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Joyner JNSZ650DLB, Owner'S Manual And Parts Manual, Page: 2 / 146

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Joyner JNSZ650DLB Owner'S Manual And Parts Manual Download Page 2

 

CONTENTS

 

WARRANTY POLICY

 ................................................................................................................................................. 5

 

OWNER’S MANUAL

 ................................................................................................................................................ 16

 

F

OREWORD

 ............................................................................................................................................................. 16

 

F

OREWORD ABOUT SAFETY

 .................................................................................................................................... 17

 

I

MPORTANT 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

 .............................................................................................................................  18

 

Drive within Your Limits

 ........................................................................................................................................ 18

 

Don’t Drink and drive

 ............................................................................................................................................ 18

 

Never run your Go- Vehical indoors.

 .................................................................................................................. 18

 

I

MPORTANT SAFETY INFORMATION

 .......................................................................................................................... 19

 

Keep away from moving parts of the Off Highway Recreational Vehicles

 .................................................... 19

 

Skidding or Sliding

 ................................................................................................................................................ 19

 

S

AFETY LABLES

 ....................................................................................................................................................... 19

 

A

RE YOU READY TO DRIVE

?

 .................................................................................................................................... 20

 

P

ROTECTIVE 

A

PPAREL

 ............................................................................................................................................ 21

 

A

DDITIONAL 

D

RIVING 

G

EAR

 .................................................................................................................................... 21

 

D

RIVE 

T

RAINING

 ...................................................................................................................................................... 21

 

Age Recommendation

 .......................................................................................................................................... 22

 

N

O 

A

LCOHOL OR 

D

RUGS

 ........................................................................................................................................ 22

 

I

S YOUR VEHICLE READY TO DRIVE

?

 ....................................................................................................................... 23

 

Pre-drive Inspection

 .............................................................................................................................................. 23

 

Engine Oil

 ............................................................................................................................................................... 23

 

Coolant

 .................................................................................................................................................................... 23

 

Fuel

 .......................................................................................................................................................................... 23

 

Tires

 ......................................................................................................................................................................... 23

 

Nuts & Bolts

 ............................................................................................................................................................ 23

 

P

RE

-

DRIVE 

I

NSPECTION

 .......................................................................................................................................... 23

 

Underbody & Exhaust System

 ............................................................................................................................ 23

 

Air Cleaner

 ............................................................................................................................................................. 23

 

Leaks, Loose Parts

 ............................................................................................................................................... 24

 

Lights

 ....................................................................................................................................................................... 24

 

Throttle

 .................................................................................................................................................................... 24

 

Brakes

 ..................................................................................................................................................................... 24

 

Engine Stop

 ............................................................................................................................................................ 24

 

Steering Wheel

 ...................................................................................................................................................... 24

 

Cable

 ....................................................................................................................................................................... 24

 

Tie rod

 ..................................................................................................................................................................... 24

 

S

AFE DRIVING PRECAUTIONS

 .................................................................................................................................. 24

 

Off-road use only

 ................................................................................................................................................... 24

 

Summary of Contents for JNSZ650DLB

Page 1: ...ANT SAFETY MINIMUM RECOMMENDED OPERATOR AGE JNSZ650DLB 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 safet...

Page 2: ...p away from moving parts of the Off Highway Recreational Vehicles 19 Skidding or Sliding 19 SAFETY LABLES 19 ARE YOU READY TO DRIVE 20 PROTECTIVE APPAREL 21 ADDITIONAL DRIVING GEAR 21 DRIVE TRAINING 2...

Page 3: ...Check transmission oil 36 Engine Coolant 36 Spark Plug 38 Carburetor Adjustment 38 Cleaning Instructions 39 Vehicles Lubrication 39 Storage Instruction 40 REPAIR 41 Front Wheel Replacement 41 Rear Wh...

Page 4: ...FRONT HOUSING 98 MUFFLER 100 FUEL TANK AND GASOLINE PUMP 102 REAR CARGO RACK AND ROLL BAR 104 REAR HOUSING 106 RADIATOR AND AIR CLEANER 108 ELECTRIC APPLIANCE 110 SEAT AND SAFETY BELT 112 OTHER PARTS...

Page 5: ...32 ATTACH REAR SHOCK ABSORBER AND REAR WHEEL 134 ATTACH REAR SHOCK ABSORBER AND REAR WHEEL 135 ATTACH REAR BUMPER BAR 136 ATTACH ROLL BAR 137 ATTACH RADIATOR AND COVER 138 ATTACH MUFFLER 139 ATTACH SE...

Page 6: ...Warranty policy...

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Page 17: ...serious injuries Be sure to follow the recommended maintenance schedule and service your Off Highway Recreational Vehicle accordingly Preventative maintenance is extremely important to the longevity o...

