Joyner JNSZ800DL Owner'S Manual Download

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Owner’s manual

Parts manual

READ THIS MANUAL CAREFULLY

IT CONTAINS IMPORTANT SAFETY INFORMATION.

MINIMUM
RECOMMENDED
OPERATOR AGE

JNSZ800DL

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

Summary of Contents for JNSZ800DL

Page 1: ...TYINFORMATION MINIMUM RECOMMENDED OPERATOR AGE JNSZ800DL 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 saf...

Page 2: ...Description Qty P T 1 3701010 ALTERNATOR 1 2 1000021D ARM GEN BELT ADJ 1 3 1000019D WASHER 6 4 1000102D BRACKET ALTERNATOR 1 5 GB5783 1986 BOLT M8x25 5 6 1000089D BOLT M8x30 2 7 1000089D BOLT M8x30 1...

Page 3: ...No Code name Description Qty 1 3706010 DISTRIBUTOR ASSY 1 2 3707011 WIRE A HIGH TENSION MID 1 3 3707012 WIRE A HIGH TENSION 3 4 1000076 CLAMP HT CORD 1 5 1000172 CIRCLE CLAMP HT CORD 1 IGNTION CABLE...

Page 4: ...3070 GASKET CYLINDER HEAD 1 5 1003051 COVER CYLINDER HEAD 1 6 1000061D GASKET BOLT 4 7 1000059D BOLT M6 68 4 8 1003064 GASKET COVER 1 9 1003052 CAP COMP OIL FILLER 1 10 GB7828 87 SPARK 3 11 1000038 CA...

Page 5: ...CARBURETTOR No Code name Description Qty P T 1 1107010 CARBURETTOR 1...

Page 6: ...OIL PUMP No Code name Description Qty P T 1 1011010D PUMP A OIL 1 2 1000051D GASKET OIL PUMP CASE 1 3 1000014D KNOCK PIN 1 4 1000083D BOLT M6 30 1 5 1000084D BOLT M6 35 5 6 1000085D BOLT M6 40 2...

Page 7: ...o Code name Description Qty P T 1 1009010 PAN OIL 1 2 GB5783 1986 BOLT M6 16 16 3 GB93 1987 LOCK WASHER 18 4 1010101 STRAINER OIL PUMP 1 5 1002031D O RING 1 6 GB93 1987 LOCK WASHER 2 7 GB5783 1986 BOL...

Page 8: ...08026 G MANIFOLD INTAKE 1 2 1000063 GASKET INTAKE MANIFOLD 1 3 1000162 BOLT 4 4 1000090D STUD BOLT M8 M8 22 5 5 1000093D STUD BOLT M8 M8 25 1 6 Q340B08 NUT 5 7 1000027 HOOK ENGINE 1 8 1107010 CARBURET...

Page 9: ...1 2 1000073D BOLT 2 3 1306010 THERMOSTAT WATER 1 4 1008031 GASKET CAP 1 5 1303013 PIPE WATER INLET 1 6 1000025D GASKET WATER INLET 1 7 1000081D BOLT 2 8 1000151 HOSE RADIATOR WATER EXHAUST 1 9 1000165...

Page 10: ...No Code name Description Qty 1 1600010 COVER ASSY CLUTCH 1 2 1602010 DISK CHUTCH 1 3 GB5783 1986 REAMER BOLT 8 20 4 4 GB93 1987 LOCK WASHER 4 CLUTCH...

Page 11: ...070 GASKET CYLINDER HEAD 1 4 1003064 GASKET COVER 1 5 1000063 GASKET INTAKE MANIFOLD 1 6 1000054 GASKET EXHAUST MANIFOLD 1 7 1000035D GASKET DISTRIBUTOR CASE 1 8 1002030D GASKET HOUSING 1 9 1000051D G...

Page 12: ...OIL PAN No Code name Description Qty 1 1008010 MANIFOLD EXHAUST 1 2 1000054 GASKET EXHAUST MANIFOLD 1 3 1000090D STUD BOLT 6 4 GB6170 1986 NUT 6...

Page 13: ...P T...

Page 14: ...NO CODE NAME Description QTY PT 1 3708010 STARTER 1 STARTER...

Page 15: ...n Qty 1 1106010 PUMP GASOLINE 1 2 1000037D GASKET GASOLINE PUMP 1 3 1000036D GASKET GASOLINE PUMP 2 4 1000166 BOLT 2 5 1000041 HOSE FILTER TO PUMP 1 6 1000034 HOSE PUMP TO CARBURETOR 1 7 1000075 HOSE...

Page 16: ...P T...

Page 17: ...EL No Code name Description Qty P T 18 1002020D HOUSING OIL SEAL 1 19 1000081D BOLT M6 20 4 20 1000082D BOLT M6 25 2 21 1000014D KNOCK PIN 2 22 1005011 FLYWHEEL 1 23 1005014D BOLT M10 1 16 5 6 24 1000...

