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Joyner JNSZ800DL Owner's Manual

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Owner's manual
JNSZ800DL

Parts manual

READ THIS MANUAL CAREFULL Y
IT CONTAINS IMPORTANT SAFETY INFORMATION.
MINIMUM
RECOMMENDED
OPERATOR AGE
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
0

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Summary of Contents for Joyner JNSZ800DL

  • Page 1: Parts Manual

    Owner’s manual JNSZ800DL Parts manual READ THIS MANUAL CAREFULL Y IT CONTAINS IMPORTANT SAFETY INFORMATION. MINIMUM RECOMMENDED OPERATOR AGE 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,...
  • Page 2 ALTERNATOR Code name Description 3701010 ALTERNATOR 1000021D ARM-GEN,BELT ADJ 1000019D WASHER 1000102D BRACKET-ALTERNATOR GB5783-1986 BOLT(M8x25) 1000089D BOLT(M8x30) 1000089D BOLT(M8x30) GB97.1-1985 WASHER...
  • Page 3 IGNTION CABLE Code name Description 3706010 DISTRIBUTOR ASSY 3707011 WIRE A-HIGH TENSION,MID 3707012 WIRE A-HIGH TENSION 1000076 CLAMP-HT CORD 1000172 CIRCLE CLAMP-HT CORD...
  • Page 4 CYLINDER HEAD Code name Description 1003010 CYLINDER HEAD 1000031D BOLT（M10×1.25×87） 1000028D KNOCK PIN 1003070 GASKET-CYLINDER HEAD 1003051 COVER -CYLINDER HEAD 1000061D GASKET-BOLT 1000059D BOLT（M6×68） 1003064 GASKET-COVER 1003052 CAP COMP-OIL FILLER GB7828-87 SPARK 1000038 CASE -DISTRIBUTOR 1000035D GASKET-DISTRIBUTOR CASE 1000171 BOLT（M8×45） 1000087D BOLT（M8×60）...
  • Page 5 CARBURETTOR Code name Description 1107010 CARBURETTOR...
  • Page 6 OIL PUMP Code name Description 1011010D PUMP A-OIL 1000051D GASKET-OIL PUMP CASE 1000014D KNOCK PIN 1000083D BOLT(M6×30) 1000084D BOLT(M6×35) 1000085D BOLT(M6×40)
  • Page 7 OIL PAN Code name Description 1009010 PAN-OIL GB5783-1986 BOLT(M6×16） GB93-1987 LOCK WASHER 1010101 STRAINER-OIL PUMP 1002031D O RING GB93-1987 LOCK WASHER GB5783-1986 BOLT(M6×16）...
  • Page 8 INTAKE MANIFOLD Code name Description 1008026(G) MANIFOLD-INTAKE 1000063 GASKET-INTAKE MANIFOLD 1000162 BOLT 1000090D STUD BOLT(M8-M8×22) 1000093D STUD BOLT(M8-M8×25) Q340B08 1000027 HOOK-ENGINE 1107010 CARBURETOR ASSY 1000022 GASKET-CARBURETOR 1008035 STUD BOLT(M8-M8×37) 1008050 PLUG 3808010 GAIGE WATERTEMPERATURE...
  • Page 9 COOLING CODE NAME Description 1008029 CAP-WATER THERMOSTAT 1000073D BOLT 1306010 THERMOSTAT-WATER 1008031 GASKET-CAP 1303013 PIPE-WATER INLET 1000025D GASKET-WATER INLET 1000081D BOLT 1000151 HOSE-RADIATOR WATER EXHAUST 1000165 HOSE-WATER INLET PIPE CLIP 1000044D CLIP 1000043 HOSE...
  • Page 10 CLUTCH Code name Description 1600010 COVER ASSY-CLUTCH 1602010 DISK -CHUTCH GB5783-1986 REAMER BOLT(8×20） GB93-1987 LOCK WASHER...
