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Joyner JNSZ650UV4S Owner's Manual

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JNSZ650UV4S

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Summary of Contents for Joyner JNSZ650UV4S

  • Page 1 Owner’s manual JNSZ650UV4S...
  • Page 2 Thank you for choosing JOYNER JNSZ650UV4S. It represents the result of many years of JOYNER experience in the production of utility vehicles. With the purchase of this JOYNER, you can now appreciate the high degree of craftsmanship and reliability that have made JOYNER a leader in this field .This manual will provide you with a good basic...

  • Page 3: Table Of Contents

    CONTENTS WARRANTY POLICY .......................... 5 LOCATION OF THE WARNING AND SPECIFICATION LABELS ......... 16 SAFETY INFORMATION ........................19 CONTROL FUNCTIONS ........................21 ............................21 AIN SWITCH ......................22 ULTI FUNCTION METER UNIT ............................22 WITCHES ..............................23 EDAL ........................24 ARKING BRAKE LEVER ..........................
  • Page 4 ATER PUMP DISASSEMBLY ......................61 ISTRIBUTOR REPLACEMENT ........................ 65 RONT HEEL LIGNMENT THE USING，MAINTENANCE AND REPAIR OF THE FRONT/REAR REDUCER ....66 PERIODIC MAINTENANCE ......................70 WIRING DIAGRAM ........................... 71 JNSZ650UV4S LIMITIED WARRANTY ..................72 DEALER PRE-DELIVERY INSPECTION .................... 159...

  • Page 5: Warranty Policy

    Warranty policy...

  • Page 16: Location Of The Warning And Specification Labels

    Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your Joyner dealer. WARNING WARNING...
  • Page 17 Keep weight in the cargo bed centered,and as low an far forward as possible. Top-heavy loads increase the risk of overturn. S650.09.04.00.04(1) JOYNER WARNING Improperly loading a trailer and failure to use extra care 3.9INCH when pulling trailer can (100MM) cause an accident or injury.
  • Page 18 JOYNER S650.09.04.00.11(3) TYPE: MANUFACTURER: JOYNER CHINA MAX . LOAD: VIN/NIV: JOYNER S650.09.04.00.12(1)

  • Page 19: Safety Information

    Note: WARNING The enclosure cannot protect occupants in all foreseeable accidents,including rollover. JOYNER S650.09.04.00.01(2) SAFETY INFORMATION THE SAFETY IS FRIST. Severe injury or death can result if you do not follow these instructions。Read this manual and all labels carefully and follow the operating procedures described: 1.
  • Page 20 schedules described in this manual. 11. Always keep both hands, arms, feet, and legs inside the vehicle at all times during operation. Keep your feet on the floorboard. Never hold onto the enclosure except when using the handgrip inside the enclosure. Otherwise, your hand could be injured if it is caught between the enclosure and an obstacle outside the vehicle.

  • Page 21: Control Functions

    CONTROL FUNCTIONS Main switch Functions of the respective switch positions are as follows: OFF: All electrical circuits are switched off except the turning signal both the left and the right when the light switch is on. The key can be removed in this position. ON 1: All electrical circuits are supplied with power, except the ignition system and fuel system, the headlights and...

  • Page 22: Multi-Function Meter Unit

    damage could occur. Wait at least 5 seconds between each operation of the electric starter to let it cool.  Do not turn the key to the "START" position with the engine running, or damage to the electric starter can result. ...

  • Page 23: Pedal

    This indicator light comes on when the drive select lever is “R” reverse position. Electricizing of the battery indicator light This indicator light comes on when the generator of the engine can’t electricize the battery. You should check the generator and battery or get help from your JOYNER dealer . Spot light switch Set the switch to turn on the spot lights.

  • Page 24: Parking Brake Lever

     If anyone of them can’t work well, please correct the problem .before operating the engine .If you can’t find or solve the problem yourself, please get the help from your JOYNER dealer. Parking brake lever Pull the parking lever up so that the unit can engage park brake. To release the unit, press button in the front end of parking lever then push the parking lever to the bottom.

