FOREWORD. We hope you will have a pleasant experience with our products and thanks again for choosing Joyner.

Transcription

1

2

3 CONTENTS

4 FOREWORD Thank you for choosing our Go-Kart. We hope you will have fun with it. Before you start operate the Go-Kart, please read through this Owner s Manual carefully as it contains 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. Beginners should drive this Go-Kart in a large open area to practice handle of this Go-Kart. Protective gear should be worn at all time when driving or riding in this Go-Kart. We hope you will have a pleasant experience with our products and thanks again for choosing Joyner.

5 A FEW WORDS ABOUT SAFETY In order to keep everyone safe, you must lake responsibility for the safe operation of your Go- Kart. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others. It is not practical or possible to warn you about all hazards associated with operating or maintaining a Go-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 one of two signal words: WARNING, or CAUTION. These signal words mean: Physical harm may result from failure to adhere to the instructions that are described within the WARNING labels. Safety Headings such as Important Safety Reminders or Important Safety Precautions. Safety Section such as Go- Kart Safety. Instructions how to use this Go Kart correctly and safely. This entire manual is filled with important safety information-please read it carefully.

6 IMPORTANT SAFETY INFORMATION Your Go-Kart will provide you with many years of service and pleasure, providing you take responsibility for your own safety and understand the challenges you can meet while driving. There is much that you can do to protect yourself when you drive. You ll find many helpful recommendations throughout this manual. The following are a few that we consider most important. Follow the Age Recommendation It is strongly recommended that no one under the age of 16 be permitted to drive this Go-Kart without adult supervision. Always Wear a Helmet It s a proven fact: helmets significantly reduce the number and severity of head injuries. Always wear an approved motorcycle helmet. We also recommend that you wear eye protection, sturdy boots, gloves, and other protective gear. Drive Off-Road 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. If you need to cross a paved or public road, get off and walk your Go-Kart across. 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. Check with your dealer for more information on training courses. Be Alert for Off-Road Hazards The terrain can present a variety of challenges when you drive off-road. Continually read the terrain for unexpected turns, drop-offs, rocks, ruts, and other hazards. Always keep your speed low enough to allow time to see and react to hazards.

7 IMPORTANT SAFETY INFORMATION Drive within Your Limits Pushing limits is another major cause of Go-Kart accidents. Never drive beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, fatigue, and inattention can significantly reduce your ability to make good judgments and driver safely. Don't Drink and drive Alcohol and driving don t mix. Even one drink can reduce your ability to respond to changing conditions, and your reaction time gets worse with every additional drink. So don t drink and drive, 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 moving parts of the Go-Kart The operator of the Go-Kart should never place 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 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 terrain, keep you speed low and drive carefully.

8 SAFETYLABELS This section presents some of the most important 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 hard to read, contact your dealer for warning labels replacements.

9 ARE YOU READY TO DRIVE Before each drive, you need to make sure you and your Go-Kart are both ready to drive. To help get you prepared, this section discusses how to evaluate your driving readiness, what items you should check on your Go-Kart, and adjustments to make for your comfort, convenience, or safety. Before you drive your Go-Kart for the first time, we urge you to: Read this owner s manual and the labels on your Go-Kart carefully. Make sure you understand all the safety messages. Know how to operate all the controls. Have adult present if under 16 years old. Before each drive, be sure: You feel well and are in good physical and mental condition. You are wearing an approved motorcycle helmet (with chin strap tightened securely), eye 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, eye protection, boots, gloves, long pants, and long-sleeved shirt or jacket whenever you drive. Although 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 offers some protection, but a full-face helmet offers more. Regardless of the style, took for a DOT (Department of Transportation) sticker in any helmet you buy. Always wear a face shield or goggles to protect your eyes and help your vision.

10 ARE YOU READY TO DRIVE Additional Driving Gear In addition to a helmet and eye protection, we also recommend: Sturdy off-road motorcycle boots to help protect your feet, ankles, and lower legs. Off-road motorcycle gloves to help protect your hands. Driving pants with knee and hip pads, a driving jersey with padded elbows, and a chest/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 handles. Practice driving the Go-Kart in a safe area to build your skills. Do not drive in rough terrain until you get accustomed to 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 this Go-Kart without adult supervision.

11 ARE YOU READY TO DRIVE / IS YOUR VEHICLE READY TO DRIVE No Alcohol or Drugs Alcohol, drugs and Go-Karts don t mix. Even a small amount of alcohol can impair your ability to operate a Go-Kart safely. Likewise, drugs - even if prescribed by a physician - can be dangerous while operating a Go-Kart. Consult your doctor to be sure it is safe to operate a vehicle after taking medication. IS YOIJR VEHICLE READY TO DRIVE? Before each drive, it is important to inspect your Go-Kart and make sure any problems you find are corrected. A pre-drive inspection is a must, not only for safety, but because 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 your dealer, There may be damages or other problems you can not see. Pre-drive Inspection Check the following items before 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 sure all accessible nuts, bolts, and fasteners are tight.

