Joyner SZ250DI Owner'S Manual Download

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Owner’s Manual

Parts Manual

READ THIS MANUAL CAREFULLY

IT CONTAINS IMPORTANT SAFETY INFORMATION.

MINIMUM
RECOMMENDED
OPERATOR AGE:

SZ250DI

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

Summary of Contents for SZ250DI

Page 1: ...SAFETY INFORMATION MINIMUM RECOMMENDED OPERATOR AGE SZ250DI 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 16 ...

Page 2: ...DI 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 subjected to a This warranty does not cover any seller vehicle in any way so to adversely affect its safety or reliability b Renting c Disassembly adjusting or repairing of the vehicle in any way so as ...

Page 3: ...EAD CASEING ASSY 32 5 CYLINGDER HEAD ASSY 34 6 CYLINGER BODY ASSY 36 7 TIMING CHAIN 37 8 MAGNETOR ASSY 38 9 ADMISSION MACHANISM 39 10 CRANK LINK LEVER PISTON 40 11 SPEED CHANGER 41 12 CLUTCH ASSY 42 13 GEARBOX COVER ASSY 43 14 TRANSMISSION GEAR ASSY 44 15 GEAR SHIFT MACHANISM 46 16 ENGINE OIL PUMP ASSY 47 17 COOLANT PUMP ASSY 48 18 ELECTRIC STARTER ASSY 49 19 CARBURETOR ASSY 50 20 FRAME AND FUEL T...

Page 4: ...3 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: ...s 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 your kart accordingly Preventive maintenance is extremely important to the longevity of your Go Kart We hope you will have a pleasant experience with our products and thanks again for choosing US ...

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 and one of two signal words WARNING or CUATION These signal words mean Physical harm may result from failure to adhere to the instructions that are described within the WARNING labels Safety Headings s...

Page 7: ...cross Take 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 accustomed to this Go Kart s size and weight Because many accidents involve inexperienced or untrained drives we urge all drivers to take a training course approved by the Go Kart Safety Institute C...

Page 8: ...her 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 affecting turns Skidding a turn is more likely to occur on slippery surfaces such as snow ice mud and loose gravel If you skid on ice you may lose all directional control To avoid skidding on slippery terra...

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 hard to read contact your dealer for warning labels replacements ...

Page 10: ...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 Protection Your helmet is your most important piece of driving gear because it offers the best protection against head injuries A helmet should fit your head comfortably and securely An open face helmet...

Page 11: ...ound 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 not recommended for his her age could lose Go Kart control and result in severe injury or death A child under 16 should have adult supervision when operate on the Go Kart No Alcohol or Drugs Alcohol d...

Page 12: ...you get on the Go Kart Engine Oil Check the level and add oil if needed Check for leaks Fuel Check the level and add 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 Bolts Check the wheels to see that the axle nuts are tightened Use a wrench to make...

Page 13: ...play 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 turn properly as you turn the steering wheel Cable Check the cable housing for wear Check the fittings for looseness Replace or tighten as needed Tie rod Check the tie rod housing for wear Check th...

Page 14: ...eing 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 can cause collision with other vehicle Never operate this Go Kart on any public streets roads or highways even dirt or gravel one Keep Hands and Feet on Controls Always keep both hands on the steering ...

Page 15: ...nd 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 between your Go Kart and other off road vehicles Always exercise caution and use extra care on rough slippery and loose terrain Failure to use extra care when operating on excessively rough slippery or l...

Page 16: ...9 NGK DPR7EA 9 NGK Plug gap 0 6 0 7mm Fuel type RQ90 unleaded Lubricate oil SAE 10W 30 CAPACITIES Maximum load Double Seats 400Ibs Fuel tank 16 0L Engine oil 1000ml Coolant 1800ml Starting 5s Climbing 20 25 Battery 12V 9Ah Head Light 12V 15W Tail Light 12V 10W 5W Fuse 10A Brake Track 7m 20miles h Top speed 40 miles h or limited as customers require CHASSIS Front Rear brake Hydraulic disc right foo...

Page 17: ... 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 replacement of worn parts contact your dealer for assistance b Brake The brake is located on the left side of the kart See Fig 1 Applying pressure to the pedal draws the brake caliper around the brake pump ...

Page 18: ...s 15kpa and 20kpa h Check Drive Chain Check for drive chain s condition and tension Lubricate if necessary i Check Throttle Check for smooth operation Assure throttle snaps back to idle j Check Engine Stop Button Perform engine stop button test Repair as necessary k Check all Nuts Bolts and fasteners Check wheels to see that all axle nuts and lug nuts are tightened properly Check and tighten as ne...