  • Page 11 GASKET Code name Description GASKET，all 1003070 GASKET-CYLINDER HEAD 1003064 GASKET-COVER 1000063 GASKET-INTAKE MANIFOLD 1000054 GASKET-EXHAUST MANIFOLD 1000035D GASKET-DISTRIBUTOR CASE 1002030D GASKET-HOUSING 1000051D GASKET-OIL PUMP CASE 1000052D GASKET-WATER PUMP 1000036D GASKET-GASOLINE PUMP 1000029D GASKET-COVER...
  • Page 12 OIL PAN Code name Description 1008010 MANIFOLD-EXHAUST 1000054 GASKET-EXHAUST MANIFOLD 1000090D STUD BOLT GB6170-1986...
  • Page 14 STARTER CODE NAME Description 3708010 STARTER...
  • Page 15 GASOLINE PUMP Code name Description 1106010 PUMP-GASOLINE 1000037D GASKET-GASOLINE PUMP 1000036D GASKET-GASOLINE PUMP 1000166 BOLT 1000041 HOSE-FILTER TO PUMP 1000034 HOSE-PUMP TO CARBURETOR 1000075 HOSE-RETAN PIPE TO CARB 1000042 CLIP...
  • Page 17 CRANKSHAFT&FLYWHEEL Code name Description 1002020D HOUSING-OIL SEAL 1000081D BOLT (M6×20） 1000082D BOLT (M6×25） 1000014D KNOCK PIN 1005011 FLYWHEEL 1005014D BOLT (M10×1×16.5） 1000122D KNOCK PIN...
  • Page 18 CYLINDER BLOCK Code name Description 1002010 BLOCK-CYLINDER 1002027D PLATE-CYLINDER BLOCK 1002028D CASKET-PLATE 1000096D BOLT (M6×10) 1012031D STAND-OIL FILTER 1012010D FILTER ASSY-OIL 1000097 PLATE-CLUTCH HOUSING UPPER 1701149D PLATE-CLUTCH HOUSING LOWER 1000096D BOLT (M6×10） 1000026 PLANK-TIMING 1002050 GAUGE-OIL LEVEL 3810010D ANNUNCIATOR-OIL PRESSURE 1000167 STUD(M10-M10×1.25×40) 1008036...
  • Page 19 WATER PUMP AND FAN PART CODE NAME Description 1307010D PUMP ASSY-WATER 1000052D GASKET-WATER PUMP 1000092D STUD BOLT(M6-M6×30) 1000176 1000083D BOLT(M6×30） 1000085D BOLT（M6×40） 1000017D PULLET-WATER PUMP 1000096D BOLT(M6×10） 1000077 BELT-WATER PUMP...
  • Page 21 CAMSHAFT Code name Description 09283-32022 OIL SEAL-CAM SHAFT 1006013 CAMESHAFT 1000129D PLATE-CAMSHAFT THRUST GB819-1985 SCREW(M6×12） 1007045 SHAFT-ROCKER ARM GB819-1985 SCREW(M6×16） 1007026D ROCKER ARM-VALVE 1007035D SPRING-ROCKER ARM 1007033D VALVE-INLET 1007032D VALVE-EXHAUST 1007030D SPRING-VALVE 1007028D COTTER-VALVE 1007029D RETAINER-VALVE SPRING 09289-07005 OIL SEAL-VALVE 1007029D SEAL-VALVE SPRING...
  • Page 23 TIMMING CODE NAME Description 1022015 COVER-INSIDE 1022018D GROMMET,NO1 1022020D GROMMET,NO2 1022013D BUSH(M6×10×7） GB96-1995 WASHER（M6.5×18×1.6) GB5783-1986 BOLT(M6×20) 1000019D WASHER 1022019D CUSHION SEAL 1022012D CUSHION SEAL 1022014D CUSHION SEAL 1000053 BELT-TIMING 1000029D GASKET-COVER 1023011D COVER-OUTSIDE 1000096D BOLT(M6×10） 1023013D GROMMET-OUTSIDE 1021010D TENSIONER-TIMING BELT...
  • Page 50 Should warranty service be required on your JNSZ800DL 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.

