0
Owner’s Manual
Parts Manual
READ THIS MANUAL CAREFULLY
IT CONTAINS IMPORTANT SAFETY INFORMATION.
MINIMUM
RECOMMENDED
OPERATOR AGE:
JNSZ250DN
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for off-road use only.
USA only:
It does not confirm to federal motor vehicle safety standards, and operation on
Public streets, roads, or highways is illegal
16
1
JNSZ250DN 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 SZ50DN during the 90 days
warranty period, please contact the nearest authorized dealer for repairs.
What is not covered under this warranty?
This warranty does not cover any seller vehicle that has been 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.
2
CONTENTS
OWNER’S MANUAL ............................................................................................................ 4
FOREWORD.................................................................................................................. 4
A FEW WORDS ABOUT SAFETY ................................................................................. 5
IMPORTANT SAFETY INFORMATION.......................................................................... 6
SAFETY LABELS .......................................................................................................... 8
ARE YOU READY TO DRIVE?.................................................................................... 10
IS YOUR VEHICLE READY TO DRIVE? ..................................................................... 12
SAFE DRIVING PRECAUTIONS................................................................................. 14
SPECIFICATIONS ....................................................................................................... 16
OPERATION ................................................................................................................ 17
SERVICE INSTRUCTION............................................................................................ 23
REPAIR........................................................................................................................ 27
PERIODICAL CHECK AND SERVICES ...................................................................... 28
WIRING DIAGRAM...................................................................................................... 29
PARTS MANUAL................................................................................................................30
1、CRANKCASE ASSY. .............................................................................................. 30
2、SIDE COVER ASSY.L ............................................................................................ 32
3、RIGHT COVER ASSY ............................................................................................ 33
4、CYLINGDER HEAD CASEING ASSY .................................................................... 35
5、CYLINGDER HEAD ASSY ..................................................................................... 37
6、CYLINGER BODY ASSY........................................................................................ 39
7、TIMING CHAIN....................................................................................................... 40
8、MAGNETOR ASSY ................................................................................................ 41
9、ADMISSION MACHANISM .................................................................................... 42
10、CRANK LINK LEVER & PISTON.......................................................................... 43
11、SPEED CHANGER............................................................................................... 44
12、CLUTCH ASSY .................................................................................................... 45
13、GEARBOX COVER ASSY.................................................................................... 46
14、TRANSMISSION GEAR ASSY............................................................................. 47
14、TRANSMISSION GEAR ASSY............................................................................. 48
15、GEAR SHIFT MACHANISM ................................................................................. 49
16、ENGINE OIL PUMP ASSY ................................................................................... 50
17、COOLANT PUMP ASSY ...................................................................................... 51
18、ELECTRIC STARTER ASSY ................................................................................ 52
19、CARBURETOR ASSY.......................................................................................... 53
20、FRAME & FUEL TANK&REDIATOR..................................................................... 54
21、FRONT SUSPENSION......................................................................................... 56
22、 STEERING&THROTTLE&BRAKE&SHIFT......................................................... 58
23、ENGINE RACK&TRANSMISSION ....................................................................... 61
24、ENGINE ASSEMBLY............................................................................................ 63
25、EXHAUST&SHIFT................................................................................................ 65
26、REAR SUSPENSION........................................................................................... 67
27、ELECTRICAL ASSEMBLY.................................................................................... 69
27、ELECTRICAL ASSEMBLY.................................................................................... 70
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28、SEAT AND MUD GUARD..................................................................................... 71
PREP ARATION A TTACH INSTRUCTION.......................................................................... 73
ATTACH BATTERY...................................................................................................... 73
ATTACH PROTECTIVE BARS .................................................................................... 75
ATTACH REAR SHOCK .............................................................................................. 76
ATTACH TRAILING ARM............................................................................................. 77
ATTACH FRONT SHOCK ............................................................................................ 78
ATTACH FRONT TIRE................................................................................................. 79
ATTACH SEAT AND SAFT BELT ................................................................................. 80
ATTACH THE RADIATOR............................................................................................ 81
ATTACH SILENCER .................................................................................................... 82
4
OWNER’S MANUAL
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.
We hope you will have a pleasant experience with our products
and thanks again for choosing US.
5
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.
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---It means Important Safety Reminders or Important Safety
Precautions.
Safety Section --- It means 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 some 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.
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.
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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
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.
9
△ WARNING
Never shift or engage the reverse lever when the Go-kart is in motion.
Only engage the shift lever when the Go-kart is at a full stop.
Give a slight throttle and release throttle, then engage shift.
Only shift from neutral.
The shift lever must be in neutral and parking lever pulled when leaving the Go-kart.
△ WARNING
Do not shift when pushing throttle.
Gear damage can occur.
Gears are not warranted from shifting in
motion or over running while shifting.
10
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.
Operating this Go-Kart without wearing an approved motorcycle helmet, eye protection,
and protective clothing could increase your chances of head and/or eye injury, possibly
death in the event of severe accident.
Always wear approved motorcycle helmet that fits properly and wear eye protection
(goggles or face shield), gloves, boots, long-sleeved shirt or jacket and long pants.
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.
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■ 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. To build skills, Practice driving the Go-Kart in a safe area, do not drive in
rough terrain until you get accustomed to the Go-Kart’s controls, and feel
comfortable with its size and weight.
Operating Go-Kart without proper instruction could increase your risk of an accident,
which could lead to serious injury or death.
Attempt supporting with your hands to the ground when the Go-cart turning over could lead
to serious injury or death.
Never support with your hands to ground 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, 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.
Operating this Go-Kart after alcohol or drugs can seriously affect your judgment, cause
you to react more slowly, affect your balance and perception, and could result in serious
injury or death.
Never consume alcohol or drugs before or while operating this Go-Kart.
12
IS YOUR VEHICLE READY TO DRIVE?
Before each drive, it is important to inspect your Go-Kart and make sure any
problems are away. A pre-drive inspection is necessary, not only for safety, but
also for comfort. 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.
Improperly maintaining this Go-Kart or failing to correct a problem before driving can
cause a crash in which you can be seriously hurt even die.
Always perform a pre-drive inspection before every drive and correct each problem.
Pre-drive Inspection
Check the following items before you get on the Go-Kart:
■ Engine Oil
Check the oil level and add oil if needed. Check for leaks.
■ Fuel
Check the fuel level and add fuel if needed. Also make sure the fuel fill cap
is securely fastened. Check 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 taillight are working properly.
13
■ 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 brake pedal several times, check for proper brake pedal free play.
Make sure there is no brake fluid leakage.
■ Steering Wheel
Check that the wheels turn properly as you turn the steering wheel.
■ Cable
Check the 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.
14
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.
Operating this Go-Kart on paved surfaces may seriously affect handling and control of
the Go-Kart, and may cause the vehicle to go out of control.
Never operate the Go-Kart on any paved surfaces, including sidewalks, driveways,
parking lots and streets.
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.
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 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.
Removing hand from Steering wheel or feet from foot controls during operation can
reduce your ability to control the Go-Kart or could cause you to lose your balance and fall
off the Go-Kart.
Always keep both hand on the steering wheel and both feet on the foot controls of your
Go-Kart during operation.
Control Speed
Driving at excessive speed increases the chance of an accident. In choosing
15
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.
Operating this Go-Kart at excessive speeds increases your changes of losing control of
the Go-Kart, which can result in an accident.
Always drive at a speed that is proper for your Go-Kart, the terrain, visibility and other
operating conditions, and your 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).
Failure to use extra care when Operating this Go-Kart on unfamiliar terrain could result in
the Go-Kart overturning or going out of control.
Go slowly and 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 loose
terrain could cause loss of traction or vehicle control, which could result in an accident,
including an overturn.