Page 19: ...18 STEERIHNG WHEEL SAFTY BELT RADIATOR FLAG POLE BRACKET BRAKE PEDAL THROTTLE PEDAL FUEL TANK Component locations ...

Page 20: ...of the Go Kart is stopped 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 Before attempting to adjust the seat ensure that engine of Go Kart is stopped E Shift Adjustment a Press down the shift lever to the L position so that the unit can move forward at low speed press the lever to H...

Page 21: ...Go Kart slowly until you are familiar with it d The turning radius of this Go Kart is small and agile so the centrifugal force is very high when turning at high speed Slow down to a more controllable speed when 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...

Page 22: ...park plug and inspect it each time you change the oil Use a spark plug wrench The electrodes should be kept clean and free of carbon The presence of carbon or excess oil will greatly reduce proper engine performance If possible check the spark plug gap area between electrodes using a wire feeler gauge This specification is 0 025 0 030 b Before installing spark plug coat threads lightly with graphi...

Page 23: ...rom 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 G Kart Lubrication Lubricate vehicle every 90 days of use Apply several drops of oil in specific points H Chain Lubrication To increase chain life it should be lubricated with a spray on type chain lubricant I Chain Adjustment C...

Page 24: ...son prepare for storage as follows a Drain fuel tank and carburetor by allowing engine to run out of fuel or use a fuel stabilizer b Lubricate engine cylinder by removing the spark plug and pour one ounce of clean lubricating oil through the spark plug hole into the cylinder Crank the engine slowly to spread oil and replace spark plug c Do not save or store gasoline over winter Using old gasoline ...

Page 25: ...h minimum 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 measure distance A and B between the centerline CL of the wheels The proper toe in dimension A should be 1 8 1 4 greater than dimension B b To adjust the alignments loose the lock nuts on bot...

Page 26: ...cing 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 oil I Replace gearbox oil I R Replace coolant I R Chassis C I L Fuel switch fuel tank I C Battery I Valve clearance of engine A A adjust C clean I inspect clean or replace if necessary L lubricate R...

Page 27: ...d Turning signal Rear R behind Tail lamp the brake light Change direction Head light OFF Fog light Low light Far light Super light Left Right caution B B R BW B R B N N NB NB B UW U UW YG YG R K K NR W P L B U Wire s colour symbol RS red grey B black R red U blue RU red blue P purple S grey W white YG yellow green L Cambridge blue N brown K pink NB brown black NR brown red UW blue white RB red bla...

Page 28: ...021005 LOCATING PIN Φ10x14 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 1P52MI 011018 BOLT M6X70 3 13 1P52MI A 011006 BOLT M6X105 1 14 152MI 011010 OUTER SLEEVE EAR 2 15 152MI 011008 O RING FOR SEAL 4 16 152MI 011009 INNER SLEEVE EAR 2 17 GB T 276 1994 6304 BEARING 630...

Page 29: ... 6201 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 SPACE SPRING 1 25 GB T308 1989 3 8 STEEL BALL 1 152MI 130004 O RING FOR SEAL13 5X1 4 1 26 172MM B 011300 ODOMETER SENSOR 1 27 172MM B 011400 SEAL CAP 1 28 152MI 023010 BOLT M6X20 1 ...

Page 30: ... 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 Φ10x14 2 7 172MM B 012003 SEAL WASHER LEFT SIDE COVER 1 8 152MI 021018 BOLT 1 ...

Page 31: ...2MM 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 021008 CAP OBSERVATION HOLE UPPER 1 14 172MM 013031 BOLT 1 15 172MM 013028 O RING 30X3 35 1 16 152MI 021009 SEAL RING CAP 1 17 172MM 013030 O RING 18X3 35 1 18 172MM 013005 OUTLET BOLT 1 19 152MI 0210...

Page 32: ...GLISH 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 1 28 1P52MI 011018 BOLT M6X70 3 ...

Page 33: ...003 SHOCK ABSORB 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 CAP OBSERVATION HOLE UPPER 3 16 152MI 021012 WASHER 8 1 17 152MI 021014 EAR WASHER 2 18 152MI 021009 SEAL OBSERVATION HOLE UPPER 1 19 152MI 021010 SEAL RING SWING ARM AXIS 2 20 GB T818 2000 M5X16 D Cr ...

Page 34: ...INGDER HEAD CASEING ASSY No P N ENGLISH Q ty 26 152MI 021018 BOLT M6X55 1 27 172MM 021404 SHOCK ABSORB SLEEVE 1 28 172MM 021002 BREATH PIPE FAUCET 1 29 172MM 021300 MOUNT AIR FILTER 1 30 172MM 021008 BLOCKING 1 ...