  • Page 51: Table Of Contents

    CONTENTS OWNER’S MANUAL Page FOREWORD------------------------------------------------------------------------------------------------------------------------------------ 3 A FEW WORDS ABOUT SAFETY--------------------------------------------------------------------------------------------------------- 4 IMPORTANT SAFETY INFORMATION------------------------------------------------------------------------------------------------- 5 SAFETY LABELS------------------------------------------------------------------------------------------------------------------------------ 7 ARE YOU READY TO DRIVE? ------------------------------------------------------------------------------------------------------------ 8 IS YOUR VEHICLE READY TO DRIVE? --------------------------------------------------------------------------------------------- 10 SAFE DRIVING PRECAUTIONS -------------------------------------------------------------------------------------------------------- 12 SPECIFICATIONS ----------------------------------------------------------------------------------------------------------------------------14 OPERATIONS ------------------------------------------------------------------------------------------------------------------------------------15 SERVICE INSTRUCTIONS ---------------------------------------------------------------------------------------------------------------- 20 REPAIR ----------------------------------------------------------------------------------------------------------------------------------------- 24...

  • Page 52: Foreword

    FOREWORD Thank you for choosing JOYNER ATV. We hope you will have fun with it. Before you start to operate the ATV, 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.

  • Page 53: A Few Words About Safety

    A FORWORDS ABOUT SAFETY In order to keep everyone safe, you must take responsibility for the safe operation of your ATV. 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.

  • Page 54: Important Safety Information

    IMPORTANT SAFETY INFORMATION Your ATV 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 a lot you can do to protect yourself when you drive. You’ll find many helpful recommendations throughout this manual.
  • Page 55 IMPORTANT SAFETY INFORMATION Keep away from moving parts of the ATV The operator of the ATV should never place their hands or other parts of their body near any moving part of the ATV. Failure to adhere to this warning will cause physical harm to your body.

  • Page 56: Safetylabels

    SAFETYLABELS This section presents some of the most important information and recommendations to help you drive your ATV safely, please take a few moments to read these pages. The labels are considered permanent parts of the ATV. If a label comes off or becomes hard to read, contact your dealer for warning labels replacements.

  • Page 57: Are You Ready To Drive

    ARE YOU READY TO DRIVE? Before each drive, you need to make sure you and your ATV 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 ATV, and adjustments to make for your comfort, convenience, or safety.
  • Page 58 ARE YOU READY TO DRIVE? Additional Driving Gear In addition to a helmet and eye protection, we also recommend: Sturdy off-road motorcycle boots to help protect your feet, ankles, and lower legs. ■ Off-road motorcycle gloves to help protect your hands. ■...
  • Page 59 No Alcohol or Drugs Alcohol, drugs and ATVs don’t mix. Even a small amount of alcohol can impair your ability to operate a ATV safely. Likewise, drugs, even if prescribed by a physician, can be dangerous while operating a ATV. Consult your doctor to be sure it is safe to operate a vehicle after taking medication.

  • Page 60: Is Your Vehicle Ready To Drive

    IS YOUR VEHICLE READY TO DRIVE? Before each drive, it is important to inspect your ATV 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 ATV has overturned or has been involved in a collision, do not drive it until your ATV has been inspected by your dealer, There may be damages or other problems you can not see.
  • Page 61 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. Clutch cable Check the free play of clutch cable and adjust if needed. Press the clutch cable to make sure it moves smoothly without sticking, and snaps back automatically when it is released.

  • Page 62: Safe Driving Precautions

    SAFE DRIVING PRECAUTIONS Off-Road Use Only Your ATV 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 ATV on pavement. Operating this ATV on paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.
  • Page 63 SAFE DRIVING PRECAUTIONS Control Speed Driving at excessive speed increases the chance of an accident. In choosing a proper speed, you need to consider the capability of your ATV, the terrain, visibility and other operating conditions, plus your own skills and experience. Operating this ATV at excessive speeds increases your changes of losing control of the ATV, which can result in an accident.

  • Page 64: Specifications

    SPECIFICATIONS DIMENSIONS Overall Length---------------------------------------------------------------------------------------122 in. (3110mm) Overall Width ---------------------------------------------------------------------------------------- 75 in. (1910mm) Overall Height ----------------------------------------------------------------------------------------58 in. (1480mm) Wheelbase --------------------------------------------------------------------------------------------- 105 in. (2670mm) Front Track ------------------------------------------------------------------------------------------- 66.5 in. (1690mm) Rear Track ---------------------------------------------------------------------------------------------65in. (1650mm) Ground Clearance ------------------------------------------------------------------------------------ 12in. (300mm) ENGINE Type ---------------------------------------------------------------------------------3-Bore,4-Stroke, Liquid-cooled Bore x Stroke -------------------------------------------------------------------------------------------- 68mm×72mm Displacement ------------------------------------------------------------------------------------------------------ 780 cc Compression ratio ------------------------------------------------------------------------------------------------8.7:1...