Page 18: ...cle You must use your own good judgment You will find important safety information in a variety of forms including Safety labels On the Vehicles Safety Messages Preceded by a safety alert symbol and o...

Page 19: ...with how this Off Highway Recreational Vehicles works and handles Practice in a safe area until you build your skills and get accustomed to this Off Highway Recreational Vehicles s size and weight Be...

Page 20: ...ctor affecting turns Skidding a turn is more likely to occur on slippery surfaces such as snow ice mud and loose gravel If you skid on ice you may lose all directional control To avoid skidding on sli...

Page 21: ...dy 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 you...

Page 22: ...bly and securely An open face helmet offers some protection but a full face helmet offers more Regardless of the style look for a DOT Department of Transportation sticker in any helmet you buy Always...

Page 23: ...that is not recommended for his her age could lose Off Highway Recreational Vehicles control and result in severe injury or death A child under 16 should have adult supervision when operate on the Of...

Page 24: ...drive inspection before every drive and correct any problems Pre drive Inspection Check the following items before you get on the Off Highway Recreational Vehicles Engine Oil Check the level and add o...

Page 25: ...witch key counterclockwise Make sure engine stops Steering Wheel Check that the wheels turn properly as you turn the steering wheel Cable Check the cable housing for wear Check the fittings are tight...

Page 26: ...in your balance and control of the Off Highway Recreational Vehicles Removing hands or feet away from the controls can reduce your ability to react and control the vehical Removing hand from Steering...

Page 27: ...f Highway Recreational Vehicles and other off road vehicles Always exercise caution and use extra care on rough slippery and loose terrain Failure to use extra care when operating on excessively rough...

Page 28: ...Reverse Spark Plug F6T or F6TC Plug gap 0 7 0 1mm Fuel type RQ93 unleaded Lubricate oil SAE 15W 30 CAPACITIES Maximum load 200kg Fuel tank 23 0L Engine oil 2900ml Coolant 4000ml Starting 5s Climbing...

Page 29: ...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 corr...

Page 30: ...s 5 Push the choke back fully If the idle of engine is not smooth pull out the choke to find the best running position and keep running for a while long until the engine runs smooth without choke If t...

Page 31: ...to the starter motor If the engine does not start after 10 seconds a second attempt to start the engine can be allowed Improper operation will damage the engine Engine stop key Stop key test Before d...

Page 32: ...and has a smooth operation Ensure the clutch can operate smoothly Adjust if necessary or replace the clutch if necessary See Figure 4 6 Check Tires Check tires condition and pressure The pressure on b...

Page 33: ...re 4 13 Check Wheels Check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins See Figure 4 14 Check Steering Check for free operation and for any unusual loosene...

Page 34: ...tempting to adjust the seat ensure that engine of Off Highway Recreational Vehicles is stopped Parking Park brake OFF Park brake On a Pull the park brake lever up so that the unit can engage park brak...

Page 35: ...lowly 3 Avoid braking strongly 4 Do not exceed the vehicle speed on the below schedule The speed of vehicle The first 1000 km Max speed in each gear 1st Gear 15 km h 2nd Gear 25km h 3rd Gear 40 km h 4...

Page 36: ...al liquid or replace them with a new one See Figure 15 Engine oil replacement You must change the oil in the crankcase refer to preventative maintenance and service log That will insure proper lubrica...

Page 37: ...plate under the transmission oil outlet Loosen the oil outlet plug in the warm engine Let the transmission oil out fully see Figure 20 c Remove the iron dust plug this plug has a magnet on it Iron du...

Page 38: ...rve coolant If the coolant in the reserve tank is less than 2 5 it needs to be topped up Opening the radiator cap while the engine is hot can be hazardous Opening the radiator cap can spray the high t...

Page 39: ...re 24 c It is advisable to replace the spark plug at least once a year to insure easy starting and good engine performance Carburetor Adjustment Never make unnecessary adjustments The factory recommen...

Page 40: ...m around controls Wipe off any spilled fuel and oil Keep the engine clean of foreign object and be sure to check that air intake fan is free of debris for proper cooling Vehicles Lubrication Lubricate...

Page 41: ...icate 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...

Page 42: ...en the nuts after replacing the wheels Castle nuts Torque 180 5 N M Wheel nuts Torque 70 5 N M Rear Wheel Replacement Do not disassemble the center castle nuts when you replace the rear wheels See Fig...

Page 43: ...fler wires and rubber cushion that is in the middle of transmission and frame 1 Remove bolt M14 See Figure 28 Figure 28 2 Remove two bolts M12 on the starter See Figure 30 Remove the starter See Figur...

Page 44: ...ure 33 Figure 34 Figure 34 2 Remove the lower mud plate See Figure 35 Figure 35 3 Remove the transmission See Figure 36 Figure 37 4 Remove upper mud plate See Figure 38 Bolt M8 Oil pan Bolt M8 Oil pan...

