owner s manual - jmc motorsjmcmotors.us/manuals/650commandoc2_owners_manual2008.pdfcargo can affect...
TRANSCRIPT
Owner’s manual
JNSZ650UV
1
INTRODUCTION
Thank you for choosing JOYNER JNSZ650UV. It represents the result of
many years of JOYNER experience in the production of utility vehicles.
With the purchase of this JOYNER, you can now appreciate the high
degree of craftsmanship and reliability that have made JOYNER a leader
in this field .This manual will provide you with a good basic
understanding of 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 features. Regular inspections and
careful maintenance, along with good operating techniques, will help
ensure that you safely enjoy the capabilities and reliability of this vehicle.
2
CONTENTS
WARRANTY POLICY .......................................................................................................................... 5
LOCATION OF THE WARNING AND SPECIFICATION LABELS ......................................... 16
SAFETY INFORMATION .................................................................................................................. 19
CONTROL FUNCTIONS .................................................................................................................... 21
MAIN SWITCH...................................................................................................................................... 21
MULTI-FUNCTION METER UNIT ............................................................................................................ 21
SWITCHES ........................................................................................................................................... 22
PEDAL ................................................................................................................................................. 23
PARKING BRAKE LEVER ....................................................................................................................... 24
DRIVE SELECT LEVER .......................................................................................................................... 24
FUEL TANK CAP ................................................................................................................................... 25
SEATS AND SAFETY BELTS ................................................................................................................... 25
GLOVE COMPARTMENT ........................................................................................................................ 26
ARE YOU READY TO DRIVE .......................................................................................................... 27
PROTECTIVE APPAREL ......................................................................................................................... 27
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 ....................................................................................................................... 31
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 ENGINE ..................................................................................................................................... 40
ENGINE STOP KEY ................................................................................................................................ 41
PRE-DRIVE INSPECTION ...................................................................................................................... 41
PASSENGER ......................................................................................................................................... 42
SEAT ADJUSTMENT .............................................................................................................................. 43
PARKING ADJUSTMENT ....................................................................................................................... 43
3
GEAR SHIFT ADJUSTMENT .................................................................................................................. 44
BREAK-IN ............................................................................................................................................ 44
STARTING AND OPERATING INSTRUCTIONS ......................................................................................... 44
SERVICE INSTRUCTION ................................................................................................................. 45
SERVICE AIR CLEANER ........................................................................................................................ 45
ENGINE LUBRICATION ......................................................................................................................... 45
TRANSMISSION LUBRICATION .............................................................................................................. 46
ENGINE COOLANT ............................................................................................................................... 47
SPARK PLUG ........................................................................................................................................ 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 ................................................................................................................. 57
DISTRIBUTOR REPLACEMENT .............................................................................................................. 59
FRONT WHEEL ALIGNMENT ................................................................................................................ 62
THE USING，MAINTENANCE AND REPAIR OF THE FRONT/REAR REDUCER ............... 63
PERIODIC MAINTENANCE ............................................................................................................. 67
WIRING DIAGRAM ........................................................................................................................... 69
JNSZ650UV LIMITIED WARRANTY .............................................................................................. 70
DEALER PRE-DELIVERY INSPECTION ........................................................................................... 157
5
Warranty policy
6
7
8
9
10
11
12
13
14
15
16
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
Read and understand all of the labels on your vehicle. They contain important
information for safe and proper operation of your vehicle.
Never remove any labels from your vehicle. If a label becomes difficult to read or
comes off, a replacement label is available from your Joyner dealer.
WARNINGThe enclosure cannot protect occupants in
all foreseeable accidents,including 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
Never set tire pressure below minimun.Tire may
dislodge from rim.
Gross Vehicle Weight Rating:1200kg(2640lbs)
maximum including weight of operator,passenger,
accessories,cargo,and trailer tongue weight.
JOYNER S650.09.04.00.02(1)
17
JOYNER
WARNING!Severe INJURY or DEATH can result if you ignore the following:
Maximum Load in Cargo Bed:350kg.(770lbs).