  • Page 65: Operations

    Parts and workmanship -------------------------------------------------------------------------------------- 90 Days OPERATION A. Operation controls WARNING-Do not attempt 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.
  • Page 66 Fig. 1 OPERATION d. Start engine 1. Engage the park brake 2. Press the clutch pedal down, put the shift lever in neutral 3. Insert the key into the ignition-switch Fig. 2 If the engine is cold; 1. Pull the choke out fully 2.
  • Page 67 Each time prior to starti ng the engine, check the thro ttle assembly to ensure that when dal is pushed all the way forward the assembly is working smoothly and returns to idle when released. Do not operate if pedal or engine throttle 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.
  • Page 68 Perform this pre-drive inspection everyday before driving vehicle. If not performed, serious damage to the vehicle or personal injury may result. 1. Check for Engine Oil Level. Check for transmission Oil Level. Check for leaks, add oil if required. 2. Check the coolant. Check for leaks, add the coolant if required. 3.
  • Page 69 Be sure seat adjustment handle snaps back into place and that seat is locked into position. (See Fig. 4 ) Before attempting to adjust the seat ensure that engine of the ATV is stopped. Never operate this ATV 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.

  • Page 70: Starting

    bolt 2 with thread glue. (See Fig. 7) Fig. 7 G. Break-in The first month is most important in the life of your vehicle. Proper operation during this break-in period will help assure maximum life and performance from your new vehicle.

  • Page 71: Service Instructions

    SERVICE INSTRUCTIONS A． Service Air Filter Service air filter every 80 hours NOTE: Service more often under dusty conditions. Fig.8 Remove filter cover(See Fig. 8) b. Check the filter cover and the air filter, if the filter cover and the air filter is dusty, please clear the filter cover and replace with a new air filter.
  • Page 72 Figure 9 Figure 10 SERVICE INSTRUCTIONS Figure 11 Figure 12 a. With the engine warm, put the vehicle on the level ground. b. Shut down the engine, put a collecting oil plate under the engine oil outlet. Loosen the oil outlet plug in the warm engine. Let the engine oil out fully (see Fig. 9). c.
  • Page 73 Check engine oil and recharge a. If the color of engine oil changes, you need to replace the engine oil. Replace the engine oil as above. b. Check the engine oil level, change if necessary from d as above. C. Transmission lubrication You must change the oil in the transmission after the first 5 hours of operating of your new engine and after 10 hours of use thereafter.
  • Page 74 Figure 15 Figure 16 Put the vehicle on level ground. 1. Turn the coolant cap counterclockwise and open the cap (see Fig. 15). 2. Pour fresh coolant to filler neck. 3. Start the engine at idle. 4. Increase the engine rev’s a few times 5.
  • Page 75 Failure to use the correct coolant or coolant not the same as one in the radiator or reserve case can harm your ATV. Engine damage may occur if you use coolant that does not meet the specifications. F. Carburetor Adjustment Never make unnecessary adjustments.

  • Page 76: Repair

    Lubricate vehicle every 90 days of use, Apply several drops of oil in specific points. I. 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.
  • Page 77 Fig. 18 2. Remove two bolts (M12) on the starter (See Fig. 19), Remove the starter (See Fig. Fig. 19 Fig. 20 REPAIR 3. Remove two nuts (M14) on two side of transmission (See Fig. 21, 22)
  • Page 78 Fig. 21 Fig. 22 5. Remove two bolts(M8) on the low mud plate of transmission (See Fig. 23, 24) Fig. 23 Fig. 24 6. Remove the mud plate (See Fig. 25). Fig. 25 REPAIR 7. Remove the transmission (See Fig. 26, 27)
  • Page 79 Fig. 26 Fig. 27 8. Remove upper mud plate (See Fig. 28) Fig. 28 REPAIR 9. Insert a shaft into the hole (See Fig. 29). Remove six bolts on the pressing plate of...
  • Page 80 clutch (See Fig. 30) Fig. 29 Fig. 30 10. Remove the pressure plate (See Fig. 31). Remove the friction disc of clutch (See Fig. 32, 33) Fig. 31 Fig. 32 Fig. 33 REPAIR 10. Insert a special shaft into the hole, fix new friction plate on the flywheel of engine...
  • Page 81 (See Fig. 34, 35). Fig. 34 Fig. 35 11. Fix pressure plate of clutch. Two bolts with “Y.G” mark must be inserted into two anchor hole (See Fig. 36) . Tighten six bolts with torque 30 N.m (See Fig. 37) Fig.