Page 45: ...on the pressing plate of clutch See Figure 39 Figure 40 6 Remove the pressure plate See Figure 42 Remove the friction disc of clutch See Figure 41 Figure 43 Figure 42 Upper mud plate Aligning shaft A...

Page 46: ...ix pressure plate of clutch Two bolts with Y G mark must be inserted into two anchor holes Tighten six bolts with torque 30 N m See Figure 46 Figure 47 Figure 47 12 Fix upper mud plate See Figure 48 F...

Page 47: ...ng shaft sprocket make sure the mark on the balancing shaft sprocket aligned to the mark made at the beginning of this step 3 Make a mark about 30mm above the bolt as the Figure 52 and turn the right...

Page 48: ...Figure 50 Figure 51 Camshaft timing sprocket wheel Mark Right balancing shaft sprocket Left balancing shaft sprocket Crank shaft Mark here Left balancing shaft sprocket Mark...

Page 49: ...52 Water pump disassembly 1 Take off fan belt and loosen 4 bolt tightening water pump pulley Figure 53 Left balancing shaft sprocket Mark Make a Mark 30mm above the bolt 30mm Fan belt Water pump pulle...

Page 50: ...he Figure 54 Figure 54 3 Loosen the clamp bolts shown as Figure 55 and disconnect two peace of water pipe and take off the water pump The engine without water pump is shown as Figure 55 Figure 55 Bolt...

Page 51: ...stributor 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 59 Figure 58 Figure 5...

Page 52: ...ion shown by Fig Repeat 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...

Page 53: ...slowly to the hole See Figure 64 Confirm the direction of distributor is as per the figure See Figure 65 Figure 66 Tighten the nut of distributor housing Figure 64 Figure 66 7 Fix the cover of the di...

Page 54: ...e nut of the distributor housing b Turn the distributor slowly Increase the spark timing by counterclockwise turn Decrease the spark timing by clockwise turn A Gear shift 1 Install thick pivot plate a...

Page 55: ...Install thin pivot plate and long crank see Figure 72 Figure 73 Figure 72 Figure 73 Thick pivot plate Shifter shaft Shifter shaft Short crank Shifter shaft Short crank Nut Washer Spring washer Step 1...

Page 56: ...centerline CL of the wheels The proper toe in dimension A should be 1 18 inches greater than dimension B c To adjust the alignments loose the lock nuts on both sides of Front Tie Rods To make Dimensi...

Page 57: ...Figure 75...

Page 58: ...5 80 80 5 4 4 B R 301 SB 121 RS GB 130 YG 127 RS SB B 133 G 131 Y 132 DJ221 4 DJ7022 6 3 11 82 C RB 215 B 50 150 100 300 BR B BR B DJ7021 1 5 11 DJ7021 1 5 11 150 204 NB 111 4 horn button 900 250 200...

Page 59: ...Wire s coloursymbol 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 gree...

Page 60: ...Parts manual CYLINDER BLOCK PART...

Page 61: ...g of balancing shaft 2 12 02 DLJ 270Q 02011 270Q 02011 Rear bearing of balancing shaft 2 13 02 DLJ QTB54 8 9 QTB54 8 9 Calathiform plug 8 9 1 14 02 DLJ 270Q 02102 270Q 02102 Main bearing cap bolt 6 15...

Page 62: ...01 276Q 02201 Sprocket cover 1 2 02 DLJ 270Q 02202 270Q 02202 Oil filter threaded sleeve 1 3 02 DLJ 900 M8X22 900 M8X22 Taper bolt AGM8 M8 22 8 8 1 4 02 DLJ QTB23 NTP1 4 QTB23 NTP1 4 Hexagon headed ta...

Page 63: ...50 8 Crankshaft front oil seal with unidirectional flow around FB35 50 8 1 13 02 DLJ QTB10 M8 78 QTB10 M8 78 Hexagon headed bolt with edge M8 78 3 14 02 DLJ 270 02005A 270 02005A Oil Pan gasket 1 15...

Page 64: ...782 M8X40 Bolt M8 40 2 2 02 DLJ 270Q 01009 270Q 01009 washer of cylinder head cover bolt 2 3 02 DLJ 270Q 01011 270Q 01011 Rubber pad of cylinder head cover bolt 2 4 02 DLJ 276Q 01300 276Q 01300 Cylind...

Page 65: ...02 DLJ 270Q 01105 270Q 01105 Exhaust valve guide 2 23 02 DLJ 899 B 899 B bolt 1 24 02 DLJ 270Q 01023A 270Q 01023A Hexagon headed taper plug 1 25 02 DLJ 898 M8X20 898 M8X20 Stud AGM8 M8 20 8 8 4 26 02...

