Joyner JNSZ650UV4S Owner'S Manual Download | Manualshive

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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

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Summary of Contents for JNSZ650UV4S

Page 1: ...Owner s manual JNSZ650UV4S ...

Page 2: ... the features and operation of this vehicle It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your vehicle please consult a JOYNER dealer Please read this manual carefully before operating this vehicle Do not attempt to operate this vehicle until you have attained adequate knowledge of its controls and operating feature...

Page 3: ...OU READY TO DRIVE 27 PROTECTIVE APPAREL 28 HELMETS AND EYES PROTECTION 28 DRIVE TRAINING 28 AGE RECOMMENDATION 29 NO ALCOHOL OR DRUGS 29 IS YOUR VEHICLE READY TO DRIVE 30 PRE DRIVE INSPECTION 30 SAFE DRIVING PRECAUTIONS 32 OFF ROAD USE ONLY 32 KEEP HANDS AND FEET ON CONTROLS 33 CONTROL SPEED 33 DO NOT PERFORM STUNTS 34 SPECIFICATIONS 35 OPERATION 38 OPERATION CONTROLS 38 BRAKE 39 CLUTCH 39 START E...

Page 4: ...49 CARBURETOR ADJUSTMENT 49 REPAIR 50 FRONT WHEEL REPLACEMENT 50 REAR WHEEL REPLACEMENT 50 CLUTCH REPLACEMENT 51 TIMING SETUP AND BALANCING SHAFT SETUP 55 WATER PUMP DISASSEMBLY 58 DISTRIBUTOR REPLACEMENT 61 FRONT WHEEL ALIGNMENT 65 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...

Page 5: ...5 Warranty policy ...

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Page 16: ... rollover JOYNER S650 09 04 00 01 2 WARNING Keep hands body other persons away when closing bed Do not operate the vehicle with bed up JOYNER S650 09 04 00 03 2 WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires cold RECOMMENDED FRONT 210kPa 2 1kg cm2 30psi REAR 210kPa 2 1kg cm2 30psi N...

Page 17: ...to use extra care when pulling trailer can cause an accident or injury Never load more than 50kg 110lbs tongue weight on the towing bracket Do not tow more than 550kg 1212lbs rolling weight trailer plus cargo Operate in low range gears only allow far increased braking distance and use extreme caution when operating on inclines Read carefully the loading information and trailer hitch sections in th...

Page 18: ...18 S650 09 04 00 11 3 JOYNER MAX LOAD JOYNER CHINA VIN NIV NW MANUFACTURER TYPE S650 09 04 00 12 1 JOYNER ...

Page 19: ...e on any paved surfaces including sidewalks driveways parking lots and streets 5 Never operate this vehicle on any public street road or highway even a dirt or gravel one 6 Never operate this vehicle without wearing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or a face shield gloves over the ankle boots long sleeved shirt or jacket and long pants 7 ...

Page 20: ...ight up and down hills where possible Maximum slope angle 15º 18 Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of you Never go over the top of a hill at speed if you cannot see what is on the other side 19 Always follow proper procedures for going uphill If you lose momentum and cannot continue up a hill back down the hill with the engine in re...

Page 21: ...his position ON 1 All electrical circuits are supplied with power except the ignition system and fuel system the headlights and taillights come on when the light switch is on ON 2 The ignition system and fuel system are supplied with power START The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts Do not operate the electric starter...

Page 22: ...chometer 11 button 12 button 2 The multi function meter unit is equipped with the following a speedometer which shows the riding speed an odometer which shows the total distance traveled a tachometer which shows the engine rotate speed a gasoline quantity meter which shows the current gasoline quantity a coolant thermometer which shows the coolant temperature an hour meter which shows the total ti...

Page 23: ...c locker can t work that changing from 2WD to 4WD when the vehicle is moving To change from 2WD to 4WD successfully you should try more times and then start the engine slowly back and forth You should try again if there is some nonnormal voice when the speed is about 20Km after changing from 2WD to 4WD Winch switch in out Set the switch to in to reel rope in Set the switch to out to reel rope out ...