Page 35: ... 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 SEAL WASHER BREATH 1 15 152MI 022600 WATER TEMP SENSOR 1 16 GB T6191 1986 M6X18 D Cr SOCKET HEAD SCREW 2 17 172MM 022007 DOUBLE SCREW BOLT 2 18 152MI 022012 WASHER 8 4 19 152MI 022013 CAP NUT M8 4 20 ...

Page 36: ...o 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 152MI 022021 SCREW BLOCKAGE 1 ...

Page 37: ... SPRING SEAT 1 5 152MI 023306 SPRING TENSION 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 10 152MI 023305 WASHER 8 5 1 11 GB T848 85 6 D ZN SMALL WASHER 1 12 152MI 021005 LOCATION PIN Φ10X14 2 13 152MI 023008 BOLT M6X18 2 14 152MI 080013 BOLT M6X22 1 ...

Page 38: ...37 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 39: ...172MM 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 040002 WASHER16 3X30X2 1 9 152MI 030002 BOLT M5X16 2 10 152MI 060002 BOLT M6X30 3 ...

Page 40: ... 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 022006 CLAMP VALVE 4 11 NTN 16002 BALL BEARING 2 12 GB894 A 1 86 15 AXIS RETAINER RING 1 13 172MM 022310 CHAIN PULLY 1 14 172MM 022301 CAM AXIS 1 ...

Page 41: ...2MM 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 152MI 040006 WOODRUFF KEY 1 8 172MM 040006 STOP RING PISTON PIN 2 9 GB T119 2000 2X14 PIN 1 ...

Page 42: ...4X1 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 051004 SLIDING BLOCK 3 8 172MM A 051002 PUSH PAN 1 9 10 11 12 ...

Page 43: ... SIDE 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 052001 GALLOWS ROLL 4 15 172MM A 052104 GREAS SEAL DRIVEN PAN 2 16 172MM A 052100 MOVABLE DRIVEN PAN 1 17 GB T3452 1 1992 46 2X1 8 O SEAL RING 2 18 172MM A 052007 SEAL BUSHING 1 19 172MM A 052004 CLUT...

Page 44: ... 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 172MM C 060003 OIL SEAL 32X62X7 1 16 CF188 310028 JOINT AIR PIPE 1 17 152MI 080008 LOCATION PIN Φ8X14 2 18 172MM C 060007 PAPER WASHER 1 19 172MM C 060006 CHAIN PULLY COVER 1 20 GB5787 86 M6X40 D Cr B...

Page 45: ...15X28X2 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 T894 1 86 24 CIRCLIP AXIS 1 14 K24X28X10 NEEDLE BEARING 1 15 172MM B 062003 DRIVEN GEAR REVERSE 1 16 172MM B 062005 DRIVE GEAR OUTPUT 1 17 172MM B 062004 DRIVEN GEAR LOW SPEED 1 18 172MM C 063000 OU...

Page 46: ... 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 172MM B 062008 WASHER 16X28X2 1 ...

Page 47: ...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 CF188 065206 WASHER 6 6X20X2 2 13 151MI 013008 BOLT M6X35 1 14 151MI 023010 BOLT M6X20 1 15 CF188 065300 SWING ARM ASSY SHIFT 1 16 172MM C 065100 DRIVE SECTOR GEAR COMP SHIFT 1 17 172MM B 066007 SHIFT AXI...

Page 48: ...71001 CHAIN PULLEY OIL PUMP 1 6 151MI 073000 CHAIN OIL PUMP 1 7 151MI 071004 ROTOR OIL PUMPL INNER 1 8 151MI 071005 ROTOR OIL PUMPL OUTTER 1 9 151MI 070002 SPACER PLATE A OIL PUMP 1 10 151MI 072000 SPACER PLATE B OIL PUMP 1 11 GB878 85 M3X12 SCREW 1 12 151MI 071006 LOCATION PIN 4X6 5 1 13 GB894 1 86 10 RETAINER RING AXIS 1 14 151MI 021019 BOLT M6X12 1 15 151MI 070003 BOLT M6X28 2 ...

Page 49: ...M 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 152MI 080011 WASHER 6X12X1 1 11 NTN 6800 NEEDLE BEARING 2 12 172MM 080005 GREAS SEAL 10X20X5 1 13 152MI 080008 LOCATION PIN Φ8X14 2 14 15 16 17 18 19 20 21 22 ...

Page 50: ...NGLISH 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 M6X22 2 7 172MM 090008 BOLT M6X14 1 ...

