WASHER 8 4 2 BRAKE DISC REAR DI250 04 01 00 04A GREASE SEAL FB 32X47X8 GB9877 1 88 FB32X47X8 8 8 GB T95 1985 10 PLAIN WASHER 10 4 GB T93...

Page 70: ...69 27 ELECTRICAL ASSEMBLY 21 23 22 24 27 ELECTRICAL ASSEMBLY 1 2 3 4 5 6 7 10 11 12 13 14 15 16 17 18 19 20 9 8...

Page 71: ...N650 N650 06 02 07 00 16 15 MUSHROOM BUTTON DS250 10 00 00 05 14 13 12 11 10 TAIL LIGHT ASSEMBLY D800 06 00 00 12 9 BATTERY D250 07 802 8 HORN D250 07 913 7 6 5 4 3 FLASH APPARATUS 2 TURNING SINGLE F...

Page 72: ...71 28 SEAT AND MUD GUARD 2 4 5 6 10 7 8 14 11 12 13 15 16 3 9 1 28 SEAT AND MUD GUARD...

Page 73: ...10 MUD GUARD D250 11 005A 9 FLANGE NUT LOCK M6 GB6177 1 2000 M6 8 RUBBER WASHER 6 D250 11 058 7 6 5 4 3 FLANGE NUT M10X1 25 2 DS250 08 01 00 03 SEAT COMP R 28 SEAT AND MUD GUARD Q TY DESCRIPTION PART...

Page 74: ...eal cap 180 degree fix it on the outlet of plastic bottle a Cut the inlet of plastic bottle b Fill the battery with electrolyte to upper lever by inserting every inlet of the battery STEP 2 Put the ba...

Page 75: ...lled electrolyte the new battery need to recharge as the Owner s manual said Otherwise the new battery will be damaged and can t recharge 2 The new battery can t overload in use otherwise it damage fo...

Page 76: ...75 ATTACH PROTECTIVE BARS 1 2 3 4 1 2 3 4...

Page 77: ...76 ATTACH REAR SHOCK a Remove the bolt and the nut b Attach the rear shock as below picture SPACER SPACER...

Page 78: ...77 ATTACH TRAILING ARM 1 2...

Page 79: ...78 ATTACH FRONT SHOCK 1 2 3 1 2 3 3...

Page 80: ...as below 1 Remove four nuts four spring washers and 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 Directi...

Page 81: ...80 ATTACH SEAT AND SAFT BELT FIX SAFTY BELT...

Page 82: ...81 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...

Page 83: ...82 ATTACH SILENCER...

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