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Joyner JNSZ1100SV Owner's Manual

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Owner's Manual
JNSZ1100SV
READ THIS MANUAL CAREFULLY
IT CONTAINS IMPORTANT SAFETY
INFORMATION.
16
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 JNSZ1100SV

  • Page 1 Owner’s Manual JNSZ1100SV READ THIS MANUAL CAREFULLY 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...

  • Page 2: Table Of Contents

    CONTENTS Warranty policy ........................ 2 OWNER‘S MANUAL ...................... 13 1. FOREWORD ....................... 13 2. A FEW WORDS ABOUT SAFETY ............... 14 3. IMPORTANT SAFETY INFORMATION ............... 14 4. SAFETY LABELS ....................15 5. ARE YOU READY TO DRIVE? ................16 6.

  • Page 3: Warranty Policy

    Warranty policy...

  • Page 14: Owner's Manual

    OWNER’S MANUAL 1. FOREWORD Thank you for choosing our off high way recreational vehicle. We hope you will have fun with it. Before you drive the off high way recreational vehicle, please read through this Owner‘s Manual carefully as it contains important safety and maintenance information.

  • Page 15: A Few Words About Safety

    2. A FEW WORDS ABOUT SAFETY In order to keep everyone safe, you must take responsibility for the safe operation of your Off high way recreational vehicle. 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 16: Safety Labels

    become familiar with how this off high way recreational vehicle works and handles. Practice in a safe area until you build your skills and get accustomed to this off high way recreational vehicle‘s size and weight. Because many accidents involve inexperienced or untrained drives, we urge all drivers to take a training course approved by the Off high way recreational vehicle Safety Institute.

  • Page 17: Are You Ready To Drive

    5. ARE YOU READY TO DRIVE? Before each drive, you need to make sure you and your Off high way recreational vehicle 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 Off high way recreational vehicle, and adjustments to make for your comfort, convenience, or safety.
  • Page 18  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. ...

  • Page 19: Is Your Vehicle Ready To Drive

    Operating Off high way recreational vehicle 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 Vehicle turning over could lead to serious injury or death. Never support with your hands to ground when the vehicle will turn over.
  • Page 20 mproperly maintaining this Off high way recreational vehicle 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.

  • Page 21: Safe Driving Precautions

    7.SAFE DRIVING PRECAUTIONS Off-Road Use Only You Off high way recreational vehicle 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 off high way recreational vehicle on pavement. Operating this Off high way recreational vehicle on paved surfaces may seriously affect handling and control of the Off high way recreational vehicle, and may cause the vehicle to go out of control.
  • Page 22 vehicle, the terrain, visibility and other operating conditions, plus your own skills and experience. Operating this Off high way recreational vehicle at excessive speeds increases your changes of losing control of the Off high way recreational vehicle, which can result in an accident. Always drive at a speed that is proper for your Off high way recreational vehicle, the terrain, visibility and other operating conditions, and your experience.

  • Page 23: Specifications

    8. SPECIFICATIONS DIMENSIONS Overall Length------------------------------------------------------------------------------------------------------------123 in. (3130mm) Overall Width ------------------------------------------------------------------------------------------------------------- 75 in. (1910mm) Overall Height ----------------------------------------------------------------------------------------------------------- 69 in. (1745mm) Wheelbase ---------------------------------------------------------------------------------------------------------------- 89 in. (2270mm) Front Track --------------------------------------------------------------------------------------------------------------- 66.5 in. (1690mm) Rear Track -------------------------------------------------------------------------------------------------------------------65 in. (1650mm) Ground Clearance -------------------------------------------------------------------------------------------------------- 12.5 in. (320mm) ENGINE Type ------------------------------------------------------------------------------------------------------- 4-Bore, 4-Stroke, Liquid-cooled Bore x Stroke --------------------------------------------------------------------------------------------------------------- 72mm×66.5mm...

