Table of Contents
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Owner's manual
READ THIS MANUAL CAREFULLY.
IT CONTAINS IMPORTANT SAFETY
INFORMA
MINIMUM
RECOMMENDED
OPERATOR AGE
TION.
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.
.
.
JNSZ650DL
.
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Table of Contents
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Summary of Contents for Joyner JNSZ650DL
- Page 1 Owner’s manual JNSZ650DL READ THIS MANUAL CAREFULLY. IT CONTAINS IMPORTANT SAFETY INFORMA MINIMUM RECOMMENDED OPERATOR AGE TION. 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...
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Page 2: Table Of Contents
CONTENTS Warranty policy ................6 Owner‘s manual ................16 Foreword ............................... 16 Foreword about safety ........................... 17 Important safety information ......................... 18 Follow the Age Recommendation ..................... 18 Always Wear a Helmet ........................18 Drive Off-Road Only ........................18 Take Time to Learn & Practice ......................18 Be Alert for Off-Road Hazards ...................... - Page 3 Engine Stop ............................24 Steering Wheel ..........................24 Cable ..............................24 Tie rod ............................... 24 Safe driving precautions ........................25 Off-road use only ..........................25 Keep Hands and Feet on Controls ....................25 Control Speed ........................... 26 Use Care on Unfamiliar or Rough Terrain ..................26 Do Not Perform Stunts ........................
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Page 4: Warranty Policy
Warranty policy... -
Page 14: Owner's Manual
Owner‘s manual Foreword Thank you for choosing JOYNER off Highway Recreational Vehicle. We hope you will have fun with it. Before you start to operate the Vehicle, please read through this Owner‘s Manual carefully as it contains important safety and maintenance information. -
Page 15: Foreword About Safety
Foreword about safety In order to keep everyone safe, you must take responsibility for the safe operation of your Off Highway Recreational Vehicles. 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: Important Safety Information
Important safety information Your Vehicle 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 17: Never Run Your Go- Vehical Indoors
additional drink. So don‘t drink and drive, and don‘t let your friends drink and drive either. Never run your Go- Vehical indoors. Y the exhaust from the engine contains a tasteless, odorless and poisonous gas called carbon monoxide. Important safety information Keep away from moving parts of the Off Highway Recreational Vehicles The operator of the Off Highway Recreational Vehicles should never place their hands or other parts of their body near any moving part of the Off Highway... -
Page 18: Safety Lables
Safety lables A this section presents some of the most important information and recommendations to help you drive your Off Highway Recreational Vehicles safely, please take a few moments to read these pages. The labels are considered permanent parts of the Off Highway Recreational Vehicles. -
Page 19: Are You Ready To Drive
Are you ready to drive? Before each drive, you need to make sure you and your Off Highway Recreational Vehicles 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 Highway Recreational Vehicles, and adjustments to make for your comfort, convenience, or safety. -
Page 20: Additional Driving Gear
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. ■ Driving pants with knee and hip pads, a driving jersey with padded elbows, ■... -
Page 21: Is Your Vehicle Ready To Drive
Operating this Off Highway Recreational Vehicles 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 Off Highway Recreational Vehicles. -
Page 22: Nuts & Bolts
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 Off Highway Recreational Vehicles. -
Page 23: Safe Driving Precautions
Safe driving precautions Off-road use only You‘r Off Highway Recreational Vehicles 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 Highway Recreational Vehicles on pavement. -
Page 24: Control Speed
Removing hand from Steering wheel or feet from foot controls during operation can reduce your ability to control the Off Highway Recreational Vehicles or could cause you to lose your balance and fall off the Off Highway Recreational Vehicles. Always keep both hand on the steering wheel and both feet on the foot controls of your Off Highway Recreational Vehicles during operation. -
Page 25: Do Not Perform Stunts
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 Off Highway Recreational Vehicles on such terrain. -
Page 26: Specifications
Specifications DIMENSIONS Overall Length---------------------------------------------------------------------------------------113 in. (2880mm) Overall Width ---------------------------------------------------------------------------------------- 62 in. (1570mm) Overall Height ---------------------------------------------------------------------------------------- 70in. (1777mm) Wheelbase --------------------------------------------------------------------------------------------- 81 in. (2050mm) Front Track ------------------------------------------------------------------------------------------- 51 in. (1300mm) Rear Track ---------------------------------------------------------------------------------------------51in. (1300mm) Ground Clearance ------------------------------------------------------------------------------------ 11in. (280mm) ENGINE Type --------------------------------------------------------------------------------- 2-Bore,4-Stroke, Liquid-cooled Bore x Stroke -------------------------------------------------------------------------------------------- 76mm×71mm Displacement ------------------------------------------------------------------------------------------------------ 644 cc... -
Page 27: Operation
Operation 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. - Page 28 Speedome Tachomete Horn Coolant temperature indicator butto Voltmete Fuel level gauge Steering wheel Battery charge light Reverse gear light Accelerator Pedal Brake pedal Clutch pedal [5pedl] Figure 1 Shift lever n.踏板 v.踩...的踏板 Speedome Tachomet Horn Fuel level gauge button Start engine 1.