Page 66: ...LJ 270Q 03006 270Q 03006 Connecting rod bearing 4 3 02 DLJ 276Q 03001 276Q 03001 Piston 2 02 DLJ 276Q 03004B 276Q 03004B Piston Pin 2 4 02 DLJ 270Q 03100 270Q 03100 Connecting rod assembly 1 2 Connect...

Page 67: ...04A Driven bevel gear 1 12 02 DLJ QTB44 4X19 QTB44 4X19 Woodruff key4 19 2 13 02 DLJ 276Q 04006B 276Q 04006B Crankshaft 1 14 02 DLJ LJ462Q1 1000135D LJ462Q1 1000135D Locating pin of fly wheel 1 15 02...

Page 68: ...h edge M6 10 4 5 02 DLJ 270Q 04301 270Q 04301 Baffle plate of Balancing shaft 2 6 02 DLJ 270Q 04302A 270Q 04302A Balancing shaft 2 7 02 DLJ 270Q 04303 270Q 04303 Front balancing weight 2 8 02 DLJ 270Q...

Page 69: ...edge M12 1 25 30 1 6 02 DLJ 270Q 05002A 270Q 05002A Camshaft timing sprocket wheel 1 7 02 DLJ 270Q 05100 270Q 05100 Timing chain assembly 1 8 02 DLJ 270Q 01502 270Q 01502 Valve clearance adjusting nu...

Page 70: ...Q 01610 Valve rocker arm of second cylinder 2 21 02 DLJ 270Q 01006 270Q 01006 Exhaust Valve 2 22 02 DLJ QTB13 M8 32 QTB13 M8 32 Small hexagon headed bolt with edge M8 32 1 23 02 DLJ 270Q 05003 270Q 05...

Page 71: ...06000 LJ276MT 2 06000 Intake mainfold 1 3 02 DLJ 898 M8X25 898 M8X25 Stud AC M8 25 8 8 4 4 02 DLJ 848 M8X28 848 M8X28 Stud AC M8 28 8 8 1 5 02 DLJ QTB77 QTB77 Flat washer 6 6 02 DLJ 93 SW 8 93 SW 8 Sp...

Page 72: ...Code name Description Q ty 1 02 DLJ 270Q 17000 270Q 17000 Oil Filter 1 2 02 DLJ 9074 17 M6X48 9074 17 M6X48 Bolt assembly M6 48 2 3 02 DLJ LJ276MT 2 16000 LJ276MT 2 16000 Oil pump 1 4 02 DLJ 9074 17 M...

Page 73: ...200 Fan assembly 1 8 02 DLJ QTB93A AV10X845 QTB93A AV10X845 Fan belt AV10 845 1 9 02 DLJ QTB10 M8 23 QTB10 M8 23 Hexagon headed bolt with edge M8 23 2 10 02 DLJ 270Q 19002B 270Q 19002B bolt 1 11 02 DL...

Page 74: ...Q 60000 Rotor 1 3 02 DLJ 7825 SP 7825 SP Spark plug 2 4 02 DLJ FDQ 1 50000 FDQ 1 50000 Distributor cap assembly 1 5 02 DLJ 270Q 23901 270Q 23901 Distributor protective cover 1 6 02 DLJ LJ276MT 2 23501...

Page 75: ...e Code name Description Q ty 1 02 DLJ 270Q 06004 270Q 06004 Carburetor gasket 2 2 02 DLJ 270Q 06003 270Q 06003 Carburetor insulator 1 3 02 DLJ 276Q 13000 276Q 13000 Carburetor 1 4 02 DLJ JB12D H JB12D...

Page 76: ...07100F Air filter housing 1 2 02 DLJ QK1706 03 QK1706 03 Flexible hose clamp 2 3 02 DLJ LJ276MT 2 07001F LJ276MT 2 07001F Flexible intake hose 1 4 02 DLJ LJ276MT 2 07002F LJ276MT 2 07002F Rubber breat...

Page 77: ...W8 Spring washer 8 1 5 02 DLJ 270Q 02203A 270Q 02203A Adjusting bolt 1 6 02 DLJ 9074 15 M8X25 9074 15 M8X25 Bolt M8 25 1 7 02 DLJ QTB30 24 8 5 3 QTB30 24 8 5 3 Thick washer 24 8 5 3 1 8 02 DLJ 270Q 25...

Page 78: ...6 AM6X40 Bolt AM6 40 1 5 02 DLJ GB5790 86 AM8X50 GB5790 86 AM8X50 Bolt AM8 50 10 6 02 DLJ GB5790 86 AM8X70 GB5790 86 AM8X7 Bolt AM8 70 5 7 02 DLJ GB5790 86 AM8X90 GB5790 86 AM8X90 Bolt AM8 90 1 8 02 D...