  • Page 25: Drive Select Lever

    Drive select lever The drive select lever is used to shift your vehicle into the 1,2,3,4 and reverse positions.  Never start the vehicle at 3 or 4 lever.  Stop the vehicle fully when shifting to reverse.  When reversing, the reverse indicator “R” comes on and there is warning voice.

  • Page 26: Glove Compartment

    the seats can be Lifted just like the cargo bed . It is very easy to install or uninstall the seats, see the table of the content“seat and safety belt” 。 Safety belts This vehicle is equipped with three-point seat belts for both the operator and passenger. Always wear the seat belt while riding in the vehicle.

  • Page 27: Are You Ready To Drive

    Cargo bed 1. Confirm the air spring well worked. 2. Adjust the rubber bumpers to proper position, then tighten the adjust nuts . 3. Pull up the release lever on the both side of the vehicle, and then lift up the cargo bed slowly until it stops 4.

  • Page 28: Protective Apparel

    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.

  • Page 29: Age Recommendation

    handles. Practice driving the UV650-4S in a safe area to build your skills. Do not drive in rough terrain until you get accustomed to the UV650-4S’s controls, and feel comfortable with its size and weight. Operating UV650-4S without proper instruction could increase your risk of an accident which could lead to serious injury or death.

  • Page 30: Is Your Vehicle Ready To Drive

    Operating this UV650-4S after consuming 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 UV650-4S. IS YOUR VEHICLE READY TO DRIVE Before each drive, it is important to inspect your UV650-4S and make sure any problems you find are corrected.
  • Page 31 Engine Oil ■ Check the level and add oil if needed. Check for leaks. Coolant ■ Check the coolant and add coolant if needed. Check for the leaks. Fuel ■ Check the level and add fuel if needed. Also make sure the fuel cap is securely fastened.

  • Page 32: Safe Driving Precautions

    Cable ■ Check the cable housing for wear. Check the fittings are tight. Replace or tighten as needed. Tie rod ■ Check the tie rod housing for wear. Check the fittings are tight. Replace or tighten as needed SAFE DRIVING PRECAUTIONS Off-Road Use Only Your UV650-4S and its tires are designed and manufactured for off-road use only, not for pavement.

  • Page 33: Keep Hands And Feet On Controls

    you, which could lead to a collision. In many states it is illegal to operate UV650-4S on public streets, roads and highways. Operating this UV650-4S on public streets, roads or highways can cause collision with other vehicle. Never operate this UV650-4S on any public streets, roads or highways, even a dirt or gravel one.

  • Page 34: Do Not Perform Stunts

    Operating this UV650-4S at excessive speeds increases your changes of losing control of the UV650-4S, which can result in an accident. Always drive at a speed that is proper for your UV650-4S, the terrain, visibility and other operating conditions, and your experience. Take Care on Unfamiliar or Rough Terrain Before driving in a new area, always check the terrain thoroughly.

  • Page 35: Specifications

    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. SPECIFICATIONS Model JNSZ650UV4S Dimensions: Overall length 2980mm Overall width 1435mm Overall height 1820mm...
  • Page 36 Electric starter Starting system Wet sumb Lubrication system Engine ail Type ＞0℃ SE15W/40, ＜0℃ SE15W/30 Recommended engine ail classification Quantity: 2.9L With oil filter cartridge replacement Final gear case oil: Type SAE85 API GL-5 hypoid gear oil Quantity 0.7L Radiator capacity(including 1.4L routes):...
  • Page 37 Tire (option) Type Tubeless Size front 27 inch rear 27 inch Brakes: System Front and rear unified Type front Dual disc brake rear Dual disc brake Operation Foot operation Suspension: Front suspension Double wishbone Rear suspension Double wishbone Shock absorber: Front shock absorber Coil spring/oil damper Rear shack absorber...

  • Page 38: Operation

    OPERATION Operation controls 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.

  • Page 39: Brake

    Accelerator pedal Clutch pedal brake pedal Throttle Figure 3 The right foot pedal is the throttle that controls the UV650-4S speed. To disengage the clutch at any time, allow the throttle to return to the idle position. (See Fig. 3) Each time prior to starting the engine, check the throttle assembly to ensure that when pedal is pushed all the way the assembly is working smoothly and returns to idle when released.