Do not operate on excessively rough, slippery or loose terrain until you have learned
and practiced the skills necessary to control the Go-Kart on such terrain. Always be
especially cautious on these kinds of 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.
Attempting wheelies, and other stunts increases the chance of an accident, including
an overturn.
Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
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SPECIFICATIONS
DIMENSIONS
Overall Length---------------------------------------------------------------------------------------98 in. (2490mm)
Overall Width ---------------------------------------------------------------------------------------- 60 in. (1520mm)
Overall Height --------------------------------------------------------------------------------------- 62 in. (1570mm)
Wheelbase -------------------------------------------------------------------------------------------- 77.5 in. (1970mm)
Front Track ------------------------------------------------------------------------------------------ 51in. (1300mm)
Rear Track -------------------------------------------------------------------------------------------50.8in. (1290mm)
Ground Clearance ----------------------------------------------------------------------------------- 11.8 in. (300mm)
ENGINE
Type ------------------------------------------------------------------------------------------ Liquid-cooled. 4-Stroke
Bore x Stroke -------------------------------------------------------------------------------------------- 72mm×60mm
Displacement ------------------------------------------------------------------------------------------------------ 244 cc
Corrected compression ratio ------------------------------------------------------------------------------------ 10:1
Carburetor -----------------------------------------------------------------------
KEI HIN: No. VE 14CEQKY
Output Power ---------------------------------------------------------------------------------------14.7hp/7000rpm
Maximum Torque ------------------------------------------------------------------------------- 17.6 Nm /5500r/min
Starting ----------------------------------------------------------------------------------------------------------- Electric
Ignition -------------------------------------------------------------------------------------------------------------- C.D.I
Lubrication -------------------------------------------------------------------------------------------- Force & Splash
Transmission ---------------------------------------------------------------------------- Automatic (C.V.T system)
Spark Plug ------------------------------------------------------------------------------------------ DPR7EA-9 (NGK)
Plug gap ------------------------------------------------------------------------------------------------------ 0.6-0.7mm
Fuel type --------------------------------------------------------------------------------------------- RQ90 (unleaded)
Lubricate oil ---------------------------------------------------------------------------------------------- SAE-10W/30
CAPACITIES
Maximum load --------------------------------------------------------------------------------------------------- 400Ibs
Fuel tank ------------------------------------------------------------------------------------------------------------ 16.0L
Engine oil ----------------------------------------------------------------------------------------------------------1000ml
Gear oil -------------------------------------------------------------------------------------------------------------1000ml
Coolant -------------------------------------------------------------------------------------------------------------1800ml
Starting ---------------------------------------------------------------------------------------------------------------- <5s
Climbing ---------------------------------------------------------------------------------------------------------- 20°-25°
Battery ---------------------------------------------------------------------------------------------------------- 12V 9Ah
Head Light ---------------------------------------------------------------------------------------------------- 12V 15W
Tail Light ---------------------------------------------------------------------------------------------- 12V 5W/10W/21W
Fuse ------------------------------------------------------------------------------------------------------------------- 10A
Brake Track --------------------------------------------------------------------------------------- < 7m @ 20miles/h
Top speed ---------------------------------------------------------- 40 miles/h (or limited as customers require)
CHASSIS
Front, Rear brake ----------------------------------------------------------------- Hydraulic disc, right foot control
Front tire --------------------------------------------------------------------------------------------------------- 21×8-10
Rear tire --------------------------------------------------------------------------------------------------------- 22×10-10
Front Suspension --------------------------------------------------------------------------- Independent Dual A-Arm
Rear Suspension ------------------------------------------------------ Trailing Arm/Double Oil& Damped Shock
Restraint System ------------------------------------------------------------------------------- Dual 4-point Harness
Final Drive Chain -------------------------------------------------------------------------------------------------- 10Ax62
TIRE PRESSURE
Front ----------------------------------------------------------------------------------------- 42kpa 0.5kg/c ㎡ 2.2psi
Rear ----------------------------------------------------------------------------------------- 56kpa 0.20kg/c ㎡ 2.9psi
WEIGHT
Net Weight -----------------------------------------------------------------------------------------------330kg/ 737lbs
WARRANTY
Parts and workmanship ------------------------------------------------------------------------------------- 90 Days
17
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. Allow the throttle to return to the idle position at any time,
and the clutch disengages. (See Fig. 1)
Each time prior to starting the engine, check the throttle assembly to ensure that when
pedal is pushed all the way forward the assembly is working smoothly and returns to idle
when released. Do not operate if pedal or engine throttles linkage fail to return to idle. If
unable to correct the problem through lubrication, adjustment or 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 at the 4 wheels
and slows or stops the kart.
c. Start engine
Insert the key into key-switch,
turn the key clockwise, and
release the key when the engine
starts. The engine will warm up
for 5 minutes and the engine
choke will close automatically
and run at normal RPM (Warning:
Don’t crank starter more than 5
seconds at one time). (See
Figure 2)
BRAKE PEDAL THROTTLE PEDAL
HORN BUTTON
ODOMETER
SPEED OMETER
WATER TEMPERATURE INDICATOR
IGNITION START SWITCH
VOLTAGE METER
Figure 1
Figure 2
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d. Run you kart
Press the shift lever forwards to “L” position,
the cart will move forwards at low speed, “H”
position, high speed; “N” position, no speed;
and “R” position the cart will move backwards.
(Note: if the shift can’t engage, give a slight
throttle, then try it again)
If the shift engages press down the throttle
pedal slowly, the cart will accelerate.
(See Figure 2)
e. Operate lights
See figure 4, press down the button, the
corresponding light will run. And if move the
shift lever to “L” position, the “L” light will shine,
“H” position, the “H” light, “N” position, the “N”
light, and “R” position, the “R” light,
B.
Pre-Drive Inspection
Perform this pre-drive inspection everyday before driving vehicle. If not performed,
serious damage to the vehicle or personal injury may result.
a. Check for Engine Oil Level. Check 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, and 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 42kpa and 56kpa.
e. Check Drive Chain. Check for drive chain’s condition and tension. Lubricate if
HIGHT BEAM HEADLIGHT
DIPPED BEAM HEADLIGHT
FOG LAMP
SHIFTER SHOW
TURNNING LIGHT
SHIFTER SHOW
Figure 4
Figure 3
19
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 tightened properly. 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.
Always follow rules for safe operation and wear a helmet.
20
STEERING WHEEL
RADIATOR
SAFETY BELT
m. Component locations
FUEL TANK
MUFFLER
BATTERY
WATER TANK
21
A
DJUSTING NUT #2
C. Passengers
The vehicle allows for two riders
only. Combine maximum weight of
driver and the passenger should not
exceed 180kg (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.
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.
Before attempting to adjust the seat ensure that engine 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” position so that the unit can move
forward at high speed, Pull back the shift
to “N” position so that the unit can’t move,
pull back the lever to “R” so that the unit
can move backward. (See Fig. 6)
b. Loosen lock nut, and remove the cotter
pin and the plain washer. Rotate the
joint, the shifter lever will rotate
clockwise or counter clockwise, so you
can adjust the lever in proper position
LOCK NUT
Figure 6
Seat adjustment handle
JOINT
Figure 5
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Never engage the shift lever when the Go-kart is in motion
Only engage the shift lever when the Go-kart is at a full stop
Give a slight throttle and loosen throttle, then engage shift from neutral to shift.
The shift lever must be on neutral and pull parking lever when leave the Go-kart
F. Parking Adjustment
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. 7)
Adjust Nut #1; Make sure cable is not
too tight or too loose. Adjust Nut #2
accordingly to adjustment of Nut #1.
(See Figure 7)
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 seat belt.
b. Testing the Go-Kart in an open place
at the beginning to learn how to start,
turn and stop.
c. Operate the Go-Kart slowly until you are familiar with it.
d. The turning radius of 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.