Page 51: ...50 19 CARBURETOR ASSY No P N ENGLISH Q ty 1 172MM 100000 CARBURETOR ASSY 1 ...

Page 52: ...51 20 FRAME AND FUEL TANK 19 20 21 22 23 24 25 26 27 28 35 38 39 41 45 46 44 49 29 32 33 34 37 36 47 48 30 31 43 40 42 20 FRAME AND FUEL TANK 11 4 1 2 3 5 10 9 8 7 6 12 13 15 14 16 17 18 ...

Page 53: ... M10 GB6177 1 2000 M10 22 2 RUBBER BAND S250 11 003 23 2 SUPPORT FUEL TANK DI250 05 02 00 01 24 1 VALVE ASSY FULE S250 11 903 25 1 TUBE FUEL 1 DI250 05 02 00 02 26 1 FILTER FUEL DS250 11 01 00 09 27 1 TUBE FUEL 2 D250 11 060 28 4 HOSE CLAMP 174020000 29 2 RUBBER BUSH BODY JD0910006 30 4 PLAIN WASHER 8 GB T95 1985 8 31 2 FLANG BOLT M8X25 GB5787 1986 M8X25 32 2 FLANG NUT LOCK M8 GB6177 1 2000 M8 33 ...

Page 54: ...53 21 SUSPENSION ARM ASSY 1 5 6 7 8 9 13 14 10 11 12 18 19 20 24 25 26 27 30 31 32 33 34 35 36 37 38 40 41 42 17 16 15 23 2 3 22 21 39 4 28 29 21 SUSPENSION ARM ASSY ...

Page 55: ...787 1986 M8X15 SPRING WASHER 8 GB3632 83 8 FRONT BRAKE CALIPER L DI250 04 01 02 00 DI250 02 00 00 02 BUSH 1 FRONT KNUCKLE GB T95 1985 10 PLAIN WASHER 10 JD0760800 RIM FRONT WHEEL GB T923 1988 M10x1 25 CAPPED NUT M10X1 25 8 GB T93 1987 10 SPRING WASHER 10 2 40 2 39 2 38 37 KNUCKLE R DS250 02 00 00 02 GB T5783 2000 M6X15 BOLT M6X15 JD0360150 DISC FRONT BRAKE 2 41 42 8 8 12 11 JD0256100 UPPER A ARM G...

Page 56: ...55 22 STEERING ASSY 22 STEERING ASSY 1 2 4 6 7 8 10 11 13 12 14 15 16 18 17 19 20 29 23 22 24 27 28 9 26 30 31 32 33 34 36 37 38 39 40 41 42 44 43 45 46 35 5 3 21 25 ...

Page 57: ...3 03 00 02 BALL JOINT DS250 03 03 00 01 TIE ROD DS250 03 00 00 02 BALL JOINT TIE ROD GB T93 1987 10 SPRING WASHER 10 GB T9457 1988 M10 SLOTTED NUT M10 GB T91 2000 2X25 COTTER PIN 2x25 FLANG BOLT M10x1 25x25 GB T93 1987 4 SPRING WASHER 4 DI250 04 01 01 00 MASTER CYLINDER GB6177 1 2000 M8 FLANG NUT M8 GB5787 1986 M8X25 FLANG BOLT M8X25 DI250 04 01 00 05 PUSH SHAFT MASTER CYLINDER GB T6172 1 2000 M8 ...

Page 58: ...57 23 ENGINE RACK 24 25 26 27 28 29 30 22 31 32 33 34 35 36 37 39 38 23 ENGINE RACK 1 2 3 4 7 6 8 9 10 11 15 16 14 13 12 5 17 18 21 20 19 22 23 ...

Page 59: ...4 5 SEAL EXHAUST PIPE D250 00 037 EXHAUST PIPE DI250 05 02 00 01 20 19 CLAMP UPPER DI250 05 02 01 01 18 FLANG NUT M8 GB6177 1 2000 M18 17 MUFFLER DI250 05 02 00 01 16 15 FLANG BOLT M8X25 GB5787 1986 M8X25 14 13 STEEL BUSH BODY JD0900011 12 MUFFLER RUBBER BUMPER DI250 05 02 00 04 11 BOLT M12X1 5X105 GB5785 86 M12X1 5X80 10 BOLT M12X1 5X80 GB5785 86 M12X1 5X80 9 NUT M12 GB6170 86 M12 8 ENGINE RACK D...

Page 60: ...59 24 ENGINE RACK 2 3 4 6 7 8 9 10 11 15 12 13 14 16 17 18 19 20 21 22 23 24 25 26 27 28 32 34 33 35 31 1 37 36 5 30 29 24 TRAILING ARM ASSY ...