  • Page 40: Start Engine

    Improper operation of the clutch will lead to excessive wear of the clutch friction surface. Note： When operate the vehicle, if it does not feel comfortable about one of the three pedals , adjust the bolt and then tighten the nut until it feels very comfortable.

  • Page 41: Engine Stop Key

    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 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 42: Passenger

    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 43: Seat Adjustment

    Seat Adjustment The left seat can remove, but the right can’t. To move a seat, pull its seat lock lever upward, lift the front of the seat, and then slide the seat forward and up. To repair the engine and the battery conveniently, the seats can be Lifted just like the cargo bed .

  • Page 44: Gear Shift 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. Gear Shift Adjustment Before operate the vehicle, check the shift lever as to change gearshift from 1 to 4 and...

  • Page 45: Service Instruction

     To prevent vehicle from rolling over, be sure to only turn the vehicle at a slow more controllable speed. SERVICE INSTRUCTION Service Air Cleaner Service air cleaner every 80 hours NOTE: Service more often under dusty conditions. Remove cleaner cover by bolt b.

  • Page 46: Transmission Lubrication

    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 c.

  • Page 47: Engine Coolant

    b. Remove the iron dust plug, this plug has a magnet on it. Iron dust caused by moving parts will stick to the plug. Clean the iron dust from this dust plug. d. Tighten the transmission oil outlet plug and the iron dust plug. e.
  • Page 48 If the coolant in the reserve tank is less than 2/5, it needs to be topped up. 1. Turn the reserve coolant case cap counterclockwise and open the cap. 2. Pour fresh coolant of the specified type into the reserve coolant tank till the coolant reaches 2/5 to 3/5 of the reserve coolant tank volume.

  • Page 49: Spark Plug

    Spark Plug Remove the spark plug and inspect it each time you change the oil. (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.

  • Page 50: Repair

    REPAIR Front Wheel Replacement Do not disassemble the center castle nuts when you replace the front wheels.(See Fig. 20) Tighten the nuts after replacing the wheels. Rear Wheel Replacement Do not disassemble the center castle nuts when you replace the rear wheels. Tighten the nuts after replacing the wheels.

  • Page 51: Clutch Replacement

    Clutch replacement Do not remove the whole engine from vehicle when you replace the clutch, but you’ll need to remove rear suspension, driven shaft, clutch cable, muffler, wires and rubber cushion that is in the middle of transmission and frame. Remove bolt M14 2.
  • Page 52 3. Remove two nuts (M14) on two side of transmission 4.Remove two bolts(M8) on the low mud plate of transmission 5.Remove the mud plate.
  • Page 53 6.Remove the transmission 7.Remove upper mud plate 8.Insert a shaft into the hole. Remove six bolts on the pressing plate of clutch...
  • Page 54 9.Remove the pressure plate. Remove the friction disc of clutch 10. Insert a special shaft into the hole, fix new friction plate on the flywheel of engine.

  • Page 55: Timing Setup And Balancing Shaft Setup

    11.Fix pressure plate of clutch. Two bolts with “Y.G” mark must be inserted into two anchor hole. Tighten six bolts with torque 30 N•m . Torque 30 N•m 12. Fix upper mud plate 13. Fix parts according to reverse operation to the disassembly. Timing setup and balancing shaft setup 1.
  • Page 56 Camshaft timing sprocket wheel...
  • Page 57 Mark Right balancing Left balancing shaft shaft sprocket sprocket Crank shaft Figure 1 Mark here Mark Left balancing shaft sprocket Figure 2...

  • Page 58: Water Pump Disassembly

    Make Mark 30mm above the bolt Mark 30mm Left balancing shaft sprocket Figure 3 Water pump disassembly 1. Take off fan belt and loosen 4 bolt tightening water pump pulley. Fan belt Bolt Water pump pulley...
  • Page 59 Figure 4 2. Loosen the 6 bolts shown as the Figure 5. Bolts Bolts Figure 5 3. Loosen the clamp bolts shown as Figure 6, and disconnect two peace of water pipe, and take off the water pump. The engine without water pump is shown as Figure 6.
  • Page 60 Clamp Bolts Water pipes Figure 6 Figure 7 1. Fix the timing chain on the sprocket of crankshaft. Mark on the sprocket of crankshaft must be in the middle of double white links of timing chain.