Page 18: ...n Qty P T 1 1002010 BLOCK CYLINDER 1 2 1002027D PLATE CYLINDER BLOCK 1 3 1002028D CASKET PLATE 1 4 1000096D BOLT M6 10 4 5 1012031D STAND OIL FILTER 1 6 1012010D FILTER ASSY OIL 1 7 1000097 PLATE CLUT...

Page 19: ...ASSY WATER 1 2 1000052D GASKET WATER PUMP 1 3 1000092D STUD BOLT M6 M6 30 2 4 1000176 NUT 2 5 1000083D BOLT M6 30 2 6 1000085D BOLT M6 40 1 7 1000017D PULLET WATER PUMP 1 8 1000096D BOLT M6 10 4 9 10...

Page 20: ......

Page 21: ...ode name Description Qty 1 09283 32022 OIL SEAL CAM SHAFT 1 2 1006013 CAMESHAFT 1 3 1000129D PLATE CAMSHAFT THRUST 1 4 GB819 1985 SCREW M6 12 2 5 1007045 SHAFT ROCKER ARM 2 6 GB819 1985 SCREW M6 16 8...

Page 22: ...P T...

Page 23: ...NAME Description QTY PT 1 1022015 COVER INSIDE 1 2 1022018D GROMMET NO1 1 3 1022020D GROMMET NO2 2 4 1022013D BUSH M6 10 7 4 5 GB96 1995 WASHER M6 5 18 1 6 4 6 GB5783 1986 BOLT M6 20 4 7 1000019D WASH...

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Page 50: ...DL 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 su...

Page 51: ...SAFETY LABELS 7 5 ARE YOU READY TO DRIVE 8 6 IS YOUR VEHICLE READY TO DRIVE 10 7 SAFE DRIVING PRECAUTIONS 12 8 SPECIFICATIONS 14 9 OPERATIONS 15 10 SERVICE INSTRUCTIONS 20 11 REPAIR 24 12 ABOUT ENGIN...

Page 52: ...in serious injuries Be sure to follow the recommended maintenance schedule and service your kart accordingly Preventative maintenance is extremely important to the longevity of your ATV JOYNER believ...

Page 53: ...a ATV You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels On the ATV Safety Messages Preceded by a safety alert symbol and one...

Page 54: ...take time to become familiar with how this ATV works and handles Practice in a safe area until you build your skills and get accustomed to this ATV s size and weight Because many accidents involve in...

Page 55: ...Failure to adhere to this warning will cause physical harm to your body Skidding or Sliding The terrain surface can be a major factor affecting turns Skidding a turn is more likely to occur on slipper...

Page 56: ...nformation and recommendations to help you drive your ATV safely please take a few moments to read these pages The labels are considered permanent parts of the ATV If a label comes off or becomes hard...

Page 57: ...e helmet eye protection boots gloves long pants and long sleeved shirt or jacket whenever you drive Although complete protection is not possible wearing proper gear can reduce the chance of injury whe...

Page 58: ...d your skills Do not drive in rough terrain until you get accustomed to the ATV s controls and feel comfortable with its size and weight Operating ATV without proper instruction could increase your ri...

Page 59: ...e dangerous while operating a ATV Consult your doctor to be sure it is safe to operate a vehicle after taking medication Operating this ATV after consuming alcohol or drugs can seriously affect your j...

Page 60: ...n the ATV Engine Oil Check the level and add oil if needed Check for leaks Coolant Check the coolant and add coolant if need Check for the leaks Fuel Check the level and add fuel if needed Also make s...

Page 61: ...tically when it is released Brakes Press the brake pedal several times check for proper brake pedal free play Make sure there is no brake fluid leakage Engine Stop When engine is running turn the swit...

Page 62: ...ers of street vehicles may have difficulty seeing and avoiding you which could lead to a collision In many states it is illegal to operate ATVs on public streets roads and highways Operating this ATV...

Page 63: ...V overturning or going out of control Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Never drive past the lim...

Page 64: ...tch 4 shift Reverse Spark Plug T4196J Plug gap 0 7 0 8mm Fuel type RQ93 unleaded Lubricate oil SAE 15W 40 CAPACITIES Maximum load 300kg Fuel tank 23 0L Engine oil 2500ml Coolant 4000ml Starting 5s Cli...

Page 65: ...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 66: ...and the clutch pedal when the engine starts Fig 3 4 Push the choke back slowly to allow the engine to run smoothly Keep engine runn ck fully If the idle of engine is not smooth pull out the choke to f...

Page 67: ...king brake is eng ver is in neutral Trying to start the engine in gear may damage the starter motor clutch or gearbox Release the key at once if n start position when the en the engine starts Holding...

Page 68: ...s 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...

Page 69: ...st the seat ensure that engine of ATV is stopped OPERATION E Parking Adjustment See Fig 4 Park brake OFF Park brake On Fig 6 a Pull the park brake lever up so that the unit can engage park brake b To...