12 IS YOUR VEHICLE READY TO DRIVE Pre-drive Inspection Underbody & Exhaust System Check for and remove any dirt, vegetation or other debris that could be fire hazard or interfere with the proper operation of the Go-Kart. Air Cleaner Housing Drain Tube Check for deposits in the drain tube. If necessary, clean the tube and check the air cleaner housing. Leaks, Loose Parts Walk around you Go-Kart and look for anything that appears unusual, such as a leak or loose cable. Lights Make sure the headlight, brake light and tail light are 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 rear brake pedal several times, check for proper brake pedal free 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 the fittings for looseness. Replace or tighten as needed.

13 SAFE DRIVING PRECAUTIONS Off-Road Use Only You Go-Kart and its tires are designed and manufactured for off-road use only, not for pavement. Driving on pavement can affect handling and control. You should not drive your Go-Kart on pavement. When driving oft-road, also remember to always obey local oft-road driving laws and regulations. Obtain permission to drive on private property. Avoid posted areas and obey no trespassing signs. You should never drive your Go-Kart on public streets, roads or highways, even if they are not paved. Drivers 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. Keep Hands and Feet on Controls Always keep both hands on the steering wheel and both feet on the foot controls When driving your Go-Kart. It is important to maintain your balance 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.

14 SAFE DRIVING PRECAUTIONS Control Speed Driving at excessive speed increases the chance of an accident. In choosing a proper speed, you need to consider the capability of your Go-Kart, the terrain, visibility and other operating conditions, plus your own skills and experience. Use Care on Unfamiliar or Rough Terrain Before driving in a new area, always check the terrain thoroughly. Don t drive fast on unfamiliar terrain or when visibility is limited, (it s sometimes difficult to see 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 caution and use extra care on rough, slippery and loose terrain. Do Not Perform Stunts You should always operate your Go-Kart in a safe and reasonable manner. When driving, always keep all four wheels on the ground. 1 9

15 SPECIFICATIONS DIMENSIONS Overall Length. 102in. {2600mm) Overall Width. 63in. (1600mro) Overall Height 65in. (1650mm) Wheelbase- 77in. (1950mm) Front Track 52in. (1330mm) Rear Thick. 53in. (1350mm) Ground Clearance 5.2in. (130mm) ENGINE Type Liquid-cooled. 4- Slroke Bore x Stroke 72mm*60mm Displacement 244 cc Corrected compression ratio.. 9.2:1 Carburetor KEIHIN No. VE 14CEQKY PD30J Output Power 16.75hp/7500RPM Maximum Torque.17.6/5500 Nm/r/min Starting.. Electric Ignition C.D.I. Lubrication. Force & Splash Transmission. Automatic (C. V.T system) Spark Plug. PR8EA-9 (NGK), DPR6EIX-9 (NGK) Plug Gap mm 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 Battery. 12V 9Ah Head Light. 12V 15W Tall Light.. 12V 10W/15W Fuse. 10A SPECIFICATIONS Brake Track-.. Top speed 30mph (or limited as customers require) CHASSIS Front, Rear brake Hydraulic disc, left foot control Front tire 19x7-8 Rear tire.. 22x10-10 Front Suspension Independent Dual A-Arm Rear Suspension Swing Arm/Double Oil Damped Shock Restraint System Dual 4-point Harness Final Drive Chain. (KMC) O-Ring Chain TIRE PRESSURE Front.15kpa 0.5kg/c 2.2psi Rear.. 20kpa 0.20kg/c 2.9psi WEIGHT Net Weight WARRANTY Parts and workmanship 726 lbs 90 Days

16 OPERATION A. Operation controls WARNING - Do not attempts to start or operate the engine until completely familiar with the location and use of each control necessary to operate this vehicle. The operator must know how to stop this machine before starting and driving it. a. Throttle 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 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 pressure to the pedal draws the brake caliper around the brake pump at the rear wheel and slows or stops the kart. Figure 1 c. Start engine Insert the key into key-switch, turn the key clockwise, release the key when the engine starts. The engine will warm up within 5 minutes and the engine choke will close automatically and operate at normal RPM (Warning: Don t crank starter more than 5 seconds at one time). (See Figure 2) Figure 2

17 d. Engine stop button Important - stop button test. Before driving this vehicle, test the Engine Stop Button to assure that it is operating properly. With the engine running, push and hold the Engine Stop Button for two seconds for the engine to shut down. B. Pre-Drive Inspection a. Check for Engine Oil Level. Check for leaks, add oil if required. b. Check for Fuel Level. Add fuel as necessary and do not overfill. Check for leaks. c. Check for Brakes. Depress the rear brake pedal several times, then check for proper brake pedal free play. Make sure there is no brake fluid leakage. Adjust if necessary. d. Check Tires. Check tires condition and pressure. 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. Assure throttle snaps back to idle. g. Check Engine Stop Button. Perform engine stop button test. Repair as necessary. h. Check all Nuts, Bolts, and fasteners. Check wheels to see that all axle nuts and lug nuts are lightened property. 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. Check for proper operation. k. Check Wheels. Check for tightness of wheel nuts and axle nuts; check that axle nuts are secured by cotter pins. l. Check Steering. Check for free operation for any unusual looseness in any area.