  • Page 24: Operation Instruction

    9. OPERATION INSTRUCTION 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. Operator must know how to stop this machine before starting and driving it. Control pedal 1) Accelerator Pedal: Changes engine rpm and vehicle ground speed.
  • Page 25 figure 2) • Set park brakes: pull-up on the park brake lever until the lever is tight. • Release park brakes: Pull-up on the park brake lever, depress the release button and push the lever 5) Shift Selector: Changes trans-axle gears from neutral to forward or reverse. Always start engine in neutral.
  • Page 26 C/215 F. and the Stop engine immediately. Check coolant lever and add if low, see authorized JOYNER dealer if temperature indicator stay on and overflow tank is full of coolant. (See figure 8) 15) Voltmeter: Indicates battery is charging. Check battery if voltmeter registers a charge that is lowers than normal.
  • Page 27 Speedomete Voltmeter Tachometer Fuel level gauge Oil pressure gauge Coolant temperature indicator FIGURE 8 Coolant temperature light Reverse gear light Battery charge light Oil pressure light FIGURE 9 Passengers The vehicle allows for two riders only. Make sure you brief your passenger on proper safety procedures like keeping hands, arms, feet and other body appendages inside the vehicle.

  • Page 28: Maintenance

    Chassis Maintenance 1. Tire Maintenance Use only tires recommended by Joyner. It is important for your safety and the safety of others that the tires have correct air pressure. Check air pressure in four tires before each use. Visually inspect tires for loss of air throughout each day of operation. See Tire inflation Chart below for correct tire pressure.
  • Page 29 Thin nut Thin nut FIGURE 12 3. Parking Adjustment Pull the park brake lever up so that the unit can engage park brake, To release the unit, press button on front end of parking lever then push the parking lever to the bottom. Adjust the parking cable if necessary.
  • Page 30 After a long time of use, it is necessary to adjust the spring as following: (See figure 15) 5.1. Loosen the lock nut with a shock absorber wrench (by Joyner); 5.2. Screw the stop-nut clockwise, and the tension of shock spring will increase;...
  • Page 31 FIGURE 17 8. Clutch replacement Remove two bolts, and demount Starter-assembly carefully. (See Fig. 18-21) Q1840845 GB/T70.1-2000-M12*1.75*75*25 FIGURE 18 FIGURE 19 S11-3708111 S11-3708110G FIGURE 21 FIGURE 20...
  • Page 32 2. Remove four bolts on the transmission case, lay down these carefully. Caution: When fix the four bolts in the transmission case; you must tighten them according to the prescribed torque 45-55N.M. (See Fig. 22-25) Q1841240 Q218B1245 GB/T70.1-2000-M12*1.75*75*25 FIGURE 23 FIGURE 22 FIGURE 24 FIGURE 25...
  • Page 33 4. Insert a spine-shaft into the hole of the Clutch assy , remove the six bolts on the Clutch pressure plate, now It‘s clear. Caution: When fix the six bolts in the Clutch pressure plate; you must tighten them according to the prescribed torque 28 N.M. (See Fig. 28-32) FIGURE 28 FIGURE 29 Spline-shaft...
  • Page 34 5. Insert a spline-shaft into the hole of the Clutch assy , fix the six bolts on the Clutch pressure plate , tighten them according to the prescribed torque 28 N.M . (See Fig. 33-34) FIGURE 33 FIGURE 34 6. Fix parts according to reverse operation to the disassembly. 9.
  • Page 36 12. 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: 12.1. Drain fuel tank by allowing engine to run out of fuel, or use a fuel stabilizer. 12.2.
  • Page 37 13. ENGINE WIRING DIAGRAM...
  • Page 38 14. MAIN WIRING DIAGRAM...
  • Page 39 Engine maintenance 1. Service Air Filter Service air filter refer to preventative log. NOTE: Service more often under dusty conditions. Filter Cover Rubber bushing FIGURE 36 Remove filter cover (See Fig. 36) Check the filter cover and the air filter, if the filter cover and the air filter are dusty, please clear the filter cover and replace with a new air filter.