H. Foot brake adjustment
a. Loosen the thin nut M8
b. Rotate the pushing bar to make space proper.
c. Tighten thin nut M8.
d. With the same way to adjust another pair.
ADJUSTING NUT
ADJUSTING NUT
Figure 7
THIN NUT M8
PUSHING BAR
Figure 8
23
SERVICE INSTRUCTION
A． Air cleaner clean.
Every 80 hours, service air
cleaner one time under dusty
conditions. Service more often.
a. Remove cleaner cover 1.
b. Remove air cleaner filter core
(See Fig. 9)
c. Check the filter paper, if the
filter paper is dusty, please
clean with pressure gas or
replace with a new one
B. Engine Lubrication
You must change the oil in the crankcase after the first 5 hours of operating of
your new engine and after 10 hours of use thereafter. That will insure proper
lubrication of internal parts and prevent costly repairs due to excessive wear.
a. Remove fill plug located on bottom
of engine (See Fig. 10). Tip kart
backwards slightly by blocking 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.
C. Engine Coolant
You should check the coolant for lack. If
lack, you should refill coolant
(approximately 1800 ml) into the radiator
or reserve coolant. The lack of coolant
will cause engine overheat. This can
cause engine damage.
D. Spark Plug
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.
Figure 9
Figure 10
Figure 11
Cover 1
Filter core
fill plug
24
a. Remove the spark plug and inspect it
(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”. (See Fig. 11)
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.
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 (5~10min)
b. Tighten the airscrew gentle. Back out 2-3/8 turns counter clockwise.
c. Connect the tachometer; adjust the throttle to limit the idle speed. The
standard value is (1500RPM).
d. Turn the airscrew slowly and observe 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 d and e until the rotate speed of engine stables.
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 off foreign object
and be sure to check that air intake fan is free off 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
Check the chain adjustment after first two hours of use. Readjust if it has more
than 1/2” flex. (See figure 13)
a. Loosen NUT #1, and NUT #2.
b. Rotate BOLT #1, the BEARING BLOCK will move forwards or backwards, so
Figure 12
25
the chain will become loose and tight. Repeat this procedure until chain is at
proper tension.
c. Tighten all of the nuts.
J. Adjustment of Front and Rear Shock
There are five adjustable positions on each Front shock. The default position is
in the first set by manufacture (See Fig.14)
Use a round nut wrench as you adjust the front shock, the tension of shock
spring will increase as you screw to left, decrease as you screw to the right.
There is screw on the rear shock; use shock wrench as you adjust the rear
shock, the tension of shock spring will increase as you screw to right, decrease
as you screw to left. (See Fig.15)
K. Storage Instruction
In the event your kart is not to be 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
Figure 13
Figure 15
LEFT ROTATE RIGHT ROTATE
SPRING ADJUSTMENT CAM
Figure 14
RIGHT ROTATE
RIGHT ROTATE
NUT #1
NUT #2
BOLT #1
26
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.
Do not drain fuel while engine is hot. Be sure to move Go-Kart outside before draining fuel.
27
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 endplay. (See Fig. 16) Tighten the nuts after replacing the
wheels.
Figure 16
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 endplay. (See Fig. 17) Tighten the nuts and put on the
cotter Pin after replacing the wheels.
Figure 17
C. Front Wheel Alignment
a. The front wheels should be “toe-in” from 1/8” to 1/4”. To check for alignment,
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.
Figure 17
Figure 16
28
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.
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: replace
Time of
service
Items
29
WIRING DIAGRAM
G
Thermometer
swich
（88
o
C）
Alternator
Reverse
sensor
Start motor
12V 600W
Battery
12V
9Ah
Speed
sensor
Flasher
12V 45W
Brakes light
switch
Horn
Horn button
Turning signal,
before R
12V 10W
Turning signal,
before L
12V 10W
Headlight
12V 35/35W
Turning signal,
Rear L
12V 10W
Tail lamp/ the brake
light 12V 5/21W
water
temp-
erature
sensor
Rectifier,
regulator
Fuse box
G
3
~
M
Ignition switch
OFF
Start
123
Ignition coil
t
v
C
t
C
n'
v
High beam
switch
ON
blue
Dipped beam
switch
green
Turn signal
switch
R
L
yellowred
Reverse
indication
Charge
indication
OFF
H
t
C
BP
ON
Radiator
fan
12V 10A
Turning signal,
Rear R
12V 10W
Thermometer
swich
（102
o
C）
5
A
5
A
1
0
A
1
5
A
5
A
RL R L
12V
ON
Start relay
ON
LNR
N-gear
sensor
L-gear
sensor
H-gear
sensor
v
Spot light
3x (12V 21W)
1
0
A
5
A
Spot light
switch
Speed
meter
Rev
meter
water
temp-
erature
meter
Voltage
meter
30
PARTS MANUAL
1、CRANKCASE ASSY.
No. P/N ENGLISH Q’ty
1
172MM-C-011100 CRANK CASE ASSY.L
1
2
172MM-C-011200 CRANK CASE ASSY.R
1
3
172MM-011001 SEAL 28X40X8
1
4
172MM-011002 SEAL RING.INNER OIL PIPE.
2
5
172MM-011004 STUD A.CYLINGDER
3
6
152MI-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 6304
1
18
172MM-060002 BALL BEARING 22X50X14
1
31
1、CRANKCASE ASSY.
No. P/N ENGLISH Q’ty
19
GB/T 9877-1988 FB33X35X5 OIL SEAL FB 33X35X5
1
20
GB/T 276-1994 6201 BEARING 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 SPACER 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
32
2、SIDE COVER ASSY.L
No. P/N ENGLISH Q’ty
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
33
3、RIGHT COVER ASSY
No. P/N ENGLISH Q’ty
1
172MM-013013 AIR PIPE.CYLINDER HEAD COVER
1
2
172MM-013100 BREATH PIPE.RIGHT SIDE COVER
1
3
172MM-013015 BREATH PIPE.AIR FILTER
1
4
172MM-013016 CLAMP.BREATH PIPE
1
5
172MM-013002 SIDE COVER.R
1
6
172MM-013008 PRESS PLATE.CABLE
1
7
172MM-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-021014 WASHER 12
1
20
152MI-08008 LOCATING PIN Φ8x14
2
21
QC/T621-1999-A10 CLAMP 12
2
34
3、RIGHT COVER ASSY
No. P/N ENGLISH 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
35
4、CYLINGDER HEAD CASEING ASSY
No. P/N ENGLISH Q’ty
1
172MM-021009 CLAMP.OIL PIPE
1
2
172MM-021001 COVER.CYLINDER HEAD
1
3
172MM-021006 STOP PLATE
1
4
152MI-021011 SEAL WASHER.