Never carry passengers in cargo bed.
Cargo can affect handling and stability.Read Owner's Manual before
loading or towing.
When loading with cargo or towing a trailer:Reduce speed and allow
more room to stop.Avoid hills and rough terrain
Be sure cargo is secured,a loose load could change handling
unexpectedly.
Keep weight in the cargo bed centered,and as low an far forward as
possible.
Top-heavy loads increase the risk of overturn.
S650.09.04.00.04(1)
JOYNER
MAX3.9INCH(100MM)
S650.09.04.00.05(1)
JOYNER
WARNINGImproperly loading a trailer
and failure 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 the
owners manual.
S650.09.04.00.06(1)JOYNER
WARNINGTurning the off road vehicle in 4WD
takes more effort.
Operate at a slow speed and allow
extra time and distance for
maneuvers to avoid loss of control.
S650.09.04.00.07
WARNINGThis off-highway utility vehicle will
handle and maneuver differently from
an ordinary passenger car or other
vehicle.
Vehicle capacity: 1 operator and 1 passenger
.Passenger must be able to reach
and hold the handgrip inside enclosure.
This vehicle is recommended only for
operators 16 and older with a valid motor
vehicle license.Adults must supervise use
by minors. Check state laws for minimum
age requirements.
Gross Vehicle Weight Rating:1200kg(2600lbs)
maximurn Including operator, passenger,
accessories, cargo and trailer tongue weight.
Passenger and cargo can affect vehicle
handling
ALWAYS wear a seat belt when riding in the
vehicle.
keep your hands and feet
inside the vehicle at all times-watch
for branches, brush, or other hazards
that could enter the vehicle.
drive straight up and down
inclines-driving across the side of an
incline increase the risk of overturn.
NEVER operate through water deeper than
12"(305mm) or fast flowing water-if
you must cross shallow, slow
moving water, choose your path
carefully to avoid sharp drop-offs
large rocks, or slippery surfaces that
could cause the vehicle to overturn.
make sharp, high-speed turns-the
vehicle could roll over or go out
of control.
Improper use can result in Severe INJURY or DEATH.
LOCATE AND READ THE OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
JOYNER S650.09.04.00.08(1)
18
S650.09.04.00.11(3)JOYNER
MAX . LOAD:JOYNER CHINA
VIN/NIV:NW:
MANUFACTURER:
TYPE:
S650.09.04.00.12(1)JOYNER
19
Note:
WARNINGThe enclosure cannot protect occupants in
all foreseeable accidents,including rollover.
JOYNER
!
S650.09.04.00.01(2)
SAFETY INFORMATION
THE SAFETY IS FRIST. Severe injury or death can result if you do not follow
these instructions。Read this manual and all labels carefully and follow the operating
procedures described:
1. This vehicle is designed to carry the driver and one passenger. Never carry
passengers in the cargo bed.
2. Always be sure the driver and passenger are wearing seat belts.
3. Never give a ride to a passenger who is too small to reach and hold the handgrip
on the enclosure.
4. Always avoid operating the vehicle 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. Never consume alcohol or drugs before or while operating this vehicle.
8. Never operate at speeds too fast for your skills or the conditions. Always go at a
speed that is proper for the terrain, visibility, operating conditions, and your
experience.
9. Never attempt jumps or other stunts.
10. Always inspect your vehicle each time you use it to be sure it is in safe
operating condition. Always follow the inspection and maintenance procedures and
20
schedules described in this manual.
11. Always keep both hands, arms, feet, and legs inside the vehicle at all times
during operation. Keep your feet on the floorboard. Never hold onto the enclosure
except when using the handgrip inside the enclosure. Otherwise, your hand could be
injured if it is caught between the enclosure and an obstacle outside the vehicle.
