Joyner JNSZ1100SV Owner'S Manual Download

Page: 32 / 132

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)

3. Remove upper steel cushions and lower steel cushion. (See Fig. 26-27)

Q218B1245

Q1841240

GB/T70.1-2000-M12*1.75*75*25

S11-17001031

372-10020301

FIGURE 22

FIGURE 23

FIGURE 27

FIGURE 26

FIGURE 25

FIGURE 24

Summary of Contents for JNSZ1100SV

Page 1: ...FORMATION 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...

Page 2: ...ORDS ABOUT SAFETY 14 3 IMPORTANT SAFETY INFORMATION 14 4 SAFETY LABELS 15 5 ARE YOU READY TO DRIVE 16 6 IS YOUR VEHICLE READY TO DRIVE 18 7 SAFE DRIVING PRECAUTIONS 20 8 SPECIFICATIONS 22 9 OPERATION...

Page 3: ...Warranty policy...

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Page 14: ...contains important safety and maintenance information Failure to follow the warnings contained in this manual can result in serious injuries Be sure to follow the recommended maintenance schedule and...

Page 15: ...his entire manual is filled with important safety information please read it carefully 3 IMPORTANT SAFETY INFORMATION Your Off high way recreational vehicle will provide you with many years of service...

Page 16: ...ur ability to respond to changing conditions and your reaction time gets worse with every additional drink So don t drink and drive and don t let your friends drink and drive either Never run your Go...

Page 17: ...tion 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 Before you dr...

Page 18: ...rtation sticker in any helmet you buy Always wear a face shield or goggles to protect your eyes and help your vision Operating this Off high way recreational vehicle without wearing an approved motorc...

Page 19: ...lity to operate a Off high way recreational vehicle safely Likewise drugs even if prescribed by a physician can be dangerous while operating a Off high way recreational vehicle Consult your doctor to...

Page 20: ...etation or other debris that could be fire hazard or interfere with the proper operation of the Off high way recreational vehicle Air Cleaner Housing Drain Tube Check for deposits in the drain tube If...

Page 21: ...is illegal to operate off high way recreational vehicles on public streets roads and highways Operating this Off high way recreational vehicle on public streets roads or highways can cause collision...

Page 22: ...when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the Off high way recreational vehicle Never drive past the limit of visibility Maintain a safe dista...

Page 23: ...Engine oil SAE 10W 30 Gear oil GL 4 75W 90 CAPACITIES Maximum load 250kg Fuel tank 42L Engine oil 3500ml Gear oil 2000ml Coolant 6000ml Starting 5s Climbing 20 25 Battery 12V45Ah Head Light 12V 55 55W...

Page 24: ...Do not operate if pedal or engine throttles linkage fail to return to idle If unable to correct the problem through lubrication adjustment or replacement of worn parts contact your dealer for assistan...

Page 25: ...firmly up on the park brake lever with your hand until the lever is tight Set shift selector in neutral Insert the key into key switch turn the key clockwise and release the key when the engine start...

Page 26: ...that is lowers than normal See your authorized JOYNER dealer if battery is good and voltmeter still register low charge See figure 8 16 Fuel level gauge The fuel gauge displays approximately how much...

Page 27: ...s the operator control of the foot pedals steering wheel and the remote stop button See figure 10 a Pull seat adjustment handle upward to disengage seat slide b Move seat to desired position c Be sure...

Page 28: ...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 cor...

Page 29: ...maximum life and performance from your new vehicle The following guidelines explain proper break in procedures 4 1 After the engine starts the engine is not allowed in high speed in the neutral gearsh...

Page 30: ...the pressure lower than 0 8MP 6 Front Wheel Replacement Do not disassemble the center castle nuts when you replace the front wheels See Fig 16 Tighten the nuts after replacing the wheels Castle nuts...

Page 31: ...Clutch replacement Remove two bolts and demount Starter assembly carefully See Fig 18 21 Q1840845 GB T70 1 2000 M12 1 75 75 25 S11 3708111 S11 3708110GA FIGURE 17 FIGURE 18 FIGURE 19 FIGURE 21 FIGURE...

Page 32: ...he transmission case you must tighten them according to the prescribed torque 45 55N M See Fig 22 25 3 Remove upper steel cushions and lower steel cushion See Fig 26 27 Q218B1245 Q1841240 1 GB T70 1 2...

Page 33: ...s 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 S11 1601020CA S1...

Page 34: ...e alignments loose the lock nuts on both sides of Front Tie Rods To make Dimension B smaller turn the rod to the left Turn the rod to the right to make Dimension B larger After adjusted to desired len...

Page 35: ......

Page 36: ...engine cylinder by removing the spark plug and pour one ounce of clean lubricating oil through the spark plug hole into the cylinder Crank the engine slowly to spread oil and replace spark plug 12 3 D...