Page 79: ...23 MQC4 1701023 Perkins joint 1 21 02 DLJ MQC4 1701027 MQC4 1701027 Breathing pipe plug 1 22 02 DLJ MQC4 1701024 MQC4 1701024 Line fastener 1 23 02 DLJ 4T06 3729010 4T06 3729010 Reverse switch 1 24 02...

Page 80: ...1 6 02 DLJ MQC4 1701510 MQC4 1701510 Clutch release bearing 1 7 02 DLJ MQC4 1701501 MQC4 1701501 Release bearing carrier 1 8 02 DLJ MQC4 1701022 MQC4 1701022 Circlip 2 9 02 DLJ MQC4 1701040 MQC4 17010...

Page 81: ...asher 0 2 6 2 02 DLJ MQC4 2303013 MQC4 2303013 Half axle adjusting washer 0 2 6 3 02 DLJ MQC4 2303014 MQC4 2303014 Half axle adjusting washer 0 2 7 02 DLJ MQC4 2303011 MQC4 2303011 Differential case 1...

Page 82: ...Differential 2 4 02 DLJ GB T276 94 6207 Z P63 GB T276 1994 Endocentric ball bearing 6207Z P63 2 5 02 DLJ 4T06C 2303013 4T06C 2303013 Bushing ring 1 1 6 02 DLJ 4T06C 2303012 4T06C 2303012 Output shaft...

Page 83: ...7 02 DLJ 4T06 1701201 4T06 1701201 Countershaft 1 8 02 DLJ MQC4 1701250 MQC4 1701250 Cylindrical roller bearing with locking notch and without inner circle 1 9 02 DLJ MQC4 1701013 MQC4 1701013 Thrust...

Page 84: ...Low synchronizer sleeve 1 33 02 DLJ MQC4 1701215 MQC4 1701215 Low synchronizer ring left 1 34 02 DLJ MQC4 1701217 MQC4 1701217 Low synchronizer ring spring left 1 35 02 DLJ MQC4 1701216 MQC4 1701216 L...

Page 85: ...MQC4 1702060 MQC4 1702060 Shift fork assembly of reverse gear 1 7 02 DLJ GB5783 86 M10 1 25 33 4h GB5783 86 Bolt M10 1 25 35 1 8 02 DLJ MQC4 1702019 MQC4 1702019 Shift fork washer of reverse gear 1 9...

Page 86: ...g spring of transposition shaft 1 27 02 DLJ MQC4 1702025 MQC4 1702025 Short spring of transposition shaft 1 28 02 DLJ 4T06C 1702070 4T06C 1702070 Shift shaft assembly 1 29 02 DLJ MQC4 1702028 MQC4 170...

Page 87: ...02 N650 04 05 0001 N650 04 05 00 01 hoop 65 82 1 3 03 01 5787 M6x30 05 5787 86 M6x30 Flange Bolt M6x30 1 4 02 N650 04 05 02 N650 04 05 02 00 Air filter joint 1 5 02 N650 04 05 03 N650 04 05 03 00 Air...

Page 88: ...Frame 24 23 25 20 21 22 1 2 3 4 5 6 7 8 9 10 12 11 13 15 14 16 17 18 19...

Page 89: ...Self locking nut M6 10 11 03 01 D818 M6X16 D818 M6X16 Cross head screw M6 16 11 12 02 JD 0900008 02 JD 0900008 Washer 6 11 13 03 02 6183 1 M6 05 6183 1 M6 Self locking nut M6 11 14 03 01 D818 M6X16 D8...

Page 90: ...01 D650 04 01 00 01 engine rubber bumper 5 7 03 02 2842 M10X1 25 05 2842 M10X1 25 bolt washer M10 1 25 12 8 02 D650 04 01 01 D650 04 01 01 00 engine LJ276M 1 9 02 D650 04 01 03 D650 04 01 03 00 engine...

Page 91: ...6X12 05 5787 M6X12 bolt washer M6 12 4 7 02 650 05 02 02 02 D650 05 02 02 02 shift gear handgrip bush 2 8 02 D650 05 02 02 01 D650 05 02 02 01 shift gear handgrip screw axle 1 9 03 04 93 6 05 93 6 spr...

Page 92: ...nk 1 22 03 03 95 10X18X1 5 05 95 10X18X1 5 washer c10 c10 5 c18 c1 6 2 23 03 04 93 10 05 93 10 spring washer c10 2 24 03 02 SJ2842 M10X1 25 05 SJ2842 M10X1 25 nut washer M10 1 25 2 25 02 D650 05 02 01...

Page 93: ...t 6 5 02 TR1100 05 01 TR1100 05 01 00 00 steering wheel subassembly 1 6 03 07 819 1 M6X10 05 819 1 M6X10 bolt M6 10 1 7 03 04 93 6 05 93 6 spring washer c6 1 8 02 N650 06 00 18 N650 06 00 18 00 integr...