12. Always keep both hands on the steering wheel when driving.
13. Never wrap your thumbs and fingers around the steering wheel. This is
particularly important when driving in rough terrain. The front wheels will move right
and left as they respond to the terrain, and this movement will be felt in the steering
wheel. A sudden jolt could wrench the steering wheel around, and your thumbs or
fingers could be injured if they are in the way of the steering wheel spokes.
14.Always go slowly and be extra careful when operating on unfamiliar terrain.
Always be alert to changing terrain conditions when driving the vehicle.
15. Never operate on excessively rough, slippery, or loose terrain until you have
learned and practiced the skills necessary to control the vehicle on such terrain.
Always be especially cautious on these kinds of terrain.
16. Never turn at excessive speed. Practice turning at slow speeds before attempting
to turn at faster speeds. Do not attempt turns on steep inclines.
17. Never operate the vehicle on hills that are too steep for it or for your abilities.
Go straight 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 reverse gear. Use
engine braking to help you go slowly. If necessary, use the brakes gradually to help
you go slowly.
20. Always check terrain carefully before going down hills. Go as slowly as
possible. Never go down a hill at high speed.
21. Always check for obstacles before operating in a new area.
22. Never operate the vehicle in fast flowing water or water deeper than the
floorboards on this model. Remember that wet brakes may have reduced stopping
ability. Test your brakes after leaving water. If necessary, apply them several times to
let friction dry out the linings.
23. Always be sure there are no obstacles or people behind you when you operate in
reverse. When it is safe to proceed in reverse, go slowly. Do not brake abruptly when
carrying loads in the cargo bed.
24. Always use the size and type of tires specified in this manual.
25. Always maintain proper tire pressure as described in this manual.
26. Never exceed the stated load capacity. Cargo should be as far forward in the bed
as possible, and distributed evenly from side to side. Be sure cargo is secured so that it
cannot move around during operation. Reduce speed and follow instructions in this
manual for carrying cargo or pulling a trailer. Allow greater distance for braking.
21
CONTROL FUNCTIONS
Main switch
Functions of the respective switch positions
are as follows:
OFF:
All electrical circuits are switched off except the turning
signal both the left and the right when the light switch is on.
The key can be removed in this 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 continuously for more than 5 seconds, or starter
damage could occur. Wait at least 5 seconds between each operation of the electric
starter to let it cool.
Do not turn the key to the "START" position with the engine running, or damage to
the electric starter can result.
See starting instructions prior to starting the engine.
Multi-function meter unit
1. turn left indicator
2. coolant temperature indicator
3. power indicator
4. turn right indicator
5. speedometer
6. gasoline quantity meter
7. coolant thermometer
8. 2WD/4WD indicator
9. odometer/ hour meter
10. tachometer
2WD
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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 time the key has been turn to “ON”)
Pushing button 1 the display between the odometer and the hour meter.
Pushing button 2 the display of unit between the Metric system and English system.
Switches
Light switch " / "
Set the switch to “ ” to turn on the low beam
and the taillights.
Set the switch to “ ” to turn on the high
beam and the taillights.
Do not use the headlights with the engine turned off for an extended period of time.
The battery may discharge to the point that the starter motor will not operate properly.
If this should happen, remove the battery and recharge it.
Turning light switch“ / ”
Set the switch to “ ” when turn left
Set the switch to “ ” when turn right
Four-wheel drive switch “2WD/4WD”
Two-wheel drive ("2WD"): Power is supplied to the rear wheels only.
Four-wheel drive ("4WD"): Power is supplied to the rear and front wheels.
To change from 2WD to 4WD, the vehicle should stop fully. It will make some parts
of the electric 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
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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.
Reverse indicator light “R”
This indicator light comes on when the drive select lever is “R” reverse position.
Electricizing of the battery indicator light
This indicator light comes on when the generator of the engine can’t electricize the
battery. You should check the generator and battery or get help from your JOYNER
dealer .
Pedal
Clutch pedal
Press the clutch pedal before you shift by
moving the drive select lever.
Brake pedal
Press the brake pedal to slow or stop the vehicle.