18 OPERATION Component locations Figure 3

19 OPERATION C. Passengers The vehicle allows for two riders only. Combine maximum weight of driver and the passenger should not exceed 180kg or 400Ibs. D. Seat Adjustment 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. Figure 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 Adjustment Figure 5 a. Press down the shift lever to the F position so that the unit can move forward, pull back the lever to N so that the 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 (RHD) and 2 (LHD). Adjust tie rod 3 can adjust the mesh status inside

20 OPERATION reverse gear box. Make sure the shift lever can be on the three positions (F, N, R) cleanly. Then tighten the nuts 1, 2. F. Parking Adjustment a. Press down the reverse lever 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 reverse gear box, Turn half a round as you rotate the nut to adjust the cable. Make sure cable is not too tight or loose. Adjust Nut #2 accordingly to adjustment of Nut #1. Figure 6

21 OPERATION/SERVICE INSTRUCTIONS G. Starting And Operating Instructions a. Before starting the engine, be sure that the driver is sealed properly in the Go-Kart and tighten the seatbelt. b. Testing the Go-Kart in a 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 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 when turning, (See Fig. 7) Keep your leg rely on the foot pedal, you can feel the kart is stable because of the gravity is adjusted and won t roll over. Figure 7 SERVICE INSTRUCTIONS A. Service Air Cleaner Service air cleaner every 80 hours. NOTE: Service more often under dusty conditions. a. Remove cleaner cover 1 b. Remove air cleaner element 2 (See Fig. 8) c. Check the paper Filter, if the filter is dusty, please replace with a new one. Figure 8 Figure 8

22 SERVICE INSTRUCTIONS B. Engine Lubrication You must change the oil in the crankcase after the first 5 hours of operating of your new engine (See Fig. 9) and after 10 hours of use thereafter. This will insure proper lubrication of internal parts and prevent costly repairs due to excessive wear. a. Remove fill plug located on rear side of engine. Tip kart backwards slightly by raising 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 SAE 10W/30 oil. Use same grade of oil as used originally. d. Check oil level before each use of dart or after each 10 hours of operation. Add oil to bring up to proper lever. Do not mix various grades of oil. Figure 9 C. Engine Coolant You must check the coolant for lack. It is lack, you need to refill coolant into the radiator (approximately 1800 ml) or reserve coolant. The lack of coolant will cause engine overheat. This can cause engine damage.

23 SERVICE INSTRUCTIONS D. Spark Plug a. Remove the spark 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 b. Before installing spark plug coat threads lightly with graphite grease if possible, to ensure easy removal next time the spark plug needs inspection. c. It is advisable to replace the spark plug at least once a year to insure easy starting and good engine performance. Figure 10 E. Carburetor Adjustment Never make unnecessary adjustments. The factory recommended settings are 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 the air screw 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 (1400RPM). d. Turn the air screw counter slowly and observe the RPM of the engine, stop adjusting as the RPM reaches the top speed. e. Adjust the screw and adjust the idle speed to an ideal value. f. Repeat step 4 and 5 until the rotate speed of engine stables. Figure II F. Cleaning Instructions Keep your kart clean. With a clean rag, wipe off and dirt and oil from 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.

24 SERVICE INSTRUCTIONS H. Chain Lubrication To increase chain life, it should be lubricated with a spray on type chain lubricant. I. Chain Adjustment Check the chain adjustment after first two hours of use. Readjust if it has more than 1/2 flex. (See Figure 12) a. Loosen 12 Bolts b. Insert the special tools into the holes. Rotate the axle clockwise to adjust the chain for a right position. At the same time, keep the same distance of two end of axle to fixed points which fixed rear swingarm 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 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, which has deteriorated from storage, will cause hard starting and affect engine performance.

25 REPAIR A. Front Wheel Replacement Do not disassemble the castle nuts when you replace the front wheels. It is only necessary to tighten the nuts so that the wheel turns freely on the axle with minimum end play. (See Fig. 13) Tighten the nuts after replacing the wheels. Figure 13 B. Rear Wheel Replacement Do not disassemble the castle nuts when you replace the front wheels. It is only necessary to tighten the nuts so that the wheel turns freely on the axle with 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 both sides of Front Tie Rods. To make Dimension B smaller, scare the rod to the left. Adjust the rod to right direction to make Dimension B larger. After adjusted to desired length, tighten the lock nut against the rod end. Recheck the dimensions for proper alignment.