Page 94: ...5 6170 M12X1 5 nut M12 1 5 2 22 02 D650 05 01 03 D650 05 01 03 00 steering gear box 1 23 02 D650 05 01 0006 D650 05 01 00 06 big iron cushion 1 24 02 D650 05 01 0005 D650 05 01 00 05 small iron cushio...

Page 95: ...ZJ609 F02 01 hydraulic threeway valve 1 7 02 TR1100 07 01 01 02 TR1100 07 01 01 02 clip 8 8 02 DLJ ZJGS 01 02 ZJGS 01 02 Hose bolt M10x1 25 10 9 02 DLJ ZJGS 01 01 ZJGS 01 01 Seal washer 20 10 02 D650...

Page 96: ...02 D650 07 02 03 02 single hydraulic oil cup 1 3 02 D650 07 02 03 03 D650 07 02 03 03 single hydraulic pump 1 4 02 D650 07 02 03 04 D650 07 02 03 04 pipe 1 5 02 D650 07 01 01 10 D650 07 01 01 10 hydr...

Page 97: ...18 16 17 24 11 12 14 14 15 14 28 34 11 23 22 21 20 19 18 12 13 11 9 10 37 39 27 40 8 2 1 1 1 1 3 4 5 6 7 16 12 No ERP code Code name Description Q t y 1 03 01 5787 M8X20 05 5787 M8X20 Flange bolt M8...

Page 98: ...60 05 882 10X60 10 60 pin roll 2 20 03 08 91 2X25 05 91 2X25 cotter pin 2 25 1 21 03 03 95 6X13X1 5 05 95 6X13X1 5 6 washer 1 22 02 D650 07 01 02 D650 07 01 02 00 brake pedal 1 23 03 07 882 6X40 05 88...

Page 99: ...0 03 01 00 02 M12 1 5 wheel nut 8 2 02 S650 03 01 01A S650 03 01 01 00A left wheel 27 8 12 1 3 03 08 91 4X40 05 91 4X40 cotter pin 4 40 2 4 03 02 9457 M18X1 5 05 9457 M18X1 5 nut castle M18 1 5 front...

Page 100: ...X1 5 05 SJ2842 M12X1 5 flange nut M12 1 5 4 25 02 D650 02 01 03 D650 02 01 03 00 FL upper suspension arm 1 26 03 02 SJ2842 M10X1 25 05 SJ2842 M10X1 25 flange nut M10 1 25 8 27 02 D650 02 01 0001 D650...

Page 101: ...4 5 03 02 6172 1 M8 05 6172 1 M8 nut M8 m 6 8 4 6 02 D650 04 04 0004 D650 04 04 00 04 sheet of heat insulation 65 65 1 7 03 02 6183 1 M8 05 6183 1 M8 nut self lock M8 2 8 02 D650 04 04 0009 D650 04 04...

Page 102: ...r rubber cover 2 17 02 JD 1910002 JD1910002 spacer 2 18 03 03 96 8X24X2 05 96 8X24X2 washer 8 8 4 24 2 2 19 02 D650 04 04 03 D650 04 04 03 00 muffer bracket 1 20 03 02 6183 1 M8 05 6183 1 M8 self lock...

Page 103: ...01 00B fuel tank 1 3 02 SR2000 04 03 000 3A SR2000 04 03 00 03 A fuel tank cap 1 4 02 SR2000 04 03 03 SR2000 04 03 03 00 fuel level sensor 1 5 02 SR2000 04 03 03 01 SR2000 04 03 03 01 rubber washer 1...

Page 104: ...06 01 TR1100 04 06 01 00 carbon canister 1 20 02 FTCARB 0409 FTCARB 0409 fuel hose 4 5x 9 CARB 0 5mete r 21 02 D650 04 06 0001 D650 04 06 00 01 carbon can bracket 1 22 02 D650 04 06 0002 D650 04 06 00...

Page 105: ...washer M12 1 5 30 2 3 02 D650 01 02 02B D650 01 02 02 00B right roll bar 1 4 03 01 5787 M10X1 25X45 05 5787 M10X1 25X45 bolt washer M10 1 25 45 4 5 02 D650 01 02 04 D650 01 02 04 00 rear cross bar 1...

Page 106: ...0 04 hoop 10 16 7 19 02 D250 09004 D25009004 radiator connecting tube 1meter 20 03 01 5787 M6X16 05 5787 M6X16 bolt washer M6 16 1 21 02 D650 04 07 0003 D650 04 07 00 03 oil separator cover 1 22 02 D6...

