Joyner Dirt Devil 250 2004 User manual

CONTENTS

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.
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.
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.

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.
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.
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.
1 9

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 ……………………………………………………………………………………………………… 0.6-0.7mm
Fuel type ……………………………………………………………………………………............ RQ90 (unleaded) !
Lubricate oil …………………………………………………………………………………………. SAE-10W/30
CAPACITIES
Maximum load …………………………………………………………………………………… Double Seats / 400lbs
Fuel Tank …………………………………………………………………………………………. 16.0L
Engine Oil ………………………………………………………………………………………… 1000ml
Coolant …………………………………………………………………………………………… 1800ml
Starting …………………………………………………………………………………………… <5s
Climbing ………………………………………………………………………………………….. 20°-25°
Battery ……………………………………………………………………………………………. 12V 9Ah
Head Light ………………………………………………………………………………………. 12V 15W
Tall Light ………………………………………………………………………………………….. 12V 10W/15W
Fuse ………………………………………………………………………………………………. 10A
SPECIFICATIONS
Brake Track- ………………………………………………………………………………………………….. <7m @20mph
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 ………………………………………………………………………………………………… 726 lbs
WARRANTY
Parts and workmanship ………………………………………………………………………………… 90 Days

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.
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 1
Figure 2

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.

OPERATION
Component locations
Figure 3

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

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