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Page 29: 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 30 3. Check for Fuel Level. Add fuel as necessary and do not overfill. Check for leaks.(see Figure 3) Brake light Fuel tank Figure 3 4. Check for Brakes. Depress the brake pedal several times, and then check for proper brake pedal free play. Make sure there is no brake fluid leakage. Adjust if necessary.
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Page 31: Passengers
7. Check Throttle. Check for smooth operation. Ensure the throttle ―snaps‖ back to idle. (See Figure 4) 8. Check Engine Stop key. Perform engine stop key test. Repair as necessary. (See page31 Engine stop key) 9. Check all Nuts, Bolts, and fasteners. Check wheels to see that all axle nuts and rim nuts are tightened properly. -
Page 32: Parking
B. Move seat to desired position. C. Be sure seat adjustment handle snaps back into place and that seat is locked into position. (See Figure 7) Before attempting to adjust the seat ensure that engine of the Off Highway Recreational Vehicles is stopped. Never operate this Off Highway Recreational Vehicles 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 33: Gear Shift
Gear Shift Adjustment nuts Connect to shift lever Lock nuts Figure 12 Figure 11 1. Operate the gear shift as the picture shown. and the max speed in every gear position is shown as the following form（see Figure 11） Gear position Max speed 26 km/h 37km/h... -
Page 34: Service Instructions
with it. d. The turning radius of this Off Highway Recreational Vehicles 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 Off Highway Recreational Vehicles from rolling over. -
Page 35: Check Engine Oil And Recharge
Figure 18 Figure 19 With the engine warm, put the vehicle on the level ground. a. 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 Figure 17). -
Page 36: Check Transmission Oil
e. Remove dipstick of transmission (see Fig. 14), fill oil (GL5 80W/90) about 1.9 liters. Insert the transmission dipstick, check the oil level in the transmission. Confirm the corrective oil level in the transmission (see Figure 21). Check transmission oil If the color of transmission oil changes, you need to replace oil. -
Page 37: Spark Plug
Opening the radiator cap while the engine is hot can be hazardous. Opening the radiator cap can spray the high temperature coolant in your eyes, face and any parts of your body. This can result in severe injury. Never open the radiator cap while the engine is hot. New and used coolant can be hazardous. -
Page 38: Cleaning Instructions
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 air screw gently. Back out 2-3/8 turns counter clockwise (see Figure 25). -
Page 39: Storage Instruction
Storage Instruction In the event your vehical 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. -
Page 40: Repair
Repair Front Wheel Replacement Do not disassemble the center castle nuts when you replace the front wheels. (See Figure 26) Tighten the nuts after replacing the wheels. Castle nuts Torque:180±5 N.M Wheel nuts Torque:70±5 N.M Figure 26 Rear Wheel Replacement Do not disassemble the center castle nuts when you replace the rear wheels. -
Page 41: Clutch Replacement
Torque:70±5 N.M 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. - Page 42 3. Remove two nuts (M14) on two side of transmission (See Figure 31,Figure 32) Bolt M14 Bolt M14 Figure 31 Figure 32 1. Remove two bolts(M8) on the lower mud plate of transmission (See Figure 33,Figure 34) Bolt M8 Bolt M8 Oil pan Oil pan Figure 33...
- Page 43 3. Remove the transmission (See Figure 36,Figure 37) Engine Transmission Figure 36 Figure 37 4. Remove upper mud plate (See Figure 38) Upper mud plate Figure 38 5. Insert the aligning shaft into hole (See Figure 40). Remove six bolts on the pressing plate of clutch (See Figure 39) Bolt Bolt...
- Page 44 Pressure plate Friction disc Figure 41 Figure 42 Engine without clutch Figure 43 10. Insert the aligning shaft into the hole; align new friction plate to the flywheel of engine (See Figure 44,Figure 45). Centering shaft Centering shaft Friction disc Friction disc Figure 44 Figure 45...