26 PERIODICAL CHECK AND SERVICES The maintenance intervals in the following table are based upon average driving conditions. Driving in unusually dusty areas, require more frequent servicing. Item Time of service Initial service (first week) Tire pressure/wear I I Brake performance I I Tightness of screws I I Monthly Quarterly Yearly Air cleaner C I Carburetor I A C Spark plug C,A Drive chain I I C,A,L Brake oil Replace gearbox oil I R Replace coolant I R Chassis C,I L Fuel switch/fuel tank I C I Battery Valve clearance of engine I A A: adjust C: clean I: inspect, clean or replace if necessary. L: lubricate R: replace

27 WIRING DIAGRAM

28 CONTENTS ENGINE Page 1. Cover comp, cylinder head Head comp, cylinder Cylinder comp Crankcase comp Cover comp, R.crankcase Cover comp, L.crankcase Piston Transmission comp Clutch comp Reduction comp Pump comp water Pump comp. oil Electrical start propeller Carburetor comp Air cleaner comp Radiator comp 45 BODY 1. Frame and fuel tank Suspension arm assy Steering assy and brake Engine rack Rear swing arm Rear housing Electrical assembly Shift lever and parking lever assy Radiator assy Reverse gear Exhaust Label Seat and safety belt Fender Front, rear wheel.. 66

29 No. P/N ENGLISH Qty 1 SZ Fuel pipe grommet 1 2 SZ Hanger, oil pipe 1 3 SZ Rubber cushion 1 4 SZ Bolt, M8x25/ Φ SZ Pin, dowel 2 6 SZ Cover, cylinder head 1 7 SZ Cam 2 8 SZ Plug M14x A O-ring 13x SZ O-ring 9.4x SZ Gasket, cylinder head 1 12 SZ Washer 1 13 SZ Bolt, M8x25/ Φ SZ Washer SZ Bolt, M12x Bolt, M6x Bolt, M6x Bolt, M6x Bolt, M6x SZ Oil tube 1 21 SZ Melt valve rocker arm shaft 1 22 SZ Exhaust 1 23 SZ Cushion 8 3

30 2. Head comp, cylinder No. P/N ENGLISH O ty 1 SZ Cotter, valve 4 2 SZ Retainer, valve spring 2 3 SZ Spring, valve inner 2 4 SZ Spring, valve outer 2 5 SZ Seal, valve stem 2 6 SZ Washer, valve spring 2 7 SZ Guide, valve Bolt M6x SZ Nut M SZ Washer Bolt M6x SZ Cover, cam bearing 1 13 SZ Head, cylinder 1 14 SZ Chain 1 15 SZ Sprocket assy 1 16 SZ Camshaft G Bearing/16002/P Washer SZ Plug 1 20 SZ Plug, spark 1 21 SZ Bolt stud M7x SZ Seat, ex valve 1 23 SZ Seat, in valve 1 24 SZ Valve, ex 1

31 2. Head comp, cylinder No. P/N ENGLISH Q' ty 25 SZ Valve, in 1 26 SZ Gasket, cylinder head 1 27 SZ Pin, dowel O-ring 30x SZ Insulator washer, carburetor 1 30 SZ O-ring 14.8x SZ Insulator comp 1 32 SZ Inlet hose clamp Clamp 4 34 SZ Rubber tube Bolt M6x SZ Thermostat lower case 1 37 SZ Constant temp valve assy 1 38 SZ Thermostat upper case 1 39 SZ Sensor, water temp Bolt, hex M6x Clamp SZ Hose, water outlet 1 43 SZ Boot 1 44 SZ Hose, thermostat 1 45 SZ Head cylinder 1 46 SZ Cam, assy Bolt M6x22 2

32 3. Cylinder comp No. P/N ENGLISH Qty Clamp 2 2 SZ Hose water inlet 1 3 SZ Pin, dowel 10x14x SZ Gasket, cylinder 1 5 SZ Cylinder assy 1 6 SZ Gasket 1 7 SZ Cam Chain Tensioner Bolt, M16x SZ Spring Washer 8-100HV 1 11 SZ Bolt, hex 1 12 SZ Plate of tension (Lower Chain Guide) 1 13 SZ Bolt, tension plate 1 14 SZ Chain guide, upper Bolt M6x SZ Sealed washer SZ Tensioner assy 1

33 4. Crankcase comp No. P/N ENGLISH Qty 1 SZ Crankcase assy, R 1 2 SZ Bolt cylinder stud M8x SZ Bolt cylinder stud M8x SZ Pin, dowel 2 5 SZ Gasket, crankcase 1 6 C O-ring 12.3x C O-ring 7.5x SZ Crankcase assy,l 1 9 SZ Rear pin Bearing Z/P SZ Seal 27*42* Nut, M SZ Rubber pin Bearing 6301/P Bearing HK1412/P Bolt M6x Bolt M6x Bolt M6x SZ Seal 20x40x SZ Shackle of inner pin 2 21 SZ O-ring 15.8x SZ Shackle of outer pin Bolt M6x SZ Oil pump 1