  • Page 40 2.1.1. With the engine warm, put the vehicle on the level ground. 2.1.2. 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). 2.1.3.
  • Page 41 4. Engine Coolant Add Coolant You must check the coolant for level and leaks. If it is low, you need to refill coolant into the radiator (approximately 6000 ml). The lack of coolant will cause the engine to overheat. This can cause engine damage. (See Fig. 41) The coolant should always be topped up, since the coolant can evaporate.
  • Page 42 New and used coolant can be hazardous. Children and pets may be harmed by new or used coolant. Continuous or brief contact with coolant may be dangerous for your health. Keep new and used coolant away from the children and pets. To minimize your exposure to new and used coolant, wear a long sleeve shirt and moisture-proof gloves (such as dishwashing gloves) when you change coolant.
  • Page 43 7. Timing Belt 1. Configuration diagram 1 Water pump pulley 2 Timing belt cover. upper 3 Timing belt cover. Lower 4 Torsion shock absorber 5 Timing pulley damper 6 Tensioner 7 Crankshaft timing pulley .8 Timing belt...
  • Page 44 2. Disassembly 2.1. According the right picture, remove water pump pulley Torque: 25±1.5 N.m 2.2. Removing timing belt cover Torque: 6±1N.m 2.3. Remove tensional vibration damper 2.3.1. Fix the flywheel and prevent the gear ring from rotating, 2.3.2. Remove bolt of tensional vibration damper.
  • Page 45 2.5. Remove the tensioner 2.5.1. Carry out the operation at the upper thrust point of compression of the first cylinder piston 2.5.2. After removing the timing cover cap, turn the bolt and rotate the timing gear clockwise with wrench, align timing mark of camshaft timing gear with the cam mark of camshaft cover cap;...
  • Page 46 2.8. Make careful and detailed checks on the timing belt. Replace with new parts if any of the conditions shown in the figure occurs. 2.8.1. Cracks on the backside rubber; 2.8.2. Cracks of teeth roots, cracks clearing off the fabric lining layer; 2.8.3.
  • Page 47 ＥＦ Model ＧＬ、ＺＬ、ＧＳ、ＺＳ Item Diameter of camshaft φ110.7 +0.1 -0.2 timing gear （mm） Diameter crankshaft φ54.65 +0.7 -0.13 timing gear（mm） Baffle of crankshaft timing gear Check to see if there is any deformation Standard size of crankshaft timing gear： Wide 28.6mm 3.
  • Page 48 towards the engine rotating direction, so that the camshaft pulley and the crankshaft pulley match the clockwise marks respectively. 3.3.3. Use hands to press down for about 5mm. The force for pressing the clockwise belt is about: ［Reference］ 20～30 N Notice: When the deflection of the timing belt fails to meet the specifications, the key is to adjust the above-mentioned stretcher fastening bolt by...
  • Page 49 3.5.2. When there is a flying wheel, 3.5.2.1. Fix the flywheel to prevent the tooth ring from turning 3.5.2.2. Then tighten bolt of tensional vibration damper. 3.6. Install timing belt cover Install seal strip in the position shown as right figure. Install the position 1 and position 2 before cylinder head assembly;...
  • Page 50 8. Camshaft 1. Configuration diagram ※:Non-reusable part Unit: N*m (kg*cm) (1) Valve cage cover (2) Valve cage cover gasket (3) Camshaft timing pulley (4) Camshaft cover (5) Circular plug (6) Camshaft bearing cap (7) Exhaust camshaft,(8) Intake camshaft,(9) Oil seal(10) Spring retainer(11) Wave washer(12) Intake camshaft sub-gear(13) Snap ring(14) Lock nut(15) Flange...
  • Page 51 2. Removal 2.1. 1) Cover-valve chamber 2) Disassembly order of Cover-valve chamber 2.2. Dismount the timing belt sprocket with a special tool. Attention: Manufacture a special tool according the right figure The special is necessary to prevent the camshaft to rotate Timing mark 2.3.
  • Page 52 Screw 2.3.2. Use bolt to position the master and slave gears on the air inlet camshaft, as shown in the right figure. Attention In order to eliminate the radial force, keep the camshaft in the leveled position before dismounting it (to avoid possible damages caused by excessive radial forces) 2.4.