Page 24: ...tion fully when released 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: ...ning counterclockwise Make sure the fuel tank cap can work well by turning clockwise Never add gasoline to the tank fully spilling out Keep the fuel tank cap clean Make sure the cover of the key hole being normal position after removing the key to prevent the impurity being in the hole Seats and Safety belts Seats The left seat can remove but the right can t To move a seat pull its seat lock lever...

Page 26: ... Push the latch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure 3 Put the lap portion of the belt low on your hips Push down on the buckle end of the belt as you pull up on the shoulder part so the belt is snug across your hips 4 Position the shoulder belt over your shoulder and across your chest The shoulder belt should fit against your chest If it is lo...

Page 27: ...properly distributed and securely attached Reduce speed when carrying cargo Allow greater distance for braking ARE YOU READY TO DRIVE Before each drive you need to make sure you and your UV650 4S 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 UV650 4S and adjustments to make for your comfort conveni...

Page 28: ...DOT Department of Transportation sticker in any helmet you buy Always wear a face shield or goggles to protect your eyes and help your vision Operating this UV650 4S without wearing an approved motorcycle helmet eye protection and protective clothing could increase your chances of head or eye injury possibly death in the event of severe accident Always wear approved motorcycle helmet that fits pro...

Page 29: ... when the vehicle will turn over Age Recommendation It is strongly recommended that no one under the age of 16 be permitted this UV650 4S without adult supervision A child driving a UV650 4S that is not recommended for his her age could lose UV650 4S control and result in severe injury or death A child under 16 should have adult supervision when operate on the UV650 4S No Alcohol or Drugs Alcohol ...

Page 30: ...ve inspection is a must not only for safety but because having a breakdown or even a flat tire can be a major inconvenience If your UV650 4S has overturned or has been involved in a collision do not drive it until your UV650 4S has been inspected by your dealer There may be damages or other problems you can not see Improperly maintaining this UV650 4S or failing to correct a problem before driving...

Page 31: ...he air filter Replace it if needed Leaks Loose Parts Walk around your UV650 4S and look for anything that appears unusual such as a leak or loose cable Lights Make sure the headlight brake light and tail light are working properly Throttle Check the free play and adjust if needed Press the throttle to make sure it moves smoothly without sticking and snaps back automatically when it is released Clu...

Page 32: ...0 4S on pavement Operating this UV650 4S on paved surfaces may seriously affect handling and control of the UV650 4S and may cause the vehicle to go out of control Never operate the UV650 4S on any paved surfaces including sidewalks driveways parking lots and streets When driving off road also remember to always obey local off road driving laws and regulations Obtain permission to drive on private...

Page 33: ...el and both feet on the foot controls When driving your UV650 4S It is important to maintain your balance and control of the UV650 4S Removing hands or feet away from the controls can reduce your ability to react and control the kart Always keep both hand on the steering wheel and both feet on the foot controls of your UV650 4S during operation Control Speed Driving at excessive speed increases th...

Page 34: ...y and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the UV650 4S Never drive past the limit of visibility Maintain a safe distance between your UV650 4S and other off road vehicles Always exercise caution and take extra care on rough slippery and loose terrain Failure to take extra care when operating on excessively rough slippe...

Page 35: ... Model JNSZ650UV4S Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius 2980mm 1435mm 1820mm 770mm 1980mm 280mm 4500mm Basic weight With oil and full fuel tank 700kg Engine Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Liquid cooled 4stroke Upstanding double cylinder 644cc 76mm 71mm 8 4 1 ...

Page 36: ...ment Dry element Fuel Type Fuel tank capacity Unleaded gasoline only 28L Carburetor Type P32Q 1 Spark plug Type manufacturer Spark plug gap T4196J 0 7 0 1mm Clutch type Dry digphragm spring Transmission Crank to primary shaft Primary to secondary Final Transmission type Operation 33 17 1 941 One 36 17 2 118 Two 29 22 1 318 Three 23 27 0 852 Reverse 33 15 2 2 One 4 111 Two 2 559 Three 1 654 Four 1 ...