1
5
172MM-021100 AXIS.SWING ARM.INLET
1
6
172MM-021200 AXIS.SWING ARM.OUTLET
1
7
172MM-021400 OIL PIPE ENGINE.OUTER
1
8
152MI-021001 RUBBER RING.OIL PIPE
1
9
172MM-021431 MOUNT.OIL PIPE
1
10
152MI-021003 SHOCK ABSORBER RUBBER STRIP
1
11
152MI-021004 REAMED BOLT A M8X25
1
12
152MI-021015 REAMED BOLT M12X1.25
1
13
152MI-021013 REAMED BOLT M8X25
1
14
152MI-021008 REAMED BOLT A M8X28
1
15
152MI-021016 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 CRUCIFORM SLOT SCREW
1
21
GB/T848-85-6-D·Cr SMALL WASHER
2
22
152MI-021005 LOCATION PIN Φ10X14
2
23
BOLT M6X12 BOLT M6X12
3
24
BOLT M6X25 BOLT M6X25
1
25
152MI-013010 BOLT M6X50
3
36
4、CYLINGDER HEAD CASEING ASSY
No. P/N ENGLISH Q’ty
26
152MI-021018 BOLT M6X55
1
27
172MM-021404 SHOCK ABSORBER SLEEVE
1
28
172MM-021002 BREATH PIPE FAUCET
1
29
172MM-021300 MOUNT.AIR FILTER
1
30
172MM-021008 BLOCKING
1
37
5、CYLINGDER HEAD ASSY
No. P/N ENGLISH Q’ty
1
172MM-022100 CYLINDER HEAD
1
2
172MM-022700 FLANGE.EXHAUST
1
3
152MI-022014 BEARING COVE.CAM AXIS
1
4
172MM-022008 NUT.EXHAUST
2
5
172MM-022010 SEAL WASNER.CYLINDER HEAD
1
6
172MM-022900 CARBURETOR SEAT UNIT
1
7
172MM-022500 CLAMP UNIT.AIR INLET PIPE
1
8
152MI-022810 THERMOSTAT
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
152MI-022804 "O" RING 14.8X1.9
1
21
172MM-022009 "O" RING 31X2
1
22
152MI-022020 BOLT M6X22
2
23
152MI-021005 LOCATION PIN Φ10X14
2
38
5、CYLINGDER HEAD ASSY
No. 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
39
6、CYLINGER BODY ASSY
No. P/N ENGLISH Q’ty
1
172MM-023100 CYLINDER
1
2
172MM-023002 SEAL WASHER.CYLINDER
1
3
152MI-023300 TENSIONER UNIT
1
4
152MI-023307 BOLT.SPRING SEAT
1
5
152MI-023306 SPRING.TENSIONER
1
6
152MI-023004 SEAL WASHER.TENSIONER
1
7
172MM-023007 RUBBER PIPE.WATER INLET
1
8
172MM-023009 JACKET.WATER PIPE
1
9
QC/T621-1999-B24 STEEL BAND CLAMP
2
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
40
7、TIMING CHAIN
No. P/N ENGLISH Q’ty
1
172MM-022200 CHAIN UNIT
1
2
172MM-023200 TENSION PLATE
1
3
172MM-023001 CHAIN GUIDE PLATE
1
4
GB96-85-6-D·Zn BIG WASHER
1
5
GB/T5781-2000-M6X12-D·Zn BOLT
1
41
8、MAGNETOR ASSY
No. P/N ENGLISH Q’ty
1
172MM-094000 FREE-WHEELING CLUTCH
1
2
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
42
9、ADMISSION MACHANISM
No. P/N ENGLISH Q’ty
1
152MI-022500 SEAL.VALVE ROD
2
2
172MM-022300 CAM UNIT
1
3
152MI-021007 SWING ARM
2
4
172MM-022001 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
43
10、CRANK LINK LEVER & PISTON
No. P/N ENGLISH Q’ty
1
172MM-A-041000 CRANK LINK UNIT
1
172MM-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
44
11、SPEED CHANGER.
No. P/N ENGLISH Q’ty
1
172MM-021007 NUT M14X1.5
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
45
12、CLUTCH ASSY
No. P/N ENGLISH Q’ty
1
172MM-052008 BOLT M12X1.25
1
2
172MM-A-052500 OUTTER WHEEL DISC
1
3
172MM-052005 THIN NUT M30X1
1
4
172MM-A-052400 DRIVE PAN UNIT
1
5
172MM-A-052200 DAMPING RUBBER BLOCK
3
6
172MM-A-052600 CLUTCH BLOCK
3
7
172MM-A-052006 RELEASE SPRING
3
8
172MM-A-052003 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 GREASE 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 CLUTCH SPING
1
20
172MM-A-052009 SLEEVE
1
21
172MM-A-052002 GUIDE PIN
4
22
172MM-B-053000 COG BELT
1
46
13、GEARBOX COVER ASSY
No. P/N ENGLISH Q’ty
1
172MM-C-060001 COVER.GEARBOX
1
2
172MM-C-060002 PAPER WASHER.GEARBOX
1
3
172MM-013005 BOLT M12X1.5.OIL OUTLET
1
4
152MI-021014 WASHER12
1
5
172MM-B-069000 SHIFT DISPLAY SWITCH
1
6
GB/T 276-1994 6202-RS BALL BEARING
1
7
GB/T 276-1994 6201 BALL BEARING
1
8
GB/T 276-1994 6203 BALL BEARING
1
9
GB/T 276-1994 6305-RS BALL BEARING
1
10
172MM-B-011107 BOLT M8X48
3
11
172 MM-B -011111 B OLT 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 BOLT
3
21
152MI-080012 BOLT M6X32
3
22
CF188-065002 OIL SEAL SD 15X25X5
1
23
172MM-B-011113 OIL STOP CHIP
1
24
GB/T 819-2000 SCREW M4X12
2
47
14、TRANSMISSION GEAR ASSY
No. P/N ENGLISH Q’ty
1
172MM-B-067000 TRANSITION GEARS ASSY
1
2
GB/T89431-1986 20 RTAINER RING
2
3
172MM-B-067000 TRANSITION GEAR
1
4
172MM-B-067001 TRANSITON GEAR-AXIS
1
5
172MM-B-060001 MAIN AXIS
1
6
172MM-B-062000 SECONDARY AXIS ASSY
1
7
172MM-B-062006 WASHER.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 DRIVEN GEAR.OUTPUT
1
17
172MM-B-062004 DRIVEN GEAR.LOW SPEED
1
18
172MM-C-063000 OUTPUT AXIS ASSY
1
19
172MM-C-063002 WASHER 20X32X2.5
1
20
172MM-C-063005 DRIVEN GEAR.OUTPUT
1
48
14、TRANSMISSION GEAR ASSY
No. 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
49
15、GEAR SHIFT MACHANISM
No. P/N ENGLISH Q’ty
1
172MM-B-066000 SHIFT DRUM ASSY
1
2
172MM-B-066002 SHIFT YOKE
2
3
172MM-B-066003 PIN.SHIFT YOKE
2
4
172MM-B-066004 SNAP RING.PIN.SHIFT YOKE
2
5
172MM-B-066001 SHIFT DRUM
1
6
172MM-B-066005 TOUCH CHIP.SPEED DISPLAY
1
7
CF188-065201 WASHER.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 AXIS
1
18
172MM-B-066009 PRESS SPRING.SHIFT
1
19
172MM-B-066008 PRESS BUSHING.SHIFT
1
50
16、ENGINE OIL PUMP ASSY
No. P/N ENGLISH Q’ty
1
151MI-071000 OIL PUMP ASSY
1
2
151MI-071002 OIL PUMP BODY
1
3
151MI-071003 OIL PUMP COVER
1
4
151MI-071001 OIL PUMP AXIS
1
5
151MI-071001 CHAIN PULLEY.OIL PUMP
1
6
151MI-073000 CHAIN OIL PUMP
1
7
151MI-071004 ROTOR.OIL PUMP.INNER
1
8
151MI-071005 ROTOR.OIL PUMP.OUTTER
1
9
151MI-070002 SPACER PLATE A.OIL PUMP
1
10
151MI-072000 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
51
17、COOLANT PUMP ASSY
No. P/N ENGLISH Q’ty
1
172MM-080004 IMPELLER.WATER PUMP
1
2
152MI-081000 WATER SEAL ASSY
1
3
172MM-080003 WATER PUMP COVER
1
4
172MM-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 GREASE SEAL 10X20X5
1
13
152MI-080008 LOCATION PIN Φ8X14
2
14
15
16
17
18
19
20
21
22
52
18、ELECTRIC STARTER ASSY
No. P/N ENGLISH 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
53
19、CARBURETOR ASSY
No. P/N ENGLISH Q’ty
1
172MM-100000
CARBURETOR ASSY
1
54
20、FRAME & FUEL TANK&REDIATOR
45
20 FRAME&FUEL TANK&REDIATOR
1
43
2
3
4
5
6
7 8
9
10
13
14
11
12
15
16
17
18
19
21
20
33
22
23
24
25
26
27
28
29
3031
32
34
35
36
37
38
39
41
40
42
44
55
20 FRAME&FUEL TANK&REDIATOR
RUBBER WASHERJD1135001 1
32
1PROTECTIVE BAR.LDN250.01.02.00.0433
1INLET PIPE.ACT
DN250.05.02.00.0434
1CAP.FUEL TANKJD113500035
1
FUEL TANK
D250.11.804
36
4FLANGE BOLT M8X20GB5787-86 M8X2037
4FLANGE NUT M8GB6177.1-2000 M838
1
39
1FUEL PIPE 1DI250.05.02.00.0240
1GAS FILTERDS250.11.01.00.0941
1
FUEL PIPE 2D250.11.060
42
1SAFTY COVER.SHIFTDN250.01.02.07.0043
44
45
46
47
48
49
JD1138000
FUEL SWITCH
FLANGE BOLT M6X15
SEAL CUSHIONG.WATER TANK
D800.04.02.02.02
1
1
DN250.01.01.00.00 MAIN FRAM
1
Q'TY
DESCRIPTIONPART NO.NO.