  • Page 53 2.7. Camshaft 2.7.1. Use the caliper to measure the height of the camshaft. If it is below the specified limits, make roper replacement. Camshaft Unit：mm Model ZL、 GL、GS、 Item φ23.0-0.02 -0.033 Standard φ23.0-0.02 -0.033 φ22.9 Limit φ22.9 2.7.2. Checks on camshaft axial clearance (1)、When the axial spacing is measured with a clipper to be larger than the benchmark value, the camshaft is to be...
  • Page 54 gear with the mark on the master gear; then fix the slave gear with bolt.(Thread: M5; pitch: 0.8) 3.2. When no using a special tool Fixer Screw bolt m6 as the right figure, and then insert a screwdriver between the bolt m6 and camshaft, and rotate driven-gear right to match the mark on both of gears, or Bolt...
  • Page 55 3.6. Installation of camshaft head cap Smear the fluid sealant on the camshaft Sealing line head cap section (With oil groove) shown as the right figure. 3.6.1. Tighten the bolts according to the sequences shown as the right figure with the specified torques. 3.6.2.
  • Page 56 Attention: process special tool according the right figure. 3.9. Installation of cylinder head gasket 3.9.1. Clean the the used cylinder head gasket 3.9.2. Put new one into the groove on the timing-belt cover accurately 3.9.3. Cover the cylinder head with cylinder head cover;...
  • Page 57 4.4. Rotate camshaft a round, keep the position as the right figure, measure the clearance again. First Second Third Fourth cylinder cylinder cylinder cylinder — — — — If exceed the standard of valve clearance, replace a adjusting washer to get a proper clearance Attention: record the position where valve clearance exceed the standard...
  • Page 58 4.4.3.2. Use a caliper to measure and adjust the thickness of the separation cushion. 4.4.3.3. Select proper separation cushion on the basis of the throttle thrusting rod benchmark values. (1). IN Selected cushion thickness = removed cushion thickness + (measured throttle spacing –...
  • Page 59 9. Cylinder head 1. Configuration diagram （1） Spark plug20±1Nm（2） Cylinder head（3） Weather seal I（4） Cylinder head gasket （5） Adjust shim （6） Valve lifter （ 7） Keeper （ 8） Valve spring seat （ 9） Valve spring （10） Intake valve（11） Exhaust valve（12） Valve oil seal（13） Valve seat（14） Valve guide...
  • Page 60 2. Dismounting 2.1. Removal of spark plug 2.2. There are 8 cylinder cover bolts. In the process of removing the cylinder, please follow the sequences shown as the right illustration, loosen the bolts one by one evenly and gently.。 2.3. Removal of the cylinder dustproof sealing and cylinder cover base.
  • Page 61 3.2. Valve spring 3.2.1. Use a square ruler to measure the right angle of the valve spring. Replace the spring if it fails to meet the specifications. [Limit] 1.2mm 3.2.2. Measure the free state of spring [Benchmark value] 37mm 3.3. Routine checks on throttles 3.3.1.
  • Page 62 3.3.3. Replacement of valve guide 3.3.3.1. Heat the cylinder cover to 80—100 degrees C with hot water 3.3.3.2. Use special tools to drive in the valve-guiding pipe to the position as shown in the right figure from the side of the combustion chamber.
  • Page 63 3.3.4.2. Correction of valve base stand ring Attention Signs of breaking or cracking should not appear on the correction surface. Take it out slowly after the correction is completed. 3.3.4.3. Use a 45 degree cone as the mating benchmark value. 3.3.4.4.
  • Page 64 3.4.3. Installation 3.4.3.1. Installation of valve spring washer and valve oil sealing Sub stool 3.4.3.1.1. Cover auxiliary tools on the valve rod head, smear Valve oil on the outer circle of the auxiliary roundness and inside of new valve oil Oil sealing seal, install it on the illustrated position, pull out the auxiliary tools of valve oil...