  • Page 61: Distributor Replacement

    2. Fix the guide plate.。 3. Fix the tensional plate. 3. Fix the sprocket. Mark on the sprocket must be in straight line to the single white link on the timing chain Distributor replacement １. turn around the crank shaft, direct the line on the pulley of crankshaft straight to the 0 degree line on the cover of engine...
  • Page 62 2. Remove the rocker cover of head by removing two bolts 3. Check the anchor hole, if it is not on the direction shown by Fig. Repeat above 1 as to obtain the hole direction shown by Fig.
  • Page 63 4. Insert the screwdriver into the hole, turn the drive of oil pump shaft until parallel to the crankshaft 5. Align the mark 2 on the shaft of distributor to the mark 1 on the aluminum housing. 6.. Insert the distributor slowly to the hole. Confirm the direction of distributor is as per the figure.
  • Page 64 7.Fix the cover of the distributor. 8. Check the spark timing. Adjust if need as followings: Loosen the nut of the distributor housing. Turn the distributor slowly. Increase the spark timing by counterclockwise turn. Decrease the spark timing by clockwise turn.

  • Page 65: Front Wheel Alignment

    Front Wheel Alignment a. Put the vehicle on level ground. b. The “toe-in” of the front wheels should be 1.18 inches. To check for alignment, measure distance A and B between the centerline (CL) of the wheels. The proper toe-in dimension A should be 1.18 inches greater than dimension B. d.

  • Page 66: The Using，Maintenance And Repair Of The Front/Rear Reducer

    The USING，MAINTENANCE AND REPAIR OF THE FRONT/REAR REDUCER Before install the front/rear main reducer to the vehicle, we have done accurate test to each one, and don’t open them in normal. But please do the following. 1. Change the oil of the front/rear main reducer after 300Km for the first using of your vehicle.
  • Page 67 b. Dismantle the bolt M6(PIC.01)/M8(PIC.02) from the main case of front/rear main reducer , then let the old oil vented out . c. Before adding the new oil ,please screw the bolt M6(PIC.01)/M8(PIC.02) properly. d. Dismantle the bolt “4”and washer “3”(PIC.03),then add the new oil (GL-5,85W-90) and it is about 400-450 mL .
  • Page 68 Never start the vehicle again. b. Dismantle the reducer from the vehicle, then open it and change a new part from your JOYNER dealer. c. When you assemble the part, all the bolts and nuts should be screwed with the...
  • Page 69 After assembling, you must make sure that the halfshaft can’t be pulled out by hand. The front and rear main reducer are important parts to the vehicle .If you have some problems which you can’t resolve by yourself, please get help from your JOYNER dealer.

  • Page 70: Periodic Maintenance

    PERIODIC MAINTENANCE The maintenance intervals in the following table are based upon average driving conditions. Driving in unusually dusty areas, require more frequent servicing. Time of service Initial Monthly Quarterly Yearly Item service Engine 1. driven belt 2. Tighten bolts on engine. 3.

  • Page 71: Wiring Diagram

    WIRING DIAGRAM...

  • Page 72: Jnsz650Uv4S Limitied Warranty

    Should warranty service be required on your JNSZ650UV4S 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 73: Dealer Pre-Delivery Inspection

    DEALER PRE-DELIVERY INSPECTION...
  • Page 74 _______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 75 reason, Seller may at Seller‘s sole option, terminate this contract and retake the vehicle, or make claims against Buyer on the check. In addition, Seller will charge Buyer a $25 returned check charge plus any actual charges assessed by Seller‘s financial institution resulting from such returned check.
  • Page 76 by Buyer, or (Ⅱ) if given in any other manner which results in Buyer‘s actual receipt of such notice. 4. BAD CHECK. If Buyer pays Seller with a check that is dishonored or unpaid for any reason, Seller may at Seller‘s sole option, terminate this contract and retake the vehicle, or make claims against Buyer on the check.

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