34 4. Crankcase comp No. P/N ENGLISH Qty 25 SZ O-ring 9x SZ Bolt M6x16 3

35 5. cover comp, R.crankcase No. P/N ENGLISH Qty 1 SZ Tube, breather tube 1 2 SZ Clamp assy Clamp SZ Pin, dowel 10x14x SZ Gasket, R, crankcase 1 6 SZ Union, breather tube 1 7 SZ Union, water outlet pipe Bolt M6x SZ Gauge, oil lever Bolt M6x A O-ring 13x SZ Plug M14x A O-ring 18x Bolt M6x Bolt M6x SZ Cap, oil filter 1 17 A O-ring35x SZ Spring, oil filter screen 1 19 SZ Screen comp, oil pump 1 20 SZ Cover, R, crankcase 1

36 6. Cover comp, L. crankcase No. P/N ENGLISH Qty 1 SZ Seal of rubber 1 2 SZ Cover, L 1 3 SZ Cushion block 2 4 SZ Cushion block seat 2 5 SZ Bolt 2 6 SZ Filter 1 7 SZ Seal 1 8 SZ Dust seal 1 9 SZ Backing plate l 10 SZ Cover plate, sub-assy 1 11 SZ Cover plate, assy Comp, screw M15x Bolt M6x12 1

37 7. Crankshaft / Piston No. P/N ENGLISH Qty 1 SZ Ring, piston first 1 2 SZ Ring, piston second 1 3 SZ Ring, piston third 1 4 SZ Piston 1 5 SZ Clip, piston pin 2 6 SZ Pin piston 1 7 SZ Crankshaft COMP 1 8 SZ Key, woodruff 1 9 SZ Pin 2x SZ Spring 1 11 SZ Oiln joint 1 12 SZ Washer 2 13 SZ Nut M14x1.25 1

38 8. Transmission comp No. P/N ENGLISH Qty 1 SZ Move side of transmission (Variator) 1 2 SZ Collar of shaft (Center Bushing) 1 3 SZ Drive side of transmission (Fan Plate) 1 4 SZ Washer 1 5 SZ Nut M14x1.5 1

39 9. Clutch comp No. P/N ENGLISH Qty 1 SZ Bearing Circlip SZ Bearing 1 4 SZ Pulley, inner 1 5 SZ Seal, oil 2 6 SZ Pulley, outer Circlip SZ Back plate 1 9 SZ Clutch retracting spring (Arm spring) 3 10 SZ Clutch block assy 3 11 SZ Washer 1 12 SZ Rubber block, cushion 3 13 SZ Drive disc assy l 14 SZ Nut l 15 SZ Gring disc assy (Clutch Bell) 1 16 SZ Nut M12 l 17 SZ Spring (Main torque) 1 18 SZ Collar O-ring 40x SZ Pin 3 21 SZ Guide pulley 3 22 SZ Gearing V-belt 1

40 10. Reduction comp No. P/N ENGLISH Qty 1 SZ Shaft of clutch Bearing 6204/P5 1 3 SZ Washer SZl Counter shaft assy Bearing HK1414/P5 1 6 SZl Output shaft Circlip, external l 8 SZl Gear, drive 1 9 SZl Thrust washer Bearing 6203/P SZl Gasket of cover 1 12 SZl Pin dowel 10x16x SZl Tube, breather rubber 1 14 SZl Cover, transmission 1 15 SZl Conical washer Bolt M6x Bolt M6x SZ Plug 1 19 SZl Sealed washer SZl Sealed washer 6 1 SZl Seal, oil 1

41 11. Pump comp, water No. P/N ENGLISH Qty Bolt M6x Bolt M6x SZ Cable clamp Clamp SZ Bolt M6x SZ Washer SZ Cover, water pump 1 8 SZ Gasket, water pump cover 1 9 SZ Pin 8x14x SZ Gose 1 11 SZ Bush 1 12 SZ Impeller of water pump 1 13 SZ Washer SZ Seal unit 1 15 SZ Seal 12x20x Bearing 61901/P SZ Shaft, water pump Bearing 6000/P Washer 26 1 *

42 12 pump comp.,oil No. P/N ENGLISH Qty Screw 1 2 SZ Cover, oil pump gear 1 3 SZl Pin, dowel 1 4 SZl Rotor, oil pump inner 1 5 SZ Rotor, oil pump outer 1 6 SZl Body, oil pump 1 7 SZ12I01005 Shaft, oil pump 1 8 SZl Pump assy, oil 1 9 SZl Front back, plate Bolt M6x SZl Chain, oil pump 1 12 SZl Sprocket, oil pump Circlip, external SZl Backing plate of oil pump Bolt M6x22 1