Page 107: ...9 17 15 16 26 27 29 33 32 31 30 27 26 27 28 26 22 23 19 18 17 16 15 8 7 6 10 37 35 8 7 34 5 4 3 2 1 20 14 25 40 38 42 41 43 46 45 39 42 40 38 24 41 42 40 44 43 39 45 40 12 13 11 21 23 22 12 13 11 No E...

Page 108: ...D650 03 02 00 01 shaft carrier 2 19 03 02 SJ2842 M10X1 25 05 SJ2842 M10X1 25 Nut washer M10 1 25 4 20 03 01 5787 M8X20 05 5787 M8X20 bolt washer M8 20 4 21 02 D650 02 02 03 D650 02 02 03 00 RL upper s...

Page 109: ...D650 04 03 0004 D650 04 03 00 04 hoop 10 16 2 2 02 D250 09004 D25009004 overflow bottle hose 1 3 02 D650 04 02 0001 D650 04 02 00 01 engine water outlet hose 1 4 02 D650 04 02 0003 D650 04 02 00 03 h...

Page 110: ...5 5787 M6x25 bolt washer M6 25 2 20 03 01 5787 M6X40 05 5787 M6x40 bolt washer M6 40 1 21 03 02 6183 1 M6 05 6183 1 M6 self locking nut M6 1 22 02 N650 04 05 02 N650 04 05 02 00 air cleaner bracket 1...

Page 111: ...Electric appliance 26 30 29 28 27 16 2 2 14 8 7 15 4 1 1 3 22 23 24 20 21 12 19 5 6 18 11 11 25 13 32 31 9 10 12 17...

Page 112: ...1A D650 06 00 11 00A regulator 1 15 02 D650 06 00 09 D650 06 00 09 00 horn 1 16 02 D650 06 00 01B D650 06 00 01 00B harness 1 17 02 D650 06 00 01 01 D650 06 00 01 01 relay box 1 18 02 N650 06 06 N650...

Page 113: ...ty belt 2 2 02 D650 08 01 0013 D650 08 01 00 13 safty belt tube 4 3 02 D650 08 01 03 D650 08 01 03 00 left seat 1 4 02 D650 08 01 04 D650 08 01 04 00 right seat 1 5 02 D650 08 01 03 01 D650 08 01 03 0...

Page 114: ...er parts NO ERP Code Part No Part Description Qty 1 02 D650 08 05 0008 D650 08 05 00 08 spark plug wrench 1 2 02 DLJ 270Q 23800 270Q 23800 spark plug 2 3 02 DLJ 270Q 40002 270Q 40002 Oil Filter wrench...

Page 115: ...code Code name Description Q ty 1 02 D650 01 02 10 D650 01 02 10 00 front rack 1 2 03 01 5787 M8X25 05 5787 M8X25 bolt washer M8X25 4 3 03 02 6183 1 M8 05 6183 1 M8 nut M8 4 4 02 D650 10 0800 D650 10...

Page 116: ...r rack option 1 2 3 No Code name Code name Description Q ty 1 02 D650 08 01 01B D650 08 01 01 00B rear rack 1 2 03 02 2842 M8 05 2842 M8 nut M8 4 3 02 D650 10 0900 D650 10 09 00 00 rear rack OPTION 1s...

Page 117: ...ock roof rack 1 2 02 D650 01 02 15 D650 01 02 15 00 paddock roof rack plate1 A1 1 3 03 01 D818 M6X35 D818 M6X35 bolt M6x35 5 4 02 JD 0900008 JD 0900008 washer 5 5 03 02 6183 1 M6 05 6183 1 M6 05 nut M...

Page 118: ...ck 1 2 02 D650 01 02 16 D650 01 02 16 00 rifle roof rack plate2 A1 1 3 03 01 D818 M6X35 03 01 D818 M6X35 bolt M6x35 5 4 02 JD 0900008 02 JD 0900008 washer 5 5 03 02 6183 1 M6 05 03 02 6183 1 M6 05 nut...

Page 119: ...Q ty 1 02 SV1100 9999 02 SV1100 99 99 02 00 left nerf bar 1 2 02 SV1100 9999 03 SV1100 99 99 03 00 right nerf bar 1 3 03 01 5787 M10X35 05 5787 M10X35 bolt washer M10X35 8 4 03 02 SJ2842 M10 05 SJ284...

Page 120: ...650 08 01 05A D650 08 01 05 00A 3000B electrical winch 1 3 02 D650 08 01 05 01 D650 08 01 05 01 electrical winch switch 1 4 02 D650 08 01 0502 D650 08 01 05 02 electrical control case 1 5 03 01 5787 M...

Page 121: ...600 06 10A D1600 06 10 00 00A spotlight 3 2 02 D1600 06 10 0002 02 D1600 06 10 0002 spotlight bulb 3 3 03 03 95 10X20X1 5 05 95 10X20X1 5 washer 10X20X1 5 3 4 03 01 5787 M10 20 05 5787 M10 20 bolt was...