1COVER.FRDN250.01.02.00.062
1SPORT WING.L
DN250.01.02.00.043
1SPORT WING.LOWERDN250.01.02.00.034
1SPORT WING.RDN250.01.02.00.05
5
1SPORT WING.UPPER
DN250.01.02.00.026
6FLANGE BOLT M12X1.25X55GB5787-86 M12X1.25X557
6
NYLON BUSHING
D250.11.7718
6FLANGE NUT M12GB6177.1-2000 M129
1PROTECTIVE BAR.RDN250.01.02.08.0010
1FLANGE BOLT M10X1.25X20GB5787-86 M10X1.25X2011
2FLANGE NUT M10GB6177.1-2000 M1012
2FLANGE BOLT M10X1.25X65GB5787-86 M10X1.25X65
13
12ARC CUSHION Φ32DN250.01.02.00.0114
2REINFORCED BARDN250.01.02.03.0015
2FLANGE BOLT M8X20GB5787-86 M8X20
16
1WATER TANK.GK800D800.04.02.02.0017
1WATER TANK CAP.GK800D800.04.02.02.0118
2
FLANGE LOCK NUT M8GB6187.1-2000 M819
1PROTECTIVE BAR1.TOPDN250.01.02.02.0020
1PROTECTIVE BAR2.TOP
DN250.01.02.05.00
21
1SAFTY COVER.REDIATORDI250.05.01.00.0122
2FLANGE BOLT M8X30GB5787-86 M8X3023
1SUPPORT.REDIATOR
DN250.01.02.06.00
24
2RUBBER BUSHING.REDIATORJD191000325
1REDIATOR CAP
D250.09.904
26
1REDIATORDI250.05.01.01.0027
1
ACT(ACTIVATED CARBON TANK)
DS150.05.02.03.0028
1BLOCK SHEET.ACT
D650.04.06.00.0229
1SUPPORT.ACTD650.04.06.00.0130
3
FLANGE LOCK NUT M6GB6187.1-2000 M6
31
3GB5787-86 M6X15
56
21、FRONT SUSPENSION
47
48
49
50
21 FRONT SUSPENSION
1
2
4
6
5
7
8
9
10
11
13
14
12
15
18
17
19
20
16
21
22
23
24
44
4546
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
41
42
43
3
40
57
1
DN250.02.03.00.00
LOWER A-ARM.R 1
Q'TY
DESCRIPTIONPART NO.NO.
1KNUCKLE.R
DN250.02.06.00.00
2
1BRAKE CLIPPER 1DN250.04.01.00.013
1
UPPER A-ARM.RDN250.02.01.00.004
2FLANGE BOLT M14X1.5X90GB5787-86 M14X1.5X90
5
1
UPPER A-ARM.LDN250.02.04.00.006
4JOINT BEARING GE20CGE20C7
4RETAINOR RING.HOLE 35GB893.1-86 358
8SPACER.GE20CDN250.02.00.00.059
12FLANGE NUT M14x1.5GB6177.1-2000 M14x1.5
10
8
FLANGE BOLT M14X1.5X60GB5787-86 M14X1.5X6011
8
ROD END BEARING 14POSA 1412
16SPACER.ROD END BEARING 14DN250.02.00.00.0413
8THIN NUT M14GB6172-86 M14
14
1
UPPER A-ARM.LDN250.02.02.00.0015
6
FLANGE NUT M12X1.5GB6177.1-2000 M12X1.5
16
8
SPACER.SHOCK ABSORBOR
DN250.09.00.00.07
17
2FLANGE BOLT M12X1.5X170GB5787-86 M12X1.5X17018
2
SHOCK ABSORBOR.FRDN250.02.07.00.0019
8
FLANGE BOLT M14X1.5X60GB5787-86 M12X1.5X60
20
2FLANGE BOLT M14X1.5X80GB5787-86 M14X1.5X8021
1KNUCKLE.L
DN250.02.05.00.00
22
4FLANGE BOLT M8X15GB5787-86 M8X15
23
1BRAKE CLIPPER 2DN250.04.01.00.0224
2
BUSHING 33.8.FRONT WHEELDN250.02.00.00.0325
2GREASE SEAL FB47X28X7GB9877.1
—88 FB47X28X7
26
2BALL BEARING 6204GB/T276-1994 620427
2BUSHING 22.FRONT WHEEL
JD036000728
229
8KNURLED BOLT.FRONT WHEELDS250.02.00.00.0230
2COTTER PIN
JD0360200
－EU31
2GB/T276-1994 6203
32
2GREAS SEAL FB40X25X6GB9877.1
—88 FB40X25X6
33
2SMALL SPACER 8JD036000634
2
PLAIN WASHER 16GB/T95-1985 1635
2SPRING WASHER 16GB/T93-1987 16
36
2SLOTTED NUT M16GB6178-86 M16
37
2 COTTER PIN 4x40GB/T91-2000 4X40
38
239
2
RIM 10X5.5JD076080040
8
SPRING WASHER 10GB/T93-1987 1041
8
PLAIN WASHER 10GB/T95-1985 1042
8
CAPPED NUT M10X1.25GB/T923-1988 10x1.25
43
44
45
46
47
48
49
JD0760000 TYRE 21X8-10
BALL BEARING 6203
8FLANGE BOLT M12X1.5X80GB5787-86 M12X1.5X80
8
8SPACERΦ12
.TIE RODD800.05.01.00.03
ROD END BEARING 12POSA 12
21 FRONT SUSPENSION
2FRACTION PLATE 1
DN250.04.01.00.03
2FRACTION PLATE 2
DN250.04.01.00.04
1SPRING PLATE 2.BRAKE CLIPPER
DN250.04.01.00.05
50
1SPRING PLATE 1.BRAKE CLIPPER
DN250.04.01.00.06
WASHER.REAR WHEEL AXLE
D250.06.011
58
22、 STEERING&THROTTLE&BRAKE&SHIFT
53
54
55
56
57
58
59
60
66
67
68
69
22 STEERING&THROTTLE&BRAKE&SHIFT
1
2
3
4
5
6
7
8
10
9
11
12
13
14
15
17
16
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
44
45
46
47
49
43
42
41
40
39
38
37
36
50
51
52
48
61
62
63
63
64
59
1
1
No.