  • Page 82: About Engine

    measure distance A and B between the centerline (CL) of the wheels. The proper toe-in dimension A should be 1.18 inches greater than dimension B. 3. To adjust the alignments, loose the lock nuts on both sides of Front Tie Rods. To make Dimension B smaller, turn the rod to the left.
  • Page 83 a. strictly observe all requirements and specifications in this manual. b. Check the earth polarity of accumulator. this gasoline engine adopts negative earth. c. Grinding in must be conducted when using a new gasoline engine. d. When gasoline engine is running, your head, hand, cloth, tool and other things should be strictly forbidden to approach the running fan and pump belt.

  • Page 84: Spark Plug

    Spark plug and distributor platina contacting point Firing timer Advancer of distributor firing Gasoline oil tube and joint Gasoline filter idle Gearbox lubricant air soft tube and joint cylinder cover Gasoline engine oil Change it once per driving 5000km Air filter Clean it once per running on 10000km asphalt road, 2500km on dust road.
  • Page 85 --------------------10w-40------------------------ --------------------10w-30---------------------- --------------------5w-30------------------------------ --------------5w-20------------------ Fig. 40 2. The oil level of gasoline engine oil pan should be between upper scale and lower scale. it is shown as in fig.41 upper scale lower scale fig. 41 When measure the oil level, the gasoline engine should be in the installing position of the car (the car is in level position), if the color of the lubrication has changed much, it should be changed.
  • Page 86 fig. 42 4. Change the lubrication should be conducted under the hot status of gasoline engine . unscrew the bleeding screw plug on the bottom of oil pan ,after bleeding all original oil and remount the bleeding screw plug according to specified torque, it is shown as fig. 43. bleeding screw plug fig.
  • Page 87 fig.44 6 . Check lubrication pressure of gasoline engine when gasoline engine running at idle, lubricant pressure warming lamp should be lighted off. or otherwise, it indicates the pressure too low, and you should stop engine and check it ,and see whether it is sufficient, and the oil road whether it is leak or jammed.
  • Page 88 Method of adjusting and changing belt of water pump: Unscrew the three fixed bolts of generator, pressing generator outward can tight the belt or inword loose it. It is shown as fig. 46. after adjusting or change, the tightness of belt meets the above mentioned requirement, screw the three fixed bolts of generator tightly.
  • Page 89 Fig .48 f. Checking and adjusting of valve mechanism 1. Check the mounting position of timing belt Remove the front shell of timing belt and rotate crankshaft clockwise in order to align the key slot center (mark1)and round dot “ . ” (mark 4) on the sheave of camshaft with “↑” （mark 5 ） on the rear shell assembly.
  • Page 90 tensioner belt tightly. 3. Checking and adjusting valve clearance The clearance between admission valve and exhaust valve is 0.13-0.18mm under cold status. when measuring the clearance, you should make the work circle of rocker lean against the base circle of cam, shown as in Fig .50. ①...
  • Page 91 Fig .52 2. Check firing advance angle by starting firstly gasoline engine under idle(900± 50r/min) .Use timing lamp to light the flywheel viewing-hole of gearbox by connecting the lamp with the high voltage resistant wire of the first cylinder, shown as in Fig .53.The timing mark on the flywheel 7°should be aligned with the timing finger of the bracket, the tolerance should be ±1°,or otherwise you should adjust it.

  • Page 92: Periodical Check And Service

    See attached list D.Storage of gasoline engine There is a small quantity of lubricant in YH368 gasoline engine when it left factory. It should be stored in clean, dry and ventilated warehouse without any corrosive gas. Storage period should be half a year. If period of storage were longer than half a year, you should fill 2.5L antirust lubricant into gasoline engine and remove spark plug of all cylinder, and make all piston be between upper dead and lower dead point, and fill 0.006L antirust lubricant into every cylinder and start...

  • Page 93: Wiring Diagram

    conditions. Driving in unusually dusty areas, require more frequent servicing. Time of service Initial Monthly Quarterly Yearly service Item Engine 1. Fan, driven belt 2. Tighten bolts on engine. 3. Engine oil 4. Coolant 5. Coolant hose and joints 6. Exhaust 7.

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