  • Page 65 3.4.4. Assembling of dustproof sealing strip and cylinder cover 3.4.4.1. Apply lubricating oil at the threads and grooves of the bolts. 3.4.4.2. The tightening of the cylinder bolts should follow the sequence as shown in the right figure. The tightening is to be carried out in 2 —3 operations till the torque meets the specifications.
  • Page 66 10. Water pump Configuration diagram (the dismounting and assembling of the cylinder body should be done in the following procedures) ※:Non-reusable part Unit: N*m (kg*cm) 1“O” ring, non-reusable2 Oil pump body3 Weather seal 2. Dismounting 2.1. Dismounting and removal of O-shaped ring Attention: These rings are not reusable.
  • Page 67 13. Oil pump 1. Configuration diagram (The dismounting and installation of the lubricating oil pump should be carried out according to the following procedures). Non-reusable part ① Oil pan， tighten bolt： 8±2 Nm② Oil strainer③ Oil collector gasket④ Oil pump⑤ Oil pump gasket⑥...
  • Page 68 2.2. Remove the oil collecting filter and its flange Attention The filter flange is not reusable. 2.3. Dismount the oil pump assembly and oil pump cushion 2.4. Dismounting of oil seal stand 3. Clearing 3.1. For the mating surfaces of the oil bottom case, oil pump and oil seal stands, For the mating surfaces of the rear oil seal stand and oil pump...
  • Page 69 4. Disintegration and assembling of oil pump 4.1. Configuration diagram ※:Non-reusable part Unit: N*m (kg*cm) 1 Weather seal2 Oil pump cover plate3 Driven rotor4 Drive rotor5 Split pin6 Relief valve spring seat7 Relief valve spring8 Relief valve9 Crankshaft front oil sealing10 Oil pump body 4.2.
  • Page 70 4.2.4. Take off the split pin Attention The split pins are not reusable. Attention: Pay attention not to make the spring and spring seat sending forth and ropping suddenly, while taking off the open pins. 4.2.5. Removal of the oil pump pressure relief valve spring stand, spiral spring, oil pump pressure relief valve...
  • Page 71 4.3.1.3. Use a feeler to measure the clearance between the rotator and the pump body [Benchmark] 0.10-0.181mm [Limit] 0.25mm 4.3.2. Routine checks on the pressure relief valve 4.3.2.1. Remove the pressure relief valve, there should be no visible tears, wears and scrapes on the pressure relief valve 4.4.
  • Page 72 4.4.3. The marks of the exterior and Mark interior gears of the lubricating oil pump should be on the visible side when being assembled into the pump body. 4.4.4. The new weather seal should be put inside the oil pump cover groove. 5.
  • Page 73 5.2. Disintegration 5.2.1. Use a flat screwdriver to remove the rear oil seal. Attention The oil seals are not reusable. 5.3. Checks Check to see if the tears and wears of the lip section of the oil seals are within the normal conditions, and if there are any damages in outer appearance.
  • Page 74 6.3. Installation of new lubricating oil collecting and filtering device, oil pump collecting and filtering device [Torque] 6±1N.m 6.4. Assembling of oil pan 6.4.1. Clear the mating surface with the cylinder body 6.4.2. Apply sealing silica before assembling [Grease] Letai 5699 Attention ·The liquid cushion with silica line diameter of ф3-4mm, without any broken section...
  • Page 75 14. Crankshaft connecting rod mechanism 1. Configuration diagram (Dismount and assemble the oil pump in the follow sequence) ※:Non-reusable part Unit: N*m (kg*cm) (1) Connecting rod cover(2) Connecting rod bearing bush(3) Piston and connecting rod assembly(4) Main bearing cover(5) Crankshaft(6) Crankshaft bush(7) Thrust washer(8) Cylinder block(9) No.1 compression ring(10) No.2 compression ring(11) Oil ring(12) Piston(13) Connecting rod(14) Piston pin...
  • Page 76 2. Disintegration of crankshaft connecting rod mechanism 2.1. Check the connecting rod axial clearance 2.1.1. Use centimeter or feeler to measure axial spacing [Benchmark]:0.15-0.24mm [Limit]:0.30mm 2.2. Check the connecting rod bush vertical clearance 2.2.1. Remove the bush cover Attention: Parts and components of various cylinders should be placed in good order.