PART NO. DESCRIPTION
Q'TY
ROD END BEARING POSA12LPOSA12L
GB6172-86 M12L
THIN NUT M12L
2
DN250.03.02.00.00
TIE ROD
3
GB5785-86 M12×80 BOLT M12X80
4
D800.05.01.00.04
REINFORCED SHEET.TIE ROD
5
D800.05.01.00.03
SPACER.TIE ROD
6
D800.05.01.03.07
DUST GUARD PLATE
7
D800.05.01.03.06
SUPPORT.TIE ROD
8
D800.05.01.03.08
GREASE CUP M8X1
9
D800.05.01.03.01
CASE.STEERING BOX
10
D800.05.01.03.04
RACK.STEERING
11
D800.05.01.03.10
BUSH BEARING14c7x18x12
12
D800.05.01.03.03 COVER PLATE.STEERING BOX
13
D800.05.01.03.02 GEAR SHIFT.STEERING14
D800.05.01.03.09 BALL BEARING 20x42x12
15
GB5787-86 M10X30 FLANGE BOLT M10x30
16
D800.05.01.03.05 STOP PLATE.BEARING17
GB5787-86 M6X25 FLANGE BOLT M6x25
18
GB5785-86 M18X30 BOLT M8X30
19
20
DN250.03.04.00.01
SHAFT.SLIP UNIVERSAL JOINT
DN250.03.04.00.03
SPRING WASHER
DN250.03.04.00.02
SLEEVE.SLIP UNIVERSAL JOINT
GB893.1-86 26 CIRCLIP FOR HOLE 26
DN250.03.03.00.01 SLEEVE.STEERING COLUMN
GB/T276-1994 61902 BALL BEARING 61902
GB893.1-86 28 CIRCLIP FOR HOLE 28
SHAFT.STEERING COLUMN
GB6187.1-2000 M8 FLANGE LOCK NUT M8
GB819-85 M6×25 CROSS SUNK SCREW M6x25
DI250.03.01.00.02 RUBBER COVE
DI250.03.01.00.01 PLASTIC COVER
GB/T2673
—1986 M4x5 INNER-HEXAGON SUNK SCREW M4x5
GB818-85 M4×5 CROSS PANHEAD SCREW M4x5
GB/T93-1987 4 SPRING WASHER 4
DN250.04.01.01.00 MAIN PISTON.BRAKE
GB6187.1-2000 M8 FLANGE LOCK NUT M8
DN250.04.01.00.05
PUSH POLE.BRAKE
GB6172-86 M8
THIN NUT M8
41
GB5787-86 M8X30 FLANGE BOLT M8x3042
D250.10.005
"T" BLOCK
43
GB91-86 3x30 COTTER PIN 3x30
44
GB/T95-1985 10 PLAIN WASHER 10
45
DN250.04.00.00.02
PIN.FOOT BRAKE BOARD
46
2
2
2
2
1
8
1
1
1
1
1
1
1
1
1
2
1
4
2
2
1
1
1
1
1
1
1
1
6
1
6
1
1
2
2
2
1
2
2
2
2
1
3
3
1
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
GB/T93-1987 8 SPRING WASHER 8
BALL BEARING 61803GB/T276-1994 61803
DN250.03.03.00.02
DI250.03.01.00.00
STEERING WHEEL
22 STEERING&THROTTLE&BRAKE&SHIFT
60
47
No.
PART NO. DESCRIPTION
Q'TY
BUFFER BUSHING.LINK RODD250.04.002
GB5787-86 M6x30 FLANGE BOLT M6x30
48
DN250.04.02.00.00
FOOT BRAKE BOARD
49
DN250.05.02.00.01
PIN.FOOT BOARD.THROTTLE
50
DN250.05.02.00.01
FOOT BOARD.THROTTLE
51
DN250.05.02.02.00
CABLE.THROTTLE
52
JD10.82.101
RUBBER BUSHING.SHIFT
53
DI250.05.03.03.00
SHIFT LEVER
54
D250.08.004
SPRING.SHIFT
55
D250.08.005
STOP RING
56
D250.08.009
COVER.SHIFT LEVER
57
GB/T95-1985 8 PLAIN WASHER 8
58
GB91-86 3x30 COTTER PIN 3x30
59
DN250.05.03.04.00 CABLE.SHIFT
60
GB5787-86 M10X1.25X30 FLANGE BOLT M10x1.25x30
61
GB6177.1-2000 M10x1.25 FLANGE NUT M10x1.25
62
GB6187.1-2000 M6 FLANGE LOCK NUT M6
63
GB/T2672
—1986 M6×20 INNER-HEXAGON PANHEAD SCREW M6x25
64
65
66
87
88
89
90
91
92
4
2
2
2
1
1
1
1
1
1
1
1
1
1
2
2
1
9
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
GB/T95-1985 6 PLAIN WASHER 6 2
GB/T93-1987 6 SPRING WASHER 6 2
GB5787-86 M6X10 FLANGE BOLT M6X10 2
GE12C JOINT BEARING GE12C 1
22 STEERING&THROTTLE&BRAKE&SHIFT
DN250.04.00.00.01 FOOT BRAKE SPRING.DN250 2
61
23、ENGINE RACK&TRANSMISSION
23 ENGINE RACK&TRANSMISSION
1
2
3
4
6
7
8
9
10
11
12
13
15
16
17
18
5
20
21
14
22
23
24
25
26
27
28
30
31
29
32
33
19
62
1
No.