Page 61: ...2 2 2 GB2673 1986 M6 20 SUNK SCREW M6X20 RUBBER BUSHING TRAILING ARM D650 02 01 00 01 GB6177 1 2000 M10X1 25 FLANG NUT M10X1 25 FLANG BOLT M12X1 5X60 GB5787 1986 M12X1 5X60 SEAL FB 32X47X8 GB9877 1 1988 FB32X47X8 HALF AXLE DI250 07 01 00 00 1 No PART NO DESCRIPTION Q TY 24 TRAINLING ARM ASSY TRAILING ARM R DI250 09 02 00 00 DI250 07 01 00 01 BRIDLE BOOT 2 INNER BOOT 3 4 5 6 7 GB T5787 86 6005 BALL...

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

Page 63: ...ING RETAINER RING DI250 07 00 00 03 23 22 21 2 4 2 2 2 1 4 1 1 4 2 4 2 4 4 2 2 8 4 2 2 2 CABLE COMP PARKING BRAKE DI250 04 02 00 00 PIN 8X24 GB T882 1986 8X24 20 19 COTTER PIN 3X30 GB T91 2000 3X30 18 FLANG NUT M8 GB6177 1 2000 M8 17 FLANG BOLT M8X30 GB5787 1986 M8X30 16 15 MID AXIS DI250 07 02 00 00 14 13 12 BEARING BLOCK LOWER SN206 3 11 10 TWO ROW BALL BEARING TWO ROW BALL BEARING 9 SCREW BOLT ...

Page 64: ...63 26 ELECTRICAL ASSY 26 ELECTRICAL ASSEMBLY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 ...

Page 65: ...RIPTION Q TY 26 ELECTRICAL ASSEMBLY TURNING SINGLE FR D250 07 900 D250 07 907 SPEED METER 2 VOLTAGE REGULATOR 3 4 5 6 7 8 DI250 10 04 00 00 FLASHER 9 D250 07 912 RELAY STRAT 10 11 D250 07 903 TRAIL LAMP 12 13 14 N6 200 NYLON CLAMP 6X200 15 16 DI250 10 05 00 00 COIL IGN 17 D250 10 917 CDI 18 19 2 1 1 1 1 1 1 1 1 1 2 2 1 1 8 2 1 1 1 D250 07 915 FACE PLATE DS250 10 00 00 02 IGNITION SWITCH D250 07 90...

Page 66: ...65 27 SEAT AND MUD GUARD 27 SEAT AND MUD GUARD 2 4 5 6 10 7 8 14 11 12 13 15 16 3 9 1 ...

Page 67: ...FLANG NUT LOCK M6 GB6177 1 2000 M6 8 RUBBER WASHER 6 D250 11 058 7 6 5 4 3 FLANG NUT M10X1 25 2 DS250 08 01 00 03 SEAT COMP R 27 SEAT AND MUD GUARD Q TY DESCRIPTION PART NO No 1 DI250 11 01 00 06 SEAT ADJUSTER L 444 6 20 SCREW PHILIPS HEAD M6X20 DS250 11 01 00 06 SUPPORT MUD GUARD REAR R DS250 11 01 00 05 SUPPORT MUD GUARD REAR L GB5787 1986 M10X1 25X20 FLANG BOLT M10X1 25X20 DS250 11 01 00 03 SUP...

Page 68: ...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 REMOVE ALL OF PLUGS BY SCREWDRIVER PUT OUT SEAL CAP FIX OVERFALL TUBER REMOVE THE BOLT AND THE REMOVE THE BATTERY CAP REMOVE THE RUBBER CUSHION ...

Page 69: ...battery cap rubber cushion and tighten both bolts and nuts Notice Before use 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 Otherwise the new battery will be damaged and can t recharge 2 The new battery can t overload in use otherwise it damage forever 3 The new battery need to maintenance with recharge as...

Page 70: ... 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 hole on the frame and the hole on the front shock 6 Tighten the nut FRONT SHOCK TIE ROD FRAME ...

Page 71: ...ked 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: ...71 ATTACH LOOKUM 1 2 3 4 1 2 3 4 ...

Page 73: ...72 ATTACH REAR SHOCK a Remove the bolt and the nut b Attach the rear shock as below picture ...

Page 74: ...73 ATTACH TRAILING ARM 1 ...

Page 75: ...74 2 ...

Page 76: ...75 ATTACH SEAT AND SAFT BELT FIX SAFTY BELT FIX SEAT FIX SEAT FIX SAFTY BELT ...

Page 77: ...H 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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