Joyner Go-kart JNSZ650DS Owner's Manual
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Joyner Go-kart JNSZ650DS Owner's Manual

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Owner's manual
JNSZ650DS

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
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Summary of Contents for Joyner Go-kart JNSZ650DS

  • Page 1: Parts Manual

    Owner’s manual JNSZ650DS 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...
  • Page 2 JNSZ650DS 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.

  • Page 3: 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 4: Foreword

    FOREWORD Thank you for choosing JOYNER Go-kart. We hope you will have fun with it. Before you start to 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.

  • Page 5: 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 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.

  • Page 6: Important Safety Information

    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 a lot you can do to protect yourself when you drive. You’ll find many helpful recommendations throughout this manual.
  • Page 7 IMPORTANT SAFETY INFORMATION 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.

  • Page 8: Safetylabels

    SAFETYLABELS This section presents some of the most important information and recommendations to help you drive your Go-Kart safely, please take 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.

  • Page 9: Are You Ready To Drive

    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.
  • Page 10 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 11: Is Your Vehicle Ready To Drive

    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.
  • Page 12 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. Pre-drive Inspection ■ Underbody & 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.

  • Page 13: Safe Driving Precautions

    SAFE DRIVING PRECAUTIONS Off-Road Use Only Your 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.
  • Page 14 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 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.

  • Page 15: Specifications

    SPECIFICATIONS DIMENSIONS Overall Length---------------------------------------------------------------------------------------113 in. (2880mm) Overall Width ---------------------------------------------------------------------------------------68in. (1740mm) Overall Height ---------------------------------------------------------------------------------------- 59in. (1500mm) Wheelbase --------------------------------------------------------------------------------------------- 82 in. (2090mm) Front Track ------------------------------------------------------------------------------------------- 58 in. (1475mm) Rear Track -------------------------------------------------------------------------------------------58in.(1470mm) Ground Clearance ---------------------------------------------------------------------------------- in. (320mm) ENGINE Type --------------------------------------------------------------------------------2-Bore,4-Stroke,Liquid-cooled Bore x Stroke -------------------------------------------------------------------------------------------- 76mm×71mm Displacement ------------------------------------------------------------------------------------------------------ 644 cc Compression ratio ------------------------------------------------------------------------------------------------8.4:1 Carburetor ------------------------------------------------------------------------------------ BJH101E or CSH101E...

  • Page 16: Operations

    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 17 Figure 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 If the engine is cold; 1. Pull the choke out fully Figure 2 2.
  • Page 18 Before you start the engine, check that the parking brake is engaged, and the gear shift lever is in neutral. Trying to start the engine in gear may damage the starter motor, clutch or gearbox. Release the key at once if the engine starts. Holding the key in start position when the engine is running will cause damage to the starter motor.
  • Page 19 8. Check Engine Stop key. Perform engine stop key test. Repair as necessary. 9. 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 torque.
  • Page 20 E. Parking Adjustment Park brake “OFF” Park brake “On” Figure 6 Pull the park brake lever up so that the unit can engage park brake. b. To release the unit, press button on front end of parking lever then push the parking lever to the bottom.

  • Page 21: Service Instructions

    H. Starting And Operating Instructions Before starting the engine, be sure that the driver is seated properly in the Go-Kart and tighten the seatbelt. b. Testing the Go-Kart in a open place at the beginning to learn how to start, turn and stop.
  • Page 22 Figure 12 Figure 13 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. 10). c.
  • Page 23 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. Remove dipstick of transmission (see Fig. 14), fill oil (GL-4 85W/90) about 1.9 liters.
  • Page 24 Top up the reserve coolant 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 25 gauge. This specification is 0.025”~0.030”. b. Before installing spark plug coat threads lightly with graphite grease if possible, to ensure easy removal next time the spark plug Figure 18 needs inspection (see Fig. 18). It is advisable to replace the spark plug at least once a year to insure easy starting and good engine performance.

  • Page 26: Repair

    H. Kart Lubrication 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 27 Figure 21 REPAIR C. 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. 1.
  • Page 28 Figure 22 2. Remove two bolts (M12) on the starter (See Fig. 23), Remove the starter (See Fig. Figure 23 Figure 24 REPAIR 3. Remove two nuts (M14) on two side of transmission (See Fig. 25, 26) Figure 25 Figure 26 5.
  • Page 29 Figure 27 Figure 28 6. Remove the mud plate (See Fig. 21). Figure 29 REPAIR 7. Remove the transmission (See Fig. 30, 31) Figure 30 Figure 31...
  • Page 30 8. Remove upper mud plate (See Fig. 32) Figure 32 REPAIR 9. Insert a shaft into the hole (See Fig. 33). Remove six bolts on the pressing plate of clutch (See Fig. 34) Figure 33 Figure 34...
  • Page 31 10. Remove the pressure plate (See Fig. 35). Remove the friction disc of clutch (See Fig. 36, 37) Figure 35 Figure 36 Figure 37 REPAIR 10. Insert a special shaft into the hole, fix new friction plate on the flywheel of engine (See Fig.
  • Page 32 11. Fix pressure plate of clutch. Two bolts with “Y.G” mark must be inserted into two anchor hole (See Fig. 40) . Tighten six bolts with torque 30 N.m (See Fig. 41) Figure 40 Figure 41 12. Fix upper mud plate (See Fig. 42, 43) Figure 42 Figure 43 13.
  • Page 33 REPAIR E. Distributor replacement １ turn around the crank shaft (See Fig. 44), direct the line on the pulley of crankshaft straight to the 0 degree line on the cover of engine (See Fig. 46)
  • Page 34 Figure 44 Figure 45 Figure 46 2. Remove the rocker cover of head by removing two bolts (See Fig. 47) Figure 47 REPAIR 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 35 3. Insert the screwdriver into the hole, turn the drive of oil pump shaft untill parallel to the crankshaft (See Fig. 48,49) Figure 48 Figure 49 4. Align the mark 2 on the shaft of distributor to the mark 1 on the aluminum housing (See Fig.
  • Page 36 distributor is as per the figure (See Fig. 52, 53). Tighten the nut of distributor housing. Figure 51 Figure 52 Figure 53 6. Fix the cover of the distributor (See Fig. 44). Figure 42 REPAIR 7. Check the spark timing. Adjust if need as followings...

  • Page 37: Periodical Check And Service

    1. Loosen the nut of the distributor housing 2. Turn the distributor slowly. Increase the spark timing by counterclockwise turn. Decrease the spark timing by clockwise turn. F. 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.

  • Page 38: Wiring Diagram

    11. Throttle cable and choke I.A.L I.R.A 12. Fuel tank cover. Breathe hose and joint. 13. Idle 14. Breathe hose 15. Fuel hose and joints Control system 16. Wire and plugs 17. The free display of clutch pedal 18. Brake fluid, hose, joints 19.

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