PART NO. DESCRIPTION
Q'TY
CV AXLE.ASSYDN250.07.01.00.00
DI250.07.01.00.01
BRIDLE.BOOT2
DI250.07.01.00.04
OUTER BOOT
3
DI250.07.01.00.03 BRIDLE.BOOT4
DI250.07.01.00.02
INNER BOOT
5
DI250.07.00.00.01 STEEL THREAD CIRCLIP6
GB894.1-86 26 CIRCLIP FOR AXIS 267
GB77-85 M5×6 HOLDING SCREW M5x6
8
DN250.07.00.00.03 SLEEVE.SPROCKET SHAFT
9
GB9877.1
—88 FB 38X62X8 GEASE SEAL FB 38x62x8
10
GB893.1-86 62 CIRCLIP FOT HOLE 62
11
GB/T281-1994 1206 BALL BEARING 120612
GB5787-86 M12X1.5X45 FLANGE BOLT M12x1.5x45
13
DI250.07.00.00.06
BEARING SEAT
（CAST STEEL）
14
GB9877.1
—88 FB 35x55x8 GEASE SEAL FB 35x55x8
15
GB6177.1-2000 M10 FLANGE NUT M12x1.5
16
GB5787-86 M8x30 FLANGE BOLT M8x3017
DI250.07.00.00.02
CHAIN PULLEY(35 TOOTH)
18
DN250.07.02.00.00
MID AXIS
19
20
GB6177.1-2000 M10x1.25
ENGINE BUMPERDS250.08.00.00.03
FLANGE BOLT M12x1.5x115GB5787-86 M12X1.5X115
BOLT M10x90DS250.03.00.00.02
THIN NUT M10
DN250.08.02.00.00
FLANGE BOLT M12x1.5x100GB5787-86 M12X1.5X105
FLANGE BOLT M12x1.5x25GB5787-86 M10X1.25X25
FLANGE BOLT M12x1.5x115
ENGINE STAY.REARDN250.08.01.00.00
ENGINE ASSY
DI250.08.00.00.01
41
42
43
44
45
46
2
4
2
4
2
2
2
2
2
2
2
2
4
2
2
2
6
1
1
6
6
4
2
2
1
1
2
1
1
1
1
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
GB6187.1-2000 M8 FLANGE LOCK NUT M8
ENGINE RACK
GB6172-86 M10
GB5787-1986 M12x1.5x115
DI250.07.04.00.00
SPACER.ENGINE STAY
1
FLANGE NUT M10x1.25
10A CHAIN(62)
DN250.07.03.00.00
1
23 ENGINE RACK&TRANSMISSION
63
24、ENGINE ASSEMBL Y
1
2
3
4
5
6
7
8
12
13
14
15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31 32
33
34
35
36
37
38
40
41
42
39
10
11
24
9
43
24 ENGINE ASSEMBLY
CONNECT TO CCA
64
SUPPORT EAR1.AIR FILTER
GB818-85 M6x20
AIR FILTER SHELLDS250.11.01.00.23-1
SUPPORT EAR2.AIR FILTERDI250.05.03.00.02
FLANGE BOLT M8X20
AIR FILTER COREDS250.11.01.00.23-2
COVER.AIR FILTER BOX
DS250.11.01.00.23-5
1
1
1
1
1
1
1
1
CROSS PANHEAD SCREW M6X20
DN250.05.03.00.01
GB5787-1986 M8x20
DS250.11.01.00.23-3
FILTER SPONGE.AIR&OIL SEPARATOR
COVER.AIR&OIL SEPARATOR
GB818-85 M5×30
1
7
DS250.11.01.00.23-4
CROSS PANHEAD SCREW M5X30
DN250.11.01.06.00 1CVT AIR FILTER.INLET
24 ENGINE ASSEMBLY
1
No. PART NO. DESCRIPTION
Q'TY
RADIATOR
DI250.05.01.01.01
DI250.05.01.01.02
VALVE.REDIATOR
2
DN250.05.01.00.04
SUCTION PIPE
3
GB5787-86 M8x20 FLANGE BOLT M8X204
D800.04.02.02.00
WATER TANK.GK800
5
D800.04.02.02.02
SEAL CUSHION
6
D800.04.02.02.01 CAP.WATER TANK7
GB6187.1-2000 M8 FLANGE LOCK NUT M8
8
DN250.05.01.00.05
OVERFLOWING PIPE
9
DN250.05.01.00.01 WATER PIPE.OUTLET.ENGINE
10
DN250.05.01.00.02
WATER PIPE.INLET.ENGINE
11
GB5787-86 M6x20 FLANGE BOLT M6X2012
D650.04.06.00.01 SUPPORT.ACC
13
D650.04.06.00.02
ACC STOP
14
GB6187.1-2000 M6 FLANGE LOCK NUT M6
15
D650.04.06.01.00 ACC
16
DN250.05.02.00.04
INLET PIPE.ACC
17
JD1135000
CAP.FUEL TANK
18
GB5787-86 M8x25 FLANGE BOLT M8X25
19
20
JD1138000
GAS PIPE1DN250.05.02.00.02
GAS FILTERDS250.11.01.00.09
GAS PIPE2
DN250.05.02.00.03
CVT AIR FILTER.OUTLET
GB818-85 M5×30
WRAP HOOP .CVT
DN250.11.01.13.00
ENGINE ASSY
DI250.07.04.00.00
OUTLET PIPE.ACC
AIR BOXDS250.11.01.00.20
WRAP HOOP.AIR FILTER
GB818-85 M5×30
41
42
43
44
45
46
1
1
1
2
1
1
1
6
1
1
1
3
1
1
3
1
1
1
4
1
1
1
1
1
2
2
2
1
1
2
2
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
D250.11.804 FUEL TANK
CROSS PANHEAD SCREW M5X30
DN250.11.01.07.00
DN250.05.02.00.06
DN250.05.03.01.00
CROSS PANHEAD SCREW M5X30
1
FUEL SWITCH
65
25、EXHAUST&SHIFT
1
2
3
4
5
6
7
8
9
10
11
12
14
21
20
22
23
24
25
26
27
28
29
30
31
32
33
36
37
35
34
38
39
40
45
46
44
41
42
43
19
13
16
17
25 EXHAUST&SHIFT&PARKING BRAKE
66
20 FLANGE BOLT M6X10 1
21
GB5787-86 M6X10
HEAT SHIELD 4
S650.04.04.03.01
JD10.82.101 RUBBER BUSHING.SHIFT22
DI250.05.03.03.00 SHIFT LEVER
23
D250.08.004
SPRING.SHIFT
24
D250.08.005 STOP RING25
D250.08.009
COVER.SHIFT LEVER
26
GB/T95-1985 8 PLAIN WASHER 827
GB91-86 3x30 COTTER PIN 3x30
28
DN250.05.03.04.00
SHIFT CABLE
29
1
1
1
1
1
1
1
1
25 EXHAUST&SHIFT
GB/T95-1985 6 PLAIN WASHER 6 2
GB/T93-1987 6 SPRING WASHER 6 2
GB5787-86 M6X10 FLANGE BOLT M6X10 2
GE12C JOINT BEARING GE12C 1
30
31
32
33
34 B PIN 8x24 1
GB882-86 8x24
GB91-86 3x3035
D650.07.02.01.00
PARKING MACHANISM
36
D650.07.02.00.04 STEEL BUSHING.PARKING37
D650.07.02.00.01 JOINT.PARKING BRAKE
38
GB91-86 3x30 COTTER PIN 3x3039
D650.07.02.02.00 CABLE.PARKING BRAKE
40
DI250.04.03.00.03
GUARD SPRING41
DN250.04.03.00.02 OIL TUBE.PARKING BRAKE42
1
1
1
1
1
1
1
1
DI250.04.03.00.01
OIL CUP.PARKING BRAKE 1
1
DN250.04.03.01.00 MAIN PISTON.PARKING BRAKE 1
DN250.04.03.00.00 1
43
44
45
46
SLOTTED PIN 3X30
DN250.04.01.00.02 BRAKE CALIPER 2
PARKING BRAKE ASSY
Q'TY
DESCRIPTIONPART NO.
No.
ENGINE ASSEMBLY 11 DI250.07.04.00.00
DI250.05.03.05.002
GEAR SHIFT ARM
1
FIXED MOUNT OF SHIFT CABLE 3.1 13 DI250.05.03.00.05A
FIXED MOUNT OF SHIFT CABLE 1.1 14
DI250.05.03.00.03A
HEXAGON-HEADED FLANGE BOLT M6X10 25
SHIFT CABLE 1
6
DN250.05.03.04.00
PLAIN WASHER 8
17
COTTER PIN 2X25 18
HEXAGON-HEADED FLANGE BOLT M8X20 1
9
ASBESTOS GASKET OF MUFFLER 110 JD1110008
MUFFLER ELBOW PIPE 111 DN250.05.02.00.01
INTAKE CLAMP OF MUFFLER
112 DI250.05.02.00.02
13 FLANGE BOLT M8X25 2
14 SHORTER MUFFLER 250 1
15
DN250.05.02.00.02
HEXAGON-HEADED FLANGE BOLT M8X30 2
16
MOUNT OF MUFFLER 1
17
DN250.05.02.00.03
RUBBER BUSHING OF MUFFLER
2
18
JD1910002A
TAIL SIDE BOARD.R 1
19
DN250.01.02.00.05
SELF-LOCKING HEXAGON-HEADED FLANGE NUT M8
4
GB/T5787-1986 M6x10
GB/T5787-1986 M8x20
GB/T5787-1986 M8x30
GB5787-86 M8X25
GB/T6177.1-2000 M8
GB/T91 2x25
GB/T95-1985 8
67
26、REAR SUSPENSION
38
39
40
41
1
2
5
4
3
9
8
7
6
10
11
12
14
13
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
37
36
35
34
33
26 REAR SUSPENSION
68
32
33
2
2
4
2
4
34
35
36
2
37
8KNURLED BOLTDI250.02.00.00.02
HUB.BRAKE DISCDI250.09.00.00.05
TIRE AT22X10-10.REARJD0780000
RIM.REAR
D250.00.037
CAPPED NUT M10X1.25GB/T923-1988 M10x1.25
JD0360010JD0360010
HUB COVER.FRONT WHEEL
CV AXLE.ASSYDN250.07.01.00.00
DI250.07.01.00.01
BIG BRIDLE.BOOT
DI250.07.01.00.04
OUTER BOOT
DI250.07.01.00.03 SMALL BRIDLE.BOOT
DI250.07.01.00.02 INNER BOOT
WASHER.REAR WHEEL AXLE
D250.06.011
SLOTTED NUT.HALF AXLEDI250.07.04.00.01
DI250.09.00.00.01
DI250.09.00.00.06
26 REAR SUSPENSIONG
2
38
FRACTION PLATE 1
DN250.04.01.00.03
2
39
FRACTION PLATE 2
DN250.04.01.00.04
1
40
41
SPRING PLATE 2.BRAKE CLIPPERDN250.04.01.00.06
SPRING PLATE 1.BRAKE CLIPPERDN250.04.01.00.05
2
1
No.