43 13. Electrical start propeller No. P/N ENGLISH Qty 1 SZ Motor, starter 1 2 SZ Gear, reduction 1 3 SZ Shaft, reduction gea Bolt M6x SZ Hold plate 1 6 SZ Gear Bolt hex M6x SZ Spring 3 9 SZ Pin 3 10 SZ Roller 3 11 SZ Plug 3 12 SZ Clutch body 1 13 SZ One-way clutch assy 1 14 SZ Flywheel assy Bolt, hex M5x SZ Stator, assy Bolt, hex M5x SZ Clamper, wire harness 1 19 SZ Flywheel pick-up sensor 1 20 SZ CDI 1 21 SZ Relay, starter 1 22 SZ Coil, ignition 1 23 SZ Rectifier, regulator 1

44 14. Carburetor comp No. P/N ENGLISH Qty 1 SZ Carburetor COMP 1

45 15. Air cleaner comp No. P/N ENGLISH Qty 1 SZ Air cleaner assy 1 2 SZ Bracket 1 3 SZ Fixing bolt 3 4 SZ Breather hose Clamp 7 2 * -

46 16. Radiator comp No. P/N ENGLISH Qty 1 SZ Radiator assy O-ring 14x SZ Water tension sensor 1 4 SZ Outlet hose Hose clamp 6 6 SZ Fan assy 1 7 SZ Fan motor assy 1 8 SZ Radiator inlet 1 9 SZ Water inlet body 1 10 SZ Radiator cap Clamp SZ Hose of radiator inlet 1 13 SZ Hose of heat inlet 1 14 SZ Sub-hose of radiator inlet 1 15 SZ Joint, backing pipe Clamp SZ Carburetor inlet 1 18 SZ Hose assy Nut M Bolt M6* SZ Water tank assy 1 22 SZ Bracket, fan 1

47 1. FRAME AND FUEL TANK No. P/N ENGLISH Qty 1 D Bumper, front Nut, flange M Bolt, flange Ml0X D Defense to dump, top Bolt, hex M10x D Protective bar, front 1 7 D Protective bar, top 2 8 D Foam set 2 9 D Protective bar, rear Bolt, flange M10X Washer Φ D Round rubber seat 2 13 D Round washer D Tube seat Φ D Protective bar, caudal Bolt, flange M12x1.5x Nut, flange M12x D Frame comp Bolt, flange M10x25 8

48 1. FRAME AND FUEL TANK No. P/N ENGLISH Qty 20 D Cap comp fuel filler (Gas Cap) 1 21 D Tank comp. fuel 1 22 D Rubber cushion 1 23 D Valve assembly, fuel petcock 1 24 D Tube comp. fuel 1 25 D Rear cargo rack Bolt, flange M8x Nut, flange lock M8 4

49 2. SUSPENSION ARM ASSY No. P/N ENGLISH Qty Nut, flange lock M10x Washer, lock Φ Washer, flat Φ D Dust cap 8 5 D Bush, upper suspension arm 8 6 D Spacer, upper suspension arm Bolt-washer M10x D Upper suspension arm Pin, cotter Nut, castle M12x Washer, lock Φ Washer, flat Φ D Dust cover, moire 2 14 D Support strut and spindle, R 1 15 D Universal knuckle, upper Bolt-washer M8x Bolt-washer M6x D Disc, FR brake 2 19 D Universal knuckle, lower Bolt-washer M10x1.25x Nut, flange lock M12x D Spacer, lower suspension arm 2 23 D Bush, lower suspension arm 4

50 2. SUSPENSION ARM ASSY No. P/N ENGLISH Qty Bolt-washer M12x D Cushion assy, FR Bolt-washer M12x1.5x D Support strut and spindle, L 1 28 D Lower arm 2 _

51 3. STEERING ASSY AND BRAKE No. P/N ENGLISH Qty 1 D Cover, steering bolt Nut. M12x D Steering wheel 1 4 D Assorted on-off assembly Circlp Φ D Nylon cover 2 7 D Steering shaft Bolt-washer M8x Nut, flange lock M D Steering knuckle 1 11 D Steering gear 1 12 D Nylon cover, R 1 13 D Bracket, steering gear 2 14 D Nylon cover, L Bolt-washer M10x1.25x Nut, flange lock M D Tie rod, L Nut. M12x D Dust cover, L ball joint 1 20 D Rod end, L Washer, lock Φ Nut, castle M Pin, cotter 2

52 3. STEERING ASSY AND BRAKE No. P/N ENGLISH Qty Bolt-washer M6x D Tie rod, R 1 26 D Rod end, R 1 27 D Axle, throttle pedal 1 28 D Bush, pedal 4 29 D Throttle pedal comp D Spring Nut. M D Cable, throttle Bolt-washer M6x Nut, flange lock M Washer, flat Φ D Brake pedal comp 1 37 D Scalar block 1 38 D Washer 2 39 D Washer Bolt-washer M8x D Axle, brake pedal 1 42 D Master cylinder 1