Page 37: ... spring oil damper Wheel travel Front wheel travel Rear wheel travel 120mm 120mm Electrical Ignition system Generator system Battery type Battery capacity Distributor block AC magneto Lead acid storage battery 12V 45Ah Specified fuses Main fuse Headlight fuse Signaling system fuse 35A 20A 15A Bulb voltage wattage quantity Headlight Tail brake light 12V 35W 35W 2 12V 5W 21W 2 Indicator lights Rever...

Page 38: ...ols 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: ...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 Brake The brake is located on the middle of the three control pedals See Fig 3 Applying pressure to the pedal applies pressure to the brake caliper around the brake disc at the front and rear wheels an...

Page 40: ... in neutral 3 Insert the key into the main switch If the engine is cold do the following 1 Pull the choke out fully 2 Press down the clutch pedal 3 Turn the key clockwise to the on position Release the key and the clutch pedal when the engine starts 4 Push the choke back slowly to allow the engine to run smoothly Keep engine running for 1 2 minutes 5 Push the choke back fully If the idle of engine...

Page 41: ...ke 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 If the engine does not start after 5 seconds a second attempt to start the engine can be allowed Improper operation will...

Page 42: ... condition and pressure The pressure on both Front and Rear tire is 30pis 7 Check Throttle Check for smooth operation Ensure the throttle snaps back to idle 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 all other fasteners to specified torque ...

Page 43: ...tent seat and safety belt Pull seat adjustment handle upward to disengage seat slide Move seat to desired position Be sure seat adjustment handle snaps back into place and that seat is locked into position Before attempting to adjust the seat ensure that engine of the UV650 4S is stopped Never operate this UV650 4S when the provided seat is not securely fastened to do so could result in a strong p...

Page 44: ...explain proper break in procedures 1 After the engine starts the engine is not allowed in high speed in the neutral gearshift 2 Drive vehicle from stop to low speed slowly 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 15km h 2nd Gear 25km h 3rd Gear 35km h 4th Gear 55km h Starting and Operatin...

Page 45: ... a Remove cleaner cover by bolt b Remove air cleaner element 1 See Fig 9 c Check the paper filter if the filter is dusty please replace with a new one 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 hours of use thereafter That will insure proper lubrication of internal parts and prevent costly ...

Page 46: ...and recharge a If the color of engine oil changes you need to replace the engine oil Replace the engine oil as above b Check the engine oil level change if necessary from d as above Transmission lubrication You must change 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 an...

Page 47: ...refill coolant into the radiator approximately 4000 ml The lack of coolant will cause the engine to overheat This can cause engine damage The coolant should always be topped up since the coolant can evaporate Put the vehicle on level ground 1 Turn the coolant cap counterclockwise and open the cap 2 Pour fresh coolant to filler neck 3 Start the engine at idle 4 Increase the engine rev a few times 5...

Page 48: ...t may be dangerous for your health Keep new and used coolant away from the children and pets To minimize your exposure to new and used coolant wear a long sleeve shirt and moisture proof gloves such as dishwashing gloves when you change coolant If coolant contacts your skin wash thoroughly with soap and water Wash any clothing or rags if wet with coolant Recycle or properly dispose of used coolant...

Page 49: ...east once a year to insure easy starting and good engine performance Carburetor Adjustment Never make unnecessary adjustments The factory recommended settings 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 ...

Page 50: ... 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: ...le 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 Remove bolt M14 2 Remove two bolts M12 on the starter See Fig 23 Remove the starter ...

Page 52: ...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: ...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: ...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: ...ollowing figure 2 Make a mark between two holes as the Figure 2 and turn the left balancing 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 3 and turn the right balancing shaft sprocket make sure the mark on the balancing shaft sprocket aligned to the mark made at the begi...