PART NO. DESCRIPTION
Q'TY
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
GB/T95-1985 8 PLAIN WASHER 8 4
2BRAKE DISC.REARDI250.04.01.00.04A
GREASE SEAL FB 32X47X8GB9877.1
—88 FB32X47X8
8
8
GB/T95-1985 10 PLAIN WASHER 10
4
GB/T93-1987 8 SPRING WASHER 8
4
DN250.09.02.00.00
TRAILING ARM.R 1
GB5787-86 M8X15 FLANGE BOLT M8X15 4
GB6177.1-2000 M10X1.25 FLANGE NUT M10X1.25
4
D650.02.01.00.02 STEEL BUSHING.TRAILING ARM 4
D650.02.01.00.01 RUBBER BUSHING.TRAILING ARM
8
GB5787-86 M10X1.25X70 FLANGE BOLT M10X1.25X70 4
GB5787-86 M12X1.5X45 FLANGE BOLT M12X1.5X45 4
DN250.09.00.00.07 SPACER.SHOCK ABSORBER
8
DN250.09.03.00.00
SHOCK ABSORBER 2
GB6177.1-2000 M10 FLANGE NUT M12X1.5
4
DN250.04.01.00.01 BRAKE CALIPER 1 1
GB/T2673
—1986 M8×20 INNER HEXAGON SUNK SCREW M8X20 4
SPACER1.REAR WHEEL 2
SPACER 2.REAR WHEEL
2
2
2
GB/T95-1985 10 SPRING WAHSER 10
8
2
2
GB91-86 4X30 COTTER PIN 4X30 2
29
30
31
DN250.04.01.00.02 BRAKE CALIPER 2 2
BALL BEARING 6005GB/T276-1994 6005 4
TRAILING ARM.L
DN250.09.01.00.00
1
2
69
27、ELECTRICAL ASSEMBLY
21
23
22
24
27 ELECTRICAL ASSEMBLY
1
2
3
4
5
6
7
10
11
12
13
14
15
16
17
18
19
20
9
8
70
27、ELECTRICAL ASSEMBLY
1
1
2
1
23
BATTERY BOXDN250.01.01.02.02
22
STOP BAND.BATTERYDN250.10.00.00.01
21
BOLT M6X110GB5785-86 M16×110
DN250.10.01.00.00 RUBBER COVE.BATTERY
24
27 ELECTRICAL ASSEMBLY
DI250.10.04.00.00
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
2
3
19
PANEL SWITCH.DN250
DN250.10.06.00.00
18
VOLTAGE METER.D1600
D1600.06.05.00.00
17
WATER TEMPERATURE INDICATOR.N650
N650.06.02.07.00
16
15
MUSHROOM BUTTONDS250.10.00.00.05
14
13
12
11
10
TAIL LIGHT ASSEMBLY
D800.06.00.00.12
9
BATTERY
D250.07.802
8
HORND250.07.913
7
6
5
4
3
FLASH APPARATUS
2 TURNING SINGLE.FRD250.07.901
D650.00.12.00
SPOT LIGHT
Q'TY
DESCRIPTIONPART NO.
No.
1
D250..07.909 IGNITION SWITCH
DN250.10.03.00.00
TACHO METER.250
DN250.10.01.01.00 BALE OF WIRE
DN250.10.02.00.00 SPEED METER.250
D250.07.915
VOLTAGE REGULATOR
STARTER RELAY
D250.07.912
CDID250.07.917
IGNITION COILDI250.10.05.00.00
2
FLASH APPARATUS
DI250.10.04.00.00
20
1
FUSE BOX
DN250.10.01.02.00
71
28、SEAT AND MUD GUARD
2
4
5
6
10
7
8
14
11
12
13
15
16
3
9
1
28 SEAT AND MUD GUARD
72
SEAT COMP.LDS250.08.01.00.02
DI250.11.01.00.07 SEAT ADJUSTER.R
D250.11.005A
SAFTY BELT
GB6177.1-2000 M10X1.25
1
1
1
4
4
1
4
12
12
12
1
1
2
8
1
1
16
15
SUPPORT.MUD GUARD.FR.L
DN250.11.01.00.04
14
13
12 FLANGE NUT M8GB6177.1-2000 M8
11
10
MUD GUARD
D250.11.005A
9
FLANGE NUT.LOCK M6GB6177.1-2000 M6
8
RUBBER WASHER 6
D250.11.058
7
6
5
4
3
FLANGE NUT M10X1.25
2
DS250.08.01.00.03 SEAT COMP.R
28 SEAT AND MUD GUARD
Q'TY
DESCRIPTIONPART NO.
No.
1
DI250.11.01.00.06 SEAT ADJUSTER.L
444.6.20
SCREW.PHILIPS HEAD M6X20
DN250.11.01.00.06
SUPPORT.MUD GUARD.REAR.R
DN250.11.01.00.05
SUPPORT.MUD GUARD.REAR.L
GB5787-1986 M8X20 FLANGE BOLT M8X20
DN250.11.01.00.03 SUPPORT.MUD GUARD.FR.R
73
PREP ARATION ATTACH INSTRUCTION
ATTACH BATTERY
STEP 1:FILL 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
a) Cut the inlet of plastic bottle
b) Fill the battery with electrolyte to upper lever by inserting every inlet of
the battery
STEP 2:Put the battery into the box on go-kart.
STEP 3:Connect the wire to battery; red to “+”, black to “-”.
STEP 4:Fix the RUBBER COVE, STOP BAND and tighten both bolts and
nuts.
74
Notice:
Before use new battery, it needs 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.
75
ATTACH PROTECTIVE BARS
1、 2、
3、 4、
1
2
3
4
76
ATTACH REAR SHOCK
a) Remove the bolt and the nut
b) Attach the rear shock as below picture:
SPACER
SPACER
77
ATTACH TRAILING ARM
1、
2、
78
ATTACH FRONT SHOCK
1. 2.
3.
1 2
3
3
79
ATTACH FRONT TIRE
The hub to fix the front tire is packed as below:
1- Remove four nuts, four spring washers, and four plain washers on the hub.
2- Fix the rim on the hub.
3- Insert the washers, spring washers through bolt on the hub. Tighten four nuts.
Notice:
Direction marked on the tire must
correspond to the vehicle forward
80
ATTACH SEAT AND SAFT BELT
FIX SAFTY BELT
81
ATTACH THE RADIATOR
1- Attach the radiator as below pictures.
2- Connect wire from fan motor to main wire.
3- Arrange the main and reserve coolant rubber tube as below picture.
82
ATTACH SILENCER
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