53 4. ENGINE RACK No. P/N ENGLISH Qty 1 D Engine rack Nut, flange lock M D Con'rod 2 4 D Bush, con'rod Bolt-washer M10x Bolt-vaulted M4x D Electric ass'y Bolt-washer M12x1.5x D Fixed rod, rear engine Bolt-washer M10x1.25x Bolt-washer M14x1.5x Washer, flat Φ D Bush Washer, lock Φ Nut, flange lock M14x D Washer, adjust engine Φ Bolt-washer M8x Nut, flange lock M Washer, flat Φ4 4

54 5. REAR SWING ARM No. P/N ENGLISH Qty Bolt M16x D Spacer, swing arm 2 3 D Bush, swing arm 4 4 D RR swing arm comp, under Washer, lock Φ Nut. M16x Nut, flange lock M12x D Bush, swing arm 2 9 D Spacer, swing arm Bolt-washer M12x1.5x D Clamp piece, prejudicial tray Bolt-hexagon, inner M8x D Cushion assy, RR Bolt-washer M12x1.5x Nut, flange lock M12x1.5 4

55 6. REAR HOUSING No. P/N ENGLISH Qty 1 D Hub cover, rear wheel Cotter pin, shaft, 3x Nut, M16x D Adjusting washer Φ Nut, wheel, M10x Washer, lock Φ Washer, flat Φ D Hub, rear 2 9 D Bolt, M10x1.25x Nut, wheel, M30x D Spacer Seal, axle carrier 38x62x Circlip Φ D Compart spacer 2 15 D Eccentricity tray Bearing Seal, axle carrier 45x65x D Sensor spacer Bolt, M6x Seal, axle carrier 45x65x D After shaft 1 22 D Compart spacer Circlip Φ45 2

56 6. REAR HOUSING No. P/N ENGLISH Qty 24 D Mounting, brake 1 25 D Limit bolt Bolt, M8x Washer, lock Φ Washer, flat Φ D Disc IT brake 1 30 D Big sprocket wheel 1 31 D Chain 1 *

57 7. ELECTRICAL ASSEMBLY No. P/N ENGLISH Qty 1 D Turning signal, front 2 2 N Nylon clamp, 6x D Headlight (35/25w) 2 4 D Tail lamp 2 5 D Harness, wiring 1 6 D Battery (12v, 9Ah) 1 7 D Turning signal, rear 2 8 D Switch box 1 9 D Function display D Function display D Panel 1 12 D Button, engine 1 13 D Ignition switch 1 14 D Speedometer 1 15 D Level switch 1 16 D Safety switch 1 17 D Relay, start 1 18 D Horn 1 19 D Flasher 1 20 D Rectifier, regulator 1 21 D Coil, IGN 1 22 D C.D.I 1 23 D Spring 1

58 8. SHIFT LEVER AND PARKING LEVER ASS'Y No. P/N ENGLISH Qty 1 D Lever, reverse gear GE12E Sliding bearing GE12E l 3 D Spring 1 4 D Bush Pin.cotter 1 6 D Cover, reverse gear lever Nut, R M10x L Nut, L M10x D Ball, reverse gear 4 10 D Long drive lever Nut, flange lock M10x D Sway arm. right-angle 1 13 D Shaft 1 14 D Short drive lever 1 15 D Ball, fixed 1 16 D Steering knuckle, reverse gear Washer, lock Φ Bolt-washer M8x D Parking brake assy 1 20 D Cable, parking brake Bolt-washer M6x D Handgrip Nut. M14x1.5 2

59 9. RADIATOR ASSY No. P/N ENGLISH Qty 1 D Water tank 1 2 D Fanner 2 3 D Water pipe for enter 1 4 D Water pipe for out 1 5 D Standby water tank 1 6 D Water pipe for tank 1 7 D Cover for add water 1 8 D Cooling pipe Nut, M Washer, flat Φ Bolt, M10x Mounting, exhaust pipe Big washer Φ D Spring Cotter pin, shaft, 3x Nut, M Bolt, M6x15 8

60 10. REVERSE GEAR

61 10. REVERSE GEAR No. P/N ENGLISH Q ty Nut, M Bolt, M6x Washer lock Φ Washer Φ D Shaft seat 1 6 D Gasket head cover 2 7 D Small shaft 1 8 D Washer 1 9 D Prick gear 1 10 D Compart spacer 1 11 D Joint spacer 1 12 D Poker 1 13 D Shaft 1 14 D Shaft for enter 1 15 D Prick gear 1 16 D Compart spacer Bearing Circlip Circlip D Shaft seat 1 21 D Prick gear 1 22 D Compart spacer 1 23 D Joint spacer 1 24 D Compart spacer 1 25 D Roll pin 1 26 D Shaft for out Bearing 6204 I Circlip D Seal, axle carrier 2 30 D Shaft seat 1 31 D Chain wheel for out Nut, M16x Cotter pin, shaft, 3x Bolt, M14x Washer Φ Bolt, M6x D Box cover 1 38 D Paper gasket Screw M6x D Pin 1