Page 56: ...56 Camshaft timing sprocket wheel ...

Page 57: ...57 Figure 1 Figure 2 Mark Right balancing shaft sprocket Left balancing shaft sprocket Crank shaft Mark here Left balancing shaft sprocket Mark ...

Page 58: ... Figure 3 Water pump disassembly 1 Take off fan belt and loosen 4 bolt tightening water pump pulley Left balancing shaft sprocket Mark Make a Mark 30mm above the bolt 30mm Fan belt Water pump pulley Bolt ...

Page 59: ...sen the 6 bolts shown as the Figure 5 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 Bolts Bolts ...

Page 60: ...60 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 Clamp Bolts Water pipes ...

Page 61: ...x 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: ...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: ...mp 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 Tighten the nut of distributor housing ...

Page 64: ...istributor 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: ... the wheels The proper toe in dimension A should be 1 18 inches greater than dimension B d To adjust the 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 length tighten the lock nut against the rod end Recheck the dimensions for proper alignment ...

Page 66: ...se do the following 1 Change the oil of the front rear main reducer after 300Km for the first using of your vehicle It will insure proper lubrication of internal parts and prevent costly repairs due to excessive wear After first changing you need to change the oil per 1000Km There is the simple process of changing the oil a Please check where is the bolt 1 for venting the old oil PIC 01 or PIC 02 ...

Page 67: ...n 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 e The final screw the bolt 4 and washer 3 properly PIC 03 ...

Page 68: ...has breaken and change a new one b If the oil leaks out from the cover for or enter please dismantle the hex M6 then add some liquid sealant to the cover and screw the hex M6 with torque 17 25 c If the oil leak out from the leaking bolt please change a new washer then screw the bolt 4 Check the working situation If there is some nonnormal noise about the front rear main reducer maybe there are som...

Page 69: ...lfshaft is not broken else you must take the broken circlip out form the reducer For the rear main reducer it s simple that using a piece of magnet to adsorb the broken circlip For the front main reducer you must open the cover for out and take it out c 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 vehi...

Page 70: ...ignition I 10 Air cleaner C I 11 Throttle cable and choke I A L I R A 12 Fuel tank cover Breathe hose and joint I I R 13 Idle I 14 Breathe hose I 15 Fuel hose and joints I I I R Control system 16 Wire and plugs I 17 The free display of clutch pedal I I R 18 Brake fluid hose joints I 19 The free display of brake pedal Brake I I I I 20 Parking I 21 Brake shoes and disc I I R Chassis 22 Tires I R 23 ...

Page 71: ...ht switch Dipped beam switch ON t Thermometer Swich 82 o C Alternator 14V 35A reverse switch Oil sensor Start motor take the electromagnetism switch 12 Battery 12V35Ah Speed sensor Radiator fan Flasher Brakes light switch Horn Ignition switc h Distributor coil ign Horn button Fuse 35A Fuse 15A Fuse 20A Turning signal indication L Turning signal indication R oil warninig indication Turning signal b...

Page 72: ...50UV4S 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 This warranty does not cover any seller vehicle in any way so as to adversely affect its safety or reliability b Renting c Disassembly adjusting or repairing of the vehicle in any way...

Page 73: ...159 DEALER PRE DELIVERY INSPECTION ...

Page 74: ...be purchases from an outside source to protect my purchase and fulfill state requirements _______I have been shown the VIN number for each machine and they match 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 can cause axle or transmission damage Bo...

Page 75: ...ept deliver of the Vehicle or product or to comply with this contract Such expenses and losses may include Seller s reasonable attorney s fees 8 NON DELIVERY Seller is not liable for failure to deliver or for delay in delivering the Vehicle or other product 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 ...

Page 76: ... executed by Seller 7 CASH DEPOSIT If Buyer fails or refuses to accept delivery of any Vehicle or product or fails to comply with this 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 suffers as a result of Buyer s failure or refusal to accept delivery of...

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