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Page 45: Timing Setup And Balancing Shaft Setup
Bolts with “GY” Torque 30 N*M Figure 46 Figure 47 12. Fix upper mud plate (See Figure 48,Figure 49Figure 49) Upper mud plate Upper mud plate Figure 48 Figure 49 13. Fix parts according to reverse operation to the disassembly Timing setup and balancing shaft setup 1. - Page 46 Camshaft timing sprocket wheel Mark Right balancing Left balancing shaft sprocket shaft sprocket Crank shaft Figure 50...
- Page 47 Mark here Mark Left balancing shaft sprocket Figure 51 Make a Mark 30mm above the bolt Mark 30mm Left balancing shaft sprocket Figure 52...
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Page 48: Water Pump Disassembly
Water pump disassembly 1. Take off fan belt and loosen 4 bolt tightening water pump pulley. Fan belt Bolt Water pump pulley Figure 53 2. Loosen the 6 bolts shown as the Figure 54. Bolts Bolts Figure 54 3. Loosen the clamp bolts shown as Figure 55, and disconnect two peace of water pipe, and take off the water pump. -
Page 49: Distributor Replacement
shown as Figure 55. Clamp Bolts Water pipes Figure 55 Figure 56 Distributor replacement 1) Turn around the crank shaft, align the line on the pulley of crankshaft straight to the 0 degree line on the cover of engine (See Figure 57,Figure 58,Figure... - Page 50 Figure 57 Figure 58 Figure 59 2) Remove the rocker cover of head by removing two bolts (See Figure 60) Figure 60 3) Check the anchor hole, if it is not on the direction shown by Fig. Repeat...
- Page 51 above 1 as to obtain the hole position shown by Figure 53. 4) Insert the screwdriver into the hole, turn the drive of oil pump shaft until parallel to the crankshaft (See Figure 62,Figure 63) Figure 62 Figure 61 5) Align the mark 2 on the shaft of distributor to the mark 1 on the aluminum housing (See Figure 63) Figure 63 6) Insert the distributor slowly to the hole (See Figure 64).
- Page 52 Figure 65 Figure 66 7) Fix the cover of the distributor (See Figure 67). Figure 67 8) Check the spark timing. Adjust if need as followings a) Loosen the nut of the distributor housing b) Turn the distributor slowly. Increase the spark timing by counterclockwise turn.
- Page 53 1) Install thick pivot plate and short crank to shifter shaft (See Figure 68 Figure 69Figure Figure 71) Short crank Thick pivot plate Shifter shaft Shifter shaft Figure 68 Figure 69 Spring washer Washer Short crank Shifter shaft Step 1 finished Figure 70 Figure 71 2) Install thin pivot plate and long crank.
- Page 54 Thin pivot plate Thin pivot plate Figure 72 Figure 73 Step 2 finished 3) Install the shifter shaft ASSY finished above to transmission. (See Figure 74) Bolt M10x1.5x20 Shifter shaft ASSY Figure 74 B. Front Wheel Alignment...
- Page 55 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.
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Page 56: Wiring Diagram
Wiring diagram Dipping switch 2 Alternator 14V 35A Distributor coil,ign block Wire's colour symbol RS---red/grey B---black R---red U---blue RU---red/blue P---purple S---grey W---white YG---yellow/green L---Cambridge blue N---brown K---pink NB---brown/black NR---brown/red UW---blue/white RB---red/black GY---green/yellow SB---grey/black BR---black/red Y---yellow WG---white/green GB---green/black WR---white/red BW---black/white Figure 76... -
Page 57: Dealer Pre-Delivery Inspection
DEALER PRE-DELIVERY INSPECTION... - Page 58 _______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. The seller is not liable for death or injury. _______I have inspected all machines for any cosmetic damage and found it/them to be satisfactory.
- Page 59 of change of address‖ on file with Seller, whether or not such notice is actually received 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.
- Page 60 acceptance of partial payments shall not in any manner modify the terms of this contract and such acceptance shall not be construed as a waiver of any subsequent defaults on Buyer‘s part nor shall it waive the ―time is of the essence‖...
- Page 61 responsible for maintaining its own theft and liability insurance coverage for the vehicle. AGE. Buyer represents and warrants to Seller that Buyer is over the age of majority and is fully competent to enter into contact. Buyer acknowledges that Seller is relying on this representation in entering into performing this contract.
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