62 10. REVERSE GEAR No. P/N ENGLISH Qty Screw M6x D Sensor Nut, M Nut, M D Sector board shaft 1 46 D Sector board 1 47 D Compart spacer Nut, M Nut, M Screw, M8x D Reverse gear box Bolt, M6x D Left shaft 1 54 D Rubber plate 1 55 D Right shaft 1 56 D Washer 1 57 D Washer 1

63 11. EXHAUST No. P/N ENGLISH Qty 1 D Seal, exhaust pipe 1 2 D Exhaust pipe Bolt, M8x D Mounting, exhaust pipe Bolt, M8x D Mounting, exhaust pipe 1 7 D Front exhaust pipe Nut, M8 4 _

64 12. LABEL No. P/N ENGLISH Qty 1 D Long-hair warning 1 2 D Colligate warning 1 3 D Safety belt warning 2 4 D Luggage carrier warning 1 5 D Chain warning 1 6 D Shift reverse gear warning 1 7 D Hand indication 1 8 D Age warning 1 1

65 13. SEAT AND SAFETY BELT No. P/N ENGLISH Qty 1 D Belt, safety 2 2 D Seat comp Bolt, flange M10x Nut, flange lock M D Seat cushion board Screw-washer, M6x Nut, flange lock M D Seat adjuster 2

66 14. FENDER No. P/N ENGLISH Qty 1 D Mudguard, left front 1 2 D Mudguard, right front 1 3 D Mudguard, left rear 1 4 D Mudguard, right rear 1 5 D Support, mudguard #1 2 6 D Support, mudguard #2 2 7 D Support, mudguard #3 2 8 D Support, mudguard # Bolt, flange M8X Nut, flange lock M Nut, flange lock M D Rrubber cushion, thin Screw-washer M6x20 16

67 15. FRONT, REAR WHEEL No. P/N ENGLISH Qty Seal, FB 28x47x Bearing, inner D Spacer, FR hub inter 2 4 D Bolt, tire M10x1.25x D Hub, FR, wheel 2 6 D Spacer, FR hub Bearing, outer Seal, FB 25x40x7 2 9 D Spacer, FR hub outer Lock washer Cotter pin 4x Nut, front axle M16x Washer, front axle Φ D Valve assy Nut, front wheel M10x D Tire, AT 19x7-8 L/R 2 17 D Hub cover, front wheel 2 18 D Tire, AT22x

68 CONTENTS PREPARATION ATTACH INSTRUCTION ATTACH BATTERY ATTACH FRONT BUMPER ATTACH FRONT SHOCK ATTACH FRONT TIRE ATTACH FUEL TANK/ATTACH HEADLIGHT/ATTACH LEFT AND RIGHT REAR TURN SIGNALS ATTACH LOOKUM ATTACH REAR BRAKE LAMP/ATTACH REAR SHOCK ATTACH REAR TIRE ATTACH SEAT ATTACH STEERING WHEEL ATTACH THE RADIATOR ATTACH THE REAR TACK PREPARATION INSTRUCTIONS FOR THE GO-CART THE WHOLE GO-KART LOOKS

69 ATTACH BATTERY Remove battery from Go-Kart Fill the electrolyte as below. 1. Put the battery into the box on ATV. 2. Connect the wire to battery as below picture; red to +; black and green to - 3. Fix the metal cover, 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. 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 the Owner s manual said.

70 ATTACH FRONT BUMPER Front of bumper is as below picture. 3- Attach upper bumper to front bumper 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 the frame under the steering wheel by inserting bolts

71 ATTACH FRONT SHOCK The front shock in packing situation is as below picture about. 1- Remove pin, nut, adjusted cushion from the bolt on the tie rod. 2- Insert the bolt on 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 groove and the hole on the front shock. (Notice; one cushion on one side of hole on the front shock.) 6- Tighten the nut.

72 ATTACH FRONT TIRE The hub fixed the front tire in packing is as below; 3- Insert the cushion, lock cushion through bolt on the hub. Tighten four nuts. 1- Remove four nuts, four lock cushion, four cushion on the hub. Notice; Direction marked on the tire must correspond to the vehicle forward 2- Fix the rim on the hub by four bolts on the hub. it *

73 ATTACH FUEL TANK/ATTACHHEADLIGHT/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 to wire from main wire.

74 ATTACH MIRROR

75 ATTACH 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. cushion

76 ATTACH 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 pictures

77 ATTACH SEAT Figure 1 Figure 3 Figure 2 Figure 4 1C

78 ATTACH STEERING WHEEL Remove the nut on the steering shaft Insert the switch Assy through the steering shaft along the groove on the frame Tighten two nut on the switch Assy. 1- Insert steering wheel through the shaft 2- Adjust two front wheel to direct straight forward by turning steering wheel. 3- Pull out the steering wheel and reinsen it as pictures. 4- Put the wire cushion into the shaft and tighten the nut. Cover the steering wheel cover.

79 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 pictures

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

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

82 THE WHOLE GO-KART LOOKS Front review Side Review Back Review Upper Review