Page 37: ...13 ENGINE WIRING DIAGRAM...

Page 38: ...lamp the brake light Tachometer Thermometer Voltage meter Fuel meter NR ON ON Fuel pump OP Oil sensor 5 21 speed 1A 1A 28 27 30 18 3D 67 87A 69 87B 65 High beam switch Dipped beam switch Turn signal...

Page 39: ...filter cover and replace with a new air filter 2 Engine Lubrication Engine oil replacement You must change the oil in the crankcase after the first 5 hours of operating of your new engine and after 10...

Page 40: ...the oil in the transmission after the first 5 hours of operating of your new engine and after 10 hours of use thereafter That will insure proper lubrication of internal parts and prevent costly repai...

Page 41: ...s come up 4 1 6 Refit the coolant cap turn it clockwise and tighten it 4 1 7 Turn the reserve coolant case cap counterclockwise and open the cap see Fig 17 4 1 8 Pour fresh coolant of the specified ty...

Page 42: ...s if wet with coolant Recycle or properly dispose of used coolant Harm or damage may occur if use coolant that don t meet the specification 50 standard green coolant and 50 distill water 6 Idle Speed...

Page 43: ...ing 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...

Page 44: ...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 2 3 3 Ens...

Page 45: ...semble according to original state 2 5 3 Make sure that the crankshaft timing pulley wheel mark is aligned with the mark of the oil pump 2 5 4 Remove the tensioner bolt and take off the tensioner 2 6...

Page 46: ...leaked which makes it necessary to refill the water continuously 2 8 5 2 There are much oil stains on the belt the belt should be replaced for the rubber will be damaged when it is expanded Specifica...

Page 47: ...to make the positioning groove on the gear be aligned with the positioning pin on the end surface of the camshaft Then use screws to fix the clockwise gear with the torque of 100 5N m 3 2 2 Make sure...

Page 48: ...t the above mentioned stretcher fastening bolt by widening he spacing tighten the S A fixing bolt of the stretcher with the specified torque of 25 3N m 3 4 Install the baffle of the crankshaft timing...

Page 49: ...mper 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 install position 3 before tighten water...

Page 50: ...ver 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 gea...

Page 51: ...with a special tool Attention Manufacture a special tool according the right figure The special is necessary to prevent the camshaft to rotate 2 3 Removal of camshaft bearing cover 2 3 1 Align the ma...

Page 52: ...amshaft slave gear 2 6 1 Use the special tool as shown in the right figure Clip the camshaft tightly and turn the gear to keep the bite state of master and slave gear remove the fixing bolts of slave...

Page 53: ...pacing is 0 1 0 173mm Limits for operation 0 18mm 2 7 3 Checks on camshaft meshing clearance 1 Put camshaft into cylinder head 2 Make sure the front mark on bearing cover and shaft number is ok and th...

Page 54: ...the camshaft Attention Size of the axial clearance of the camshaft 3 3 1 Smear lubricating oil at the camshaft gear section and the cylinder cover axial diameter section 3 3 2 Fix the camshaft slave g...

Page 55: ...head end surface after pressing 1 1mm 3 7 Smear engine oil on the oil seal installation port of cylinder head camshaft oil seal edge of blade and outside ring use M10 bolt length 50 60 mm and SST pre...

Page 56: ...Cover the cylinder head with cylinder head cover tighten the bolts according the right figure Torque 6 1N m 4 Routine check 4 1 Standard of valve clearance 4 2 Align the timing marks on the drive gear...

Page 57: ...e exceed the standard upwards and gap of valve lifter towards inside 4 4 2 Rotate camshaft and the cam press valve lifter down 4 4 3 Load the special tool at the top of the valve lifter around the val...

Page 58: ...ness Shown as the illustration 4 4 3 4 Use the selected adjusting gasket to adjust the throttle clearance Attention Install the feeler with the identification mark facing downwards 4 4 3 5 Rotate cams...

Page 59: ...agram 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...

Page 60: ...ng locking block throttle spring stand valve spring IN valve and EX valve 2 6 Removal of valve oil seal and valve spring washer 2 7 Clearing 1 The accumulated carbon residue covered on the valve must...

Page 61: ...rod 3 3 2 1 Use a dial gauge to measure the inner diameter of the throttle guiding pipe and use a caliper to measure the outer diameter 3 3 2 2 Work out the differences of the measured values If it is...

Page 62: ...e right figure Attention In the process of driving in the guiding pipe into the cylinder cover the operation should be carried out slowly until the pipe gets to the proper position No excessive drivin...

Page 63: ...twards 3 3 4 6 Use polishing agent to grind and polish the throttle sealing 3 4 Assemble of cylinder head 3 4 1 Cylinder head Pay attention to the following instructions in the process of assembling f...