Page 70: ...e The first 1000 km 1st Gear 25km h 2nd Gear 45km h 3rd Gear 70 km h Max speed in each gear 4th Gear 100km h OPERATION H Starting And Operating Instructions a Before starting the engine be sure that t...

Page 71: ...lter if the filter cover and the air filter is dusty please clear the filter cover and replace with a new air filter B Engine Lubrication Engine oil replacement You must change the oil in the crankcas...

Page 72: ...te under the engine oil outlet Loosen the oil outlet plug in the warm engine Let the engine oil out fully see Fig 9 c Tighten the engine oil outlet plug d Remove the oil filler cap see Fig 10 fill oil...

Page 73: ...oil out fully see Fig 14 c Remove the iron dust plug this plug has a magnet on it Iron dust caused by moving parts will stick to the plug Clean the iron dust from this dust plug d Tighten the transmi...

Page 74: ...resh coolant of the specified type into the reserve coolant tank till the coolant reaches 2 5 to 3 5 of the reserve coolant tank volume 3 Close the reserve coolant case cap turn it clockwise and tight...

Page 75: ...ently Back out 2 3 8 turns counter clockwise see Fig 17 c Connect the tachometer adjust the throttle to limit the idle speed The standard value is 1400RPM d Turn the air screw counter slowly and obser...

Page 76: ...ating oil through the spark plug hole into the cylinder Crank the engine slowly to spread oil and replace spark plug c Do not save or store gasoline over winter Using old gasoline which has deteriorat...

Page 77: ...Fig 18 2 Remove two bolts M12 on the starter See Fig 19 Remove the starter See Fig 20 Fig 19 Fig 20 REPAIR 3 Remove two nuts M14 on two side of transmission See Fig 21 22 28...

Page 78: ...Fig 21 Fig 22 5 Remove two bolts M8 on the low mud plate of transmission See Fig 23 24 Fig 23 Fig 24 6 Remove the mud plate See Fig 25 Fig 25 REPAIR 7 Remove the transmission See Fig 26 27 29...

Page 79: ...Fig 26 Fig 27 8 Remove upper mud plate See Fig 28 Fig 28 REPAIR 9 Insert a shaft into the hole See Fig 29 Remove six bolts on the pressing plate of 30...

Page 80: ...g 29 Fig 30 10 Remove the pressure plate See Fig 31 Remove the friction disc of clutch See Fig 32 33 Fig 31 Fig 32 Fig 33 REPAIR 10 Insert a special shaft into the hole fix new friction plate on the f...

Page 81: ...ee Fig 36 Tighten six bolts with torque 30 N m See Fig 37 Fig 36 Fig 37 12 Fix upper mud plate See Fig 38 39 Fig 38 Fig 39 13 Fix parts according to reverse operation to the disassembly D Front Wheel...

Page 82: ...on B 3 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 adju...

Page 83: ...s Engine oil fuel coolant and electrolyte of accumulator should be sufficient Don t operate it at high speed at once after starting the engine You should preheat it step by step You d better drive it...

Page 84: ...torque of gasoline engine No Description of parts Tightening torque N m 1 Cylinder cover connecting bolt 55 60 2 Valve rocker adjusting nut 18 22 3 Spark plug 20 30 4 Main bearing cap bolt of cranksh...

Page 85: ...l level the gasoline engine should be in the installing position of the car the car is in level position if the color of the lubrication has changed much it should be changed 2 before filling lubricat...

Page 86: ...il and remount the bleeding screw plug according to specified torque it is shown as fig 43 bleeding screw plug fig 43 5 choose lubrication for gearbox s gear oil AP GL 4 SAE 75W 85 85W 80W 90 or 90 Wh...

Page 87: ...g system 1 Coolant of gasoline engine is glycol water antifreeze mixture Don t use antifreeze mixture with different character river water and well water etc coolant amount should be enough 3 6L coola...

Page 88: ...ening You should often remove the carbon deposit between the two poles The clearance should be adjusted as 0 7 0 8mm and it should be even on the overall pole plane shown as in Fig 47 when you change...

Page 89: ...r adjusting screw Fig 49 2 Change of timing belt The timing belt with excessive wear aliquation and off teeth should be changed When changing it loose the rocker nut and make adjust screw back to posi...

Page 90: ...ack cover and camshaft center should be 0 120 240 and confirm that the cambered surface of work circle of rocker has leaned against the base face circle of cam And then adjust the clearance between ad...

Page 91: ...ywheel 7 should be aligned with the timing finger of the bracket the tolerance should be 1 or otherwise you should adjust it Fig 53 3 Adjust the firing advance angle by loosing the fastening bolt of d...

Page 92: ...l 2 5L antirust lubricant into gasoline engine and remove spark plug of all cylinder and make all piston be between upper dead and lower dead point and fill 0 006L antirust lubricant into every cylind...

Page 93: ...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 Br...

Page 94: ...45...

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