  • Page 77 2.2.5. Replace the bush if width is beyond the limit. Attention: Connecting ·In replacing the bushes, you should use the Connecting rod bush rod cover products of same brand and from the same manufacturer, which can accord with the request of clearings. 2.2.6.
  • Page 78 2.4. Check the radial clearance of the crankshaft 2.4.1. Remove the crankshaft bearing cover; use a resin hammer to knock the bearing cover off gently. Clean the inside of the bushes, the 2.4.2. inside of the bearing cover, the cylinder walls, the axle diameter, etc. Make thorough checks for any tears and wears as well as other damages.
  • Page 79 st washer Attention: tighten the bolts fixing bearing cover according the order show as right figure 2.5. Disassembling of connecting rod assembly of the piston 2.5.1. Use the piston ring pliers to remove the primary ring, the secondary ring and the oil ring Attention Do not mix up the pistons and piston rings for each unit of assembly.
  • Page 80 4. Routine checks 4.1. Cylinder block 4.1.1. Checks on the levelness of cylinder top surface (1). Use a ruler and feeler to do the measurements of the six parts as shown in the right figure. [Limit] 0.08mm 4.1.2. The use of cylinder meter: Measure the values at the parts as shown in Top dead center the right figure and work out the...
  • Page 81 4.2.4. Measurement of the piston diameter 4.2.4.1. Make the measurement at the position 11mm below the piston skirt and along the vertical direction of the piston pin. [Benchmark] –0.013–0.025 4.2.5. Check the clearance between the piston ring and the ring groove Use a feeler to measure the rings 4.2.5.1.
  • Page 82 4.2.7. Check the clearance between the Outside diameter piston and the cylinder wall The Measure position positions for measuring the inner diameter of the cylinder and the piston skirt are as shown in the right figure. Replace and repair the piston Inside diameter or the cylinder body, or bore the Measure position...
  • Page 83 5. Assmbling of the crankshaft connecting rod mechanism 5.1. Assembly of the piston and connecting rod 5.1.1. Use special tools to assemble the piston, connecting rod and piston pin in the following specified procedures. 5.1.1.1. Smear lubricating oil to the connecting rod pin hole, and make the assembly according to the marks for the same unit and in the...
  • Page 84 5.3. Assemble the crankshaft main bearing cover, the crankshaft, shaft Thruster bush, shaft body and thruster according to the following instructions. 5.3.1. The protruding thrust block on the bush should match the groove on the cylinder body for installation.. Oil groove Attention Use the bush made by the same manufacturer.
  • Page 85 5.4. Assemble the piston connecting rod Ay, connecting rod bush and connecting rod bearing cover according to the following instructions. 5.4.1. The openings of the air ring and oil ring should match the specified direction. 5.4.2. Use nylon sleeves for the bolts of the connecting rod to prevent from scraping the cylinder hole and axial diameter...
  • Page 86 16. ELECTRIC INJECTION SYSTE...

  • Page 129: Dealer Pre-Delivery Inspection

    DEALER PRE-DELIVERY INSPECTION...
  • Page 130 _______Jumping the vehicle can cause serious damage to the drive train (axle, transmission, suspension). _______Injury or death can result from jumping vehicle. Do Not Jump. _______I understand that the roll bars are cosmetic and a roll over could cause death or serious injury.
  • Page 131 not prohibited by law. The deposit may also be used reimburse Seller for any expenses and losses Seller incurs or suffers as a result of Buyer‘s failure or refusal to accept deliver of the Vehicle or product or to comply with this contract. Such expenses and losses may include Seller s reasonable attorney‘s fees.
  • Page 132 entering into performing this contract.

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