Joyner Dirt Devil SZ250DS 2006 User manual

SZ250DS Limited Warranty
The warranty policy applies to those cases where the new seller vehicle is unloaded
from its shipping container, set up and delivered by authorized dealer, and under normal
use and service is found to have defects in parts or workmanship under the following
terms and conditions. This warranty covers the engine and engine related components
for a period of 90 days.
This warranty does not apply to any part, which in opinion of seller was defective
because of improper maintenance, improper assembly, alterations, abuse, negligence or
accident.
Should warranty service be required on your SZ250DS 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 to adversely
affect its safety or reliability.
d. Competition or racing
The warranty does not cover loss of use of the seller vehicle, loss of time,
inconvenience, or other consequential damage which includes, but is not limited to,
loss or damage to persons or property or any expense of returning any damaged
units to the seller distributor or its authorized dealer.
Seller has the right to make changes without notice.

CONTENTS
OWNER’SMAUNUAL
1. FOREWORD............................................................................................. 4
2. A FEW WORDS ABOUT SAFETY......................................................... 5
3. IMPORTANT SAFETY INFORMATION................................................. 6
4. SAFETY LABELS.................................................................................. 8
5. ARE YOU READY TO DRIVE................................................................ 9
6. IS YOUR VEHICLE READY TO DRIVE.................................................. 11
7.SAFE DRIVING PRECAUTIONS................................................................ 13
8.SPECIFICATIONS....................................................................................... 15
9.OPERATION................................................................................................ 16
10.SERVICE INSTRUCTIONS....................................................................... 20
11. REPAIR..................................................................................................... 24
12. PERIODICAL CHECK AND SERVICES................................................... 25
13. WIRING DIAGRAM................................................................................... 26
PARTS MANUAL.................................................................................... 27

FOREWORD
Thank you for choosing our Go-Kart. We hope you will have fun
with it. Before you start operating 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.
We hope you will have a pleasant experience with our products
and thanks again for choosing us.

A FEW WORDS ABOUT SAFETY
In order to keep everyone safe, you must take 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 safety information in a variety of forms, including:
Safety Labels - On the Go-Kart.
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.
Safety Messages - Preceded by a safety alert symbol and one of two
signal words: WARNING, or CAUTION.
These signal words mean:
5

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 may have driven other Go-Karts, 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.
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 or in enclosed spaces with poor ventilation.
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.
7

SAFETY LABELS
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 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.

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, look 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.
Additional Driving Wear
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 driven 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 to drive this
Go-Kart without adult supervision.
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 YOUR 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 dealer has inspected your Go-Kart, There may be damages or other problems
you cannot 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.
■Under body & 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 taillights 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.
When driving off-road, also remember to always obey local off-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
and keep control of the kart.
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.

SPECIFICATIONS
DIMENSIONS
Overall Length---------------------------------------------------------------------------------------93 in. (2380mm)
Overall Width--------------------------------------------------------------------------------------54.3 in. (1380mm)
Overall Height---------------------------------------------------------------------------------------65.4 in. (1660mm)
Wheelbase--------------------------------------------------------------------------------------------72.8 in. (1850mm)
Front Track------------------------------------------------------------------------------------------47 in. (1200mm)
Rear Track------------------------------------------------------------------------------------------43.5 in. (1105mm)
Ground Clearance-----------------------------------------------------------------------------------4.7 in. (120mm)
ENGINE
Type------------------------------------------------------------------------------------------Liquid-cooled. 4-Stroke
Bore x Stroke--------------------------------------------------------------------------------------------72mmx60mm
Displacement------------------------------------------------------------------------------------------------------244 cc
Corrected compression ratio------------------------------------------------------------------------------------9.2:1
Carburetor-----------------------------------------------------------------------KEI HIN; No. VE 14CEQKY
Output Power---------------------------------------------------------------------------------------16.75hp/7500rpm
Maximum Torque------------------------------------------------------------------------------- 17.6/5500Nm/r/min
Starting-----------------------------------------------------------------------------------------------------------Electric
Ignition--------------------------------------------------------------------------------------------------------------C.D.I.
Lubrication--------------------------------------------------------------------------------------------Force & Splash
Transmission----------------------------------------------------------------------------Automatic (C.V.T system)
Spark Plug----------------------------------------DPR5EA-9 (NGK), DPR6EA-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/400lbs
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----------------------------------------------------------30miles/h (or limited as customers require)
CHASSIS
Front, Rear brake---------------------------------------------------------------Hydraulic disc, right foot control
Front tire---------------------------------------------------------------------------------------------------------21x8-10
Rear tire-------------------------------------------------------------------------------------------------------22x10-10
Front Suspension-----------------------------------------------------------------------Independent Dual A-Arm
Rear Suspension-------------------------------------------------------Trailing 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 m22.2psi
Rear-----------------------------------------------------------------------------------------20kpa 0.20kg/c m22.9psi
WEIGHT
Net Weight-----------------------------------------------------------------------------------------------330kg/ 728 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)
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 2
Figure 1

Figure 3
B. Pre-Drive Inspection
b. Check for Engine Oil Level. Check for leaks, add oil if required.
c. Check for Fuel Level. Add fuel as necessary and do not overfill. Check for
leaks.
d. Check for Brakes. Depress the rear brake pedal several times, and then check for
proper brake pedal free play. Make sure there is no brake fluid leakage. Adjust if
necessary.
e. Check Tires. Check tires condition and pressure. The pressure on both Front and
Rear tire is 15kpa and 20kpa.
f. Check Drive Chain. Check for drive chain’s condition and tension. Lubricate if
necessary.
g. Check Throttle. Check for smooth operation. Assure throttle “snaps” back to
idle.
h. Check Engine Stop Button. Perform engine stop button test. Repair as
necessary.
i. Check all Nuts, Bolts, and fasteners. Check wheels to see that all axle nuts and lug
nuts are tightened properly. Check and tighten as necessary all other fasteners to
specified condition.
j. Check Roll Cage Bar. Ensure all protective roll cage bar are in place before
operating the Go-Kart.
k. Check Brake Light. Check for proper operation.
L. Check Wheels. Check for tightness of wheel nuts and axle nuts; check that axle nuts
are secured by cotter pins.
m. Check Steering. Check for free operation for any unusual looseness in any area.

C. Passengers
The vehicle allows for two riders only.
Combine maximum weight of driver And the
passenger should not exceed 180kg or 400lbs.
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.
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.
Figure 4

a. Press down the shift lever to the “F” position so that the unit can move forward, Pull
back the shift to “N” position 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 and #2. Adjust nut #3 can adjust the mesh status inside the reverse
gear box. Make sure the shift lever can be on the three positions (F,N,R) cleanly. Then
tighten the nuts #1, # 2.
Figure 5
E. Shift Adjustment

G .Starting And Operating Instructions
a. Before starting the engine, be sure that the driver is seated properly in the Go-Kart
and tighten the seatbelt.
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 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, 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.
SERVICE INSTRUCTION
A. Service Air Cleaner Service air cleaner every
80 hours.
Service more often under dusty conditions.
a. Remove cleaner cover 1
b. Remove air cleaner element 2 (See Fig.
7)
c. Check the paper filter, if the filter is
dusty, please replace with a new one. Figure 7
Figure 6
F. Parking Adjustment
a. Press down the reverse lever to the “F”
position so that the unit can move forwards;
pull back the lever to “P” so that the unit can
park. (See Fig. 6) Adjust Nut #1; Make sure
cable is not too tight or too loose. Adjust Nut
#2 accordingly to adjustment of Nut
#1 .Figure 6