Page 64: ...paintings on the valve spring valve spring of same engine should have the same identification paint marking 3 4 3 3 Install the locking blocks for the valve spring stands Warning Protective eye glasse...

Page 65: ...s to be carried out in 2 3 operations till the torque meets the specifications The torque for the first tightening operation is 30 2N m the torque for the second tightening operation is 50 3N m and th...

Page 66: ...bolts and dismount the water pump principal body 2 3 Removal of the dustproof sealing stripe 3 Clearing 3 1 Clearing of the mating surface of the water pump 4 Routine checks 4 1 Check to see if there...

Page 67: ...g procedures Oil pan tighten bolt 8 2 Nm Oil strainer Oil collector gasket Oil pump Oil pump gasket Rear oil seal bracket 2 Dismounting 2 1 The engine being turned upside down on the dismounting frame...

Page 68: ...mp 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: ...valve spring8 Relief valve9 Crankshaft front oil sealing10 Oil pump body 4 2 Disintegration 4 2 1 Weather seal Attention The weather seal are not reusable 4 2 2 Remove the oil pump cover Attention Th...

Page 70: ...pressure relief valve 4 2 6 Removal of the front oil seal of the crankshaft Attention The removed oil seals are not reusable 4 3 Routine checks 4 3 1 Checks on lubricating oil pump spacing 4 3 1 1 Fo...

Page 71: ...no visible tears wears and scrapes on the pressure relief valve 4 4 Installation 4 4 1 After smearing lubricating oil on the lips of the new T shaped oil seals use SST to make the assembly Attention U...

Page 72: ...ting 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 Disintegrating and assembling of oil sea...

Page 73: ...ating oil on the new oil seal lip section 5 4 2 Install the oil seal shown as the right figure 6 Assembling 6 1 Assembling of the oil sealing stands Smear oil sealing silica on the oil sealing stands...

Page 74: ...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 3 4mm without any broken section Make the assem...

Page 75: ...ence 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 r...

Page 76: ...learance 2 2 1 Remove the bush cover Attention Parts and components of various cylinders should be placed in good order 2 2 2 Clean the bush and axle diameter 2 2 3 Place clearance gauge on the connec...

Page 77: ...ive sleeve to prevent from scraping the cylinder hoe and crankshaft connecting rod axle diameter Then knock the piston connecting rod out with the handle of a hammer Attention Put the parts and compon...

Page 78: ...ial clearance of the crankshaft tighten the bolts of bearing bush cover with specified torque Torque 70 3 5N m Attention Tighten the bolts of the crankshaft bearing cover in three times to the regulat...

Page 79: ...ton pin to take off the piston and the connecting rod by using SST 3 Clearing 15 3 1 Cylinder body Warning Wear eyeglasses during the clearing operation to protect your eyes 3 1 1 Use flat chisel to c...

Page 80: ...e Cylinder standard diameter 72 00 72 01mm 4 2 Piston 4 2 1 Check the clearance between the piston pinholes Use a caliper to measure the positions of the piston shown in the following figure with the...

Page 81: ...the rings 4 2 6 Check the clearance of piston ring ends 4 2 6 1 Put the piston ring i n the position which is 45 mm under the cylinder hole top surface in order to make the piston ring keep flattened...

Page 82: ...eeded to confirm the clearance of the replaced cylinder once again Datum 0 018 0 030 4 3 Crankshaft 4 3 1 Check the coaxiality of the main shaft diameter 4 3 1 1 Use the centimeter to measure the coax...

Page 83: ...ating oil to the piston pin use pressurizing device to assemble the piston and the connecting rod Attention Pay attention to the assembling direction when pressing in the piston pin The small bit of c...

Page 84: ...of the oil sink The bush lower installed in bearing cover must match thruster groove 5 3 4 Smear lubricating oil on the friction side opposite to the contact of the bush lower parts Install the parts...

Page 85: ...Make sure the frontward indication mark on the piston Should be frontward and assemble the piston connecting rod Ay with SST Attention The cylinder number on the piston connecting rod should be ident...

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Page 129: ...205 DEALER PRE DELIVERY INSPECTION...

Page 130: ...DITIONAL TERMS AND CONDITIONS OF SALE 1 PROMISE TO PAY By signing this contract Buyer agrees to pay Seller the TOTAL DUE 2 TIME OF ESSENCE Time is of the essence of this contract Sellers acceptance of...

Page 131: ...ssed by Seller s financial institution resulting from such returned check 5 ATTORNEYS FEES If it is necessary for Seller to take legal action to enforce any of Seller s rights under this contract Buye...

Page 132: ...208 entering into performing this contract...

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