Page 122: ...3 4 No ERP Code Code name Description Q ty 1 02 JD 1500004 JD1500004 TOW BALL 50 1 2 03 04 93 18 05 93 18 spring washer 18 1 3 03 02 SJ2842 M18 05 SJ2842 M18 nut M18 1 4 02 D650 10 04 D650 10 04 00 0...

Page 123: ...safty belt tube option NO ERP Code Part No Part Description Qty 1 02 D650 08 01 0013 D650 08 01 00 13 safty belt tube 2...

Page 124: ...k absorber coat option NO ERP Code Part No Part Description Qty 1 02 D650 08 01 07 01 D650 08 01 07 01 Front shock absorber coat 2 2 02 D650 08 01 07 02 D650 08 01 07 02 Rear shock absorber coat 2 1 1...

Page 125: ...1 4 02 D650 08 05 0004 D650 08 05 00 04 Open jawed spanner 17 19 1 5 02 JD 1400004 JD1400004 Thread locking anaerobic adhesive 1 6 02 D650 08 05 0006 D650 08 05 00 06 Screwdriver 1 7 02 D650 08 05 000...

Page 126: ...rear upper 1 4 02 D650 08 01 02 04 D650 08 01 02 04 Protect jacket side front 2 5 02 D650 08 01 02 06 D650 08 01 02 06 Protect jacket side rear 2 6 02 D650 08 01 02 07 D650 08 01 02 07 Small Protect...

Page 127: ...Preparation attach instruction Remove packing...

Page 128: ...moving parts put 3 Lithium grease into the moving part if necessary 3 Jesus Tighten the bolts and nuts with thread glue Install the front suspension arm frame 1 1 Q ty 1 1 3 FR lower suspension arm 3...

Page 129: ...front shock absorber stub axle Attach...

Page 130: ...as wheel alignment is done before packing 3 Attach the wheel 27 8 12 FR 2 on the hub tighten the nuts 4 Attach the wheel 27 8 12 FL 3 as described above Attach tie rod end and front wheel Q ty Descri...

Page 131: ......

Page 132: ...nsert the bolt 5 Tighten the bolts and nuts with thread glue Note apply 3 Lithium grease to the move part of arm if necessary 3 Attach lower upper suspension arm LB as described above Description Q ty...

Page 133: ...if necessary 4 Insert other end of right proppeller shaft 2 into shaft carrier 1 5 Insert bolt into the hole of hub and upper arm Tighten the bolt and nut with thread glue 6 Attach lower arm to the h...

Page 134: ......

Page 135: ...r and rear wheel 1 Attach rear shock absorber 1 on the frame and lower suspension BR 2 Insert bolt into the hole of shock and lower suspension BR Tighten the bolt and nut with thread glue 3 Attach whe...

Page 136: ...Attach rear shock absorber and rear wheel...

Page 137: ...as figure 2 Tighten four bolts 2 with thread glue Attach rear bumper bar forward rear part of frame Description code name Q ty 1 1 D650 01 02 06 00 rear bumper bar 1 bolt M12 1 5 30 5787 M12X1 5X30 4...

Page 138: ...xing all roll bar Caution all bolts insert from outer of vehicle to inner cage mount welded frame 4 1 3 2 1 left roll bar front cross bar right roll bar rear cross bar 1 1 1 4 3 2 1 D650 01 02 01 00B...

Page 139: ...5787 1986 radiator 1 water inlet hose of engine 4 1 1 Attach radiator and cover 1 Attach the radiator as above figure tighten all bolts Note check all electrical plug connections are good Description...

Page 140: ...96 big washer 8 8 4 24 2 2 7 muffer bracket 1 D650 04 04 03 00 9 8 12 11 10 catalac convertor D650 04 04 04 00 D650 04 04 00 09 D650 04 04 02 00 cushion flange front exhaust pipe GB T6177 1 2000 self...

Page 141: ...Attach seats and safety belt...

Page 142: ...check vehical...

Page 143: ...DEALER PRE DELIVERY INSPECTION _______Jumping the vehicle can cause serious damage to the drive train axle...

Page 144: ...ch this form and all paperwork received _______I understand that I have only 72 hours to notify the seller of any issues to the paperwork or the vehicle _______Off Road use only Driving on paved roads...

Page 145: ...oduct where such failure or delay is due in whole or in part to any cause beyond Seller s control or without Seller s fault or negligence 9 RISK OF LOSS INSURANCE The risk of loss to the Vehicle or an...

Page 146: ...contract Seller may keep any cash deposit as liquidated damages to the extent not prohibited by law The deposit may also be used to reimburse Seller for any expenses and losses Seller incurs or suffe...

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