Clutch pedal Brake pedal
Accelerator pedal
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Accelerator pedal
Press the accelerator pedal down to increase
engine speed.
Before start the engine, you should check the three pedal to be they are operating
smoothly.
Before start the engine, you must make sure that the spring pressure can returns
the three pedals to the rest position 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.
Never use parking brake lever when the vehicle don’t stop fully.
Adjust the parking cable if necessary.
Be sure to fully release the parking brake lever before start the vehicle.
Drive select lever
The drive select lever is used to shift your
25
vehicle into the 1,2,3,4 and reverse positions.
Never start the vehicle at 3 or 4 lever.
Stop the vehicle fully when shifting to reverse.
When reversing, the reverse indicator “R” comes
on and there is warning voice.
Fuel tank cap
Remove the fuel tank cap by turning
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 upward,
lift the front of the seat, and then slide the seat
forward and up.
To repair the engine and the battery conveniently,
the seats can be Lifted just like the cargo bed .
It is very easy to install or uninstall the seats, see
the table of the content“seat and safety belt”。
26
Safety belts
This vehicle is equipped with three-point
seat belts for both the operator and passenger.
Always wear the seat belt while riding in the vehicle.
To wear the seat belt properly, do the following.
1. Hold the latch plate as you pull the bell across
your lap and chest. Make sure the belt is not twisted
and is not caught on any portion of the vehicle,
your clothing, or any equipment you are carrying.
2. 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 loose, pull the belt out all the way and then let
it retract.
5. To release the buckle, firmly press the release button.
Glove compartment
Push down turn to open the glove box.
To protect from damage, do not put metal products, like tools or sharply edged
products directly in the glove compartment. If they must be stored, wrap them in
appropriate cushion material.
Cargo bed
1. Confirm the air spring well worked.
2. Adjust the rubber bumpers to proper position,
27
then tighten the adjust nuts .
3. Pull up the release lever on the both side of
the vehicle, and then lift up the cargo bed slowly
until it stops
4. Lower the cargo bed slowly to its original
position and be sure it is locked into place.
Before closing the bed, be sure others are standing away from the vehicle. Keep
hands and fingers away from the pinch points between the bed and frame.
The max load is 350Kg. To protect anybody from damage or injury, never exceed
the stated maximum load limit for this cargo bed. Cargo should be 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 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, and adjustments to make for
your comfort, convenience, or safety.
Before you drive your UV650 for the first time, we urge you to:
■ Read this owner’s manual and the labels on your UV650 carefully.
■ Make sure you understand all the safety messages.
■ Know how to operate all the controls.
Before each drive, be sure:
■ You are wearing an approved motorcycle helmet (with chin strap tightened
securely), eye protection, and other protective clothing.
■ You don’t have any alcohol or drugs.
Protective Apparel
For your safety, we strongly recommend that you always wear an approved
motorcycle helmet, eye protection, boots, gloves, long pants, and long-sleeved shirt or
28
jacket whenever you drive.
Although complete protection is not possible, wearing proper gear can reduce the
chance of injury when you drive.
The following suggestions will help you choose the proper driving gear.
Helmets and Eyes Protection
Your helmet is your most important piece of driving gear because it offers the best
protection against head injuries. A helmet should fit your head comfortably 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 wear a face shield or goggles to protect your eyes and help
your vision.
Operating this UV650 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 properly and wear eye protection
(goggles or face shield), gloves, boots, long-sleeved shirt or jacket and long pants.
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.
Drive Training
Developing your driving skills is an on-going process. Even if you have driven other
UV650s, take time to become familiar with how this UV650 works and handles.
Practice driving the UV650 in a safe area to build your skills. Do not drive in rough
terrain until you get accustomed to the UV650’s controls, and feel comfortable with
its size and weight.
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Operating UV650 without proper instruction could increase your risk of an accident
which could lead to serious injury or death.
Attempt supporting with your hands to the ground when the Vehicle turning over could lead
to serious injury or death.
Never support with your hands to ground when the Vehicle will turn over.
Age Recommendation
It is strongly recommended that no one under the age of 16 be permitted this UV650
without adult supervision.
A child driving a UV650 that is not recommended for his/her age could lose UV650
control and result in severe injury or death.
A child under 16 should have adult supervision when operate on the UV650.
No Alcohol or Drugs
Alcohol, drugs and UV650s don’t mix. Even a small amount of alcohol can impair
your ability to operate a UV650 safely. Likewise, drugs, even if prescribed by a
physician, can be dangerous while operating a UV650. Consult your doctor to be sure
it is safe to operate a vehicle after taking medication.
30
Operating this UV650 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 UV650.
IS YOUR VEHICLE READY TO DRIVE
Before each drive, it is important to inspect your UV650 and make sure any problems
you find are corrected. A pre-drive 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 has overturned or has been involved in a collision, do not drive it until
your UV650 has been inspected by your dealer. There may be damages or other
problems you can not see.
Improperly maintaining this UV650 or failing to correct a problem before driving can
cause a crash in which you can be seriously hurt or even dead.
Always perform a pre-drive inspection before every drive and correct any problems.
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Pre-drive Inspection
Check the following items before you get on the UV650:
■ Engine Oil
Check the level and add oil if needed. Check for leaks.
■ Coolant
Check the coolant and add coolant if needed. Check for the leaks.
■ Fuel
Check the level and add fuel if needed. Also make sure the fuel cap is securely
fastened. Check for leaks.
■ Tires
Use a gauge to check the air pressure. Adjust if needed. Also look for signs of
damages or excessive wear.
■ 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.
■ 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 UV650.
■ Air Cleaner
Check the air filter. Replace it if needed.
■ Leaks, Loose Parts
Walk around your UV650 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.
■ Clutch cable
Check the free play of clutch cable and adjust if needed. Press the clutch cable to
make sure it moves smoothly without sticking, and snaps back automatically 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 switch key counterclockwise. Make sure engine
32
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. Replace or tighten as
needed.
■ Tie rod
Check the tie rod housing for wear. Check the fittings are tight. Replace or tighten
as needed
SAFE DRIVING PRECAUTIONS
Off-Road Use Only
Your UV650 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 UV650 on pavement.
Operating this UV650 on paved surfaces may seriously affect handling and control of
the UV650, and may cause the vehicle to go out of control.
Never operate the UV650 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
33
regulations. Obtain permission to drive on private property. Avoid posted areas and
obey “no trespassing” signs.
You should never drive your UV650 on public streets, roads or highways, even if they
are not paved. Drivers of street vehicles may have difficulty seeing and avoiding you,
which could lead to a collision. In many states it is illegal to operate UV650 on public
streets, roads and highways.
Operating this UV650 on public streets, roads or highways can cause collision with
other vehicle.
Never operate this UV650 on any public streets, roads or highways, even a dirt or
gravel one.
Keep Hands and Feet on Controls
Always keep both hands on the steering wheel and both feet on the foot controls.
When driving your UV650. It is important to maintain your balance and control of the
UV650. 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 during operation.
Control Speed
Driving at excessive speed increases the chance of an accident. In choosing a proper
speed, you need to consider the capability of your UV650, the terrain, visibility and
other operating conditions, plus your own skills and experience.
34
Operating this UV650 at excessive speeds increases your changes of losing control of the
UV650, which can result in an accident.
Always drive at a speed that is proper for your UV650, the terrain, visibility and other
operating conditions, and your experience.
Take Care on Unfamiliar or Rough Terrain
Before driving in a new area, always check the terrain thoroughly. Don’t drive fast on
unfamiliar terrain or when visibility is limited. (it sometimes difficult to see and react
obstructions, such as hidden rocks, bumps, or holes).
Failure to take extra care when Operating this UV650 on unfamiliar terrain could result
in the UV650 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 UV650.
Never drive past the limit of visibility. Maintain a safe distance between your UV650
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, 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 UV650 on such terrain. Always be
especially cautious on these kinds of terrain.
Do Not Perform Stunts
You should always operate your UV650 in a safe and reasonable manner. When
driving, always keep all wheels on the ground.
35
Attempting wheelies and other stunts increases the chance of an accident, including an
overturn.
Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
SPECIFICATIONS
Model JNSZ650UV
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
645kg
Engine:
Engine type
Cylinder arrangement
Displacement
Bore×stroke
Compression ratio
Liquid cooled—4stroke
Upstanding double cylinder
644cc
76mm×71mm
8.4:1
36
Starting system
Lubrication system
Electric starter
Wet sumb
Engine ail
Type
Recommended engine ail classification
Quantity:
With oil filter cartridge replacement
＞0℃ SE15W/40, ＜0℃ SE15W/30
2.9L
Final gear case oil:
Type
Quantity
SAE85 API GL-5 hypoid gear oil
0.7L
Radiator capacity(including all
routes):
1.4L
Air filter:
Engine
Intake duct
Wet element
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
Reverse:4.271
Manual
Right hand operation
Chassis
Frame type
Caster angle
Steel tube frame
6º
Tire
Type
Size front
rear
Tubeless
25 inch
25 inch
37
Tire (option)
Type
Size front
rear
Tubeless
27 inch
27 inch
Brakes:
System
Type front
rear
Operation
Front and rear unified
Dual disc brake
Dual disc brake
Foot operation
Suspension:
Front suspension
Rear suspension
Double wishbone
Double wishbone
Shock absorber:
Front shock absorber
Rear shack absorber
Coil spring/oil damper
Coil 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 36Ah
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:
Reverse indicator light
Coolant temperature warning light
Parking brake indicator light
Four-wheel-drive indicator light
LED
LED
LED
LED
38
OPERATION
Operation controls
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.
39
Throttle Figure 3 The right foot pedal is the throttle that controls the UV650 speed. To disengage the
clutch at any time, allow the throttle to return to the idle position. (See Fig. 3)
Each time prior to starting the engine, check the throttle assembly to ensure that when
pedal is pushed all the way 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.
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 and slows or stops the vehicle.
Clutch
The left foot pedal controls the clutch cable . With the pedal down, you can shift the
shift lever.
Clutch pedal Brake pedal
Accelerator pedal
40
Improper operation of the clutch will lead to excessive wear of the clutch friction surface.
Note：
When operate the vehicle, if it does
not feel comfortable about one of the
three pedals , adjust the bolt and then
tighten the nut until it feels very
comfortable.
Start engine
1. Engage the park brake
2. Press the clutch pedal down,
put the shift lever 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 is not smooth, pull out the choke
to find the best running position and keep running for a while long until the engine
running smooth without choke.
41
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.
Before you start the engine, check that the parking brake 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 damage the engine.
Engine stop key
Before driving this vehicle, test the Engine Stop key to assure that it is operating
properly. With the engine running, turn the key counterclockwise to the “off” position
for the engine to shut down.
Pre-Drive Inspection
42
Perform this pre-drive inspection everyday before driving vehicle. If not performed,
serious damage to the vehicle or personal injury may result.
1. Check for Engine Oil Level. Check for transmission Oil Level. Check for leaks,
add oil if required.
2. Check the coolant. Check for leaks, add the coolant if required.
3. Check for Fuel Level. Add fuel as necessary and do not overfill. Check for leaks.
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.
5. Check the clutch cable, Assure the cable snaps back and has a smooth operation.
Ensure the clutch can operate smoothly. Adjust if necessary, or replace the clutch if
necessary.
6. Check Tires. Check tires 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 as necessary.
10. Check Roll Cage Bars. Ensure all protective roll cage bars are in place before
operating the UV650.
12. Check Brake Light. Check for proper operation.
13. Check Wheels. Check for tightness of wheel nuts and axle nuts; check that axle
nuts are secured by cotter pins.
14. Check Steering. Check for free operation and for any unusual looseness in any
area.
Passenger
The vehicle allows for two riders only.
Combined maximum weight of driver
and the passenger should not exceed 180kg
or 400Ibs.
Caution: The passenger should wearing seat belt all the time.
43
Seat Adjustment
The left seat can remove, but the right can’t.
To move a seat, pull its seat lock lever upward,
lift the front of the seat, and then slide the seat
forward and up.
To repair the engine and the battery conveniently,
the seats can be Lifted just like the cargo bed .
It is very easy to install or uninstall the seats, see
the table of the content“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 is stopped.
Never operate this UV650 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. Before attempting to
adjust the seat ensure that engine of UV650 is stopped.
Parking Adjustment
44
Pull the park brake lever up so that the unit can engage park brake.
To release the unit, press button on front end of parking lever then push the parking
lever to the bottom.
Adjust the parking cable if necessary.
Gear Shift Adjustment
Before operate the vehicle, check the shift
lever as to change gearshift from 1 to 4 and
reverse smoothly.
The shift lever should be vertical when the
gear is in neutral .If not ,adjust the shift cable
and then Tighten the nuts of the shift cable
Break-in
The first month is most important in the life of your vehicle. Proper operation during
this break-in period will help assure maximum life and performance from your new
vehicle. The following guidelines 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 Operating Instructions
Before starting the engine, be sure that the driver is seated properly in the UV650
and tighten the seat belts.
Testing the UV650 in a open place at the beginning to learn how to start, turn and
stop.
Operate the UV650 slowly until you are familiar with it.
The turning radius of this UV650 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 UV650 from rolling over.
45
To prevent vehicle from rolling over, be sure to only turn the vehicle at a slow more
controllable speed.
SERVICE INSTRUCTION
Service Air Cleaner
Service air cleaner every 80 hours
NOTE: Service more often under dusty
conditions.
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 repairs due to excessive wear.
46
a. With the engine warm, put the vehicle on the level ground.
b. 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
c. Tighten the engine oil outlet plug.
d. Remove the oil filler cap fill oil (SE 15W/40 or SF 15W/40) about 2.8 liters to
the engine.
e. Pull out the engine oil dip stick, confirm the corrective oil level in the crankcase .
Check engine oil 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 and prevent costly repairs due to excessive wear.
Put the vehicle on the level ground:
a. Shut down the engine, put a collecting oil plate under the transmission oil outlet.
Loosen the oil outlet plug in the warm engine. Let the transmission oil out fully .
47
b. 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 transmission oil outlet plug and the iron dust plug.
e. Remove dipstick of transmission, fill oil (GL-4 85W/90) about 1.9 liters.
f. Insert the transmission dipstick, check the oil level in the transmission. Confirm
the corrective oil level in the transmission.
Check transmission oil If the color of transmission oil changes, you need to replace oil. Replace transmission
oil as above.
Engine Coolant
You must check the coolant for level and leaks. If it is low, you need to 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. Repeat 2,3,4 till the coolant is at neck and no bubbles come up.
6. Refit the coolant cap, turn it clockwise and tighten it
7. Turn the reserve coolant case cap counterclockwise and open the cap.
8. Pour fresh 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.
9. Close the reserve coolant case cap, turn it clockwise and tighten it
Top up the reserve coolant
48
If the coolant in the reserve tank is less than 2/5, it needs to be topped up.
1. Turn the reserve coolant case cap counterclockwise and open the cap.
2. Pour fresh 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 tighten it
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.
Children and pets may be harmed by new or used coolant.
Continuous or brief contact with coolant 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.
Failure to use the correct coolant or coolant not the same as one in the
radiator or reserve case can harm your VEHICLE. Engine damage may occur if
you use coolant that does not meet the specifications.
Change the coolant
For some time, you should change the coolant, please do the following:
1. Check the new coolant fits the engine.
2. Lift the vehicle head up, and fill the coolant to the tank and the reserve tank
slowly.
3. Start the engine about 3 minutes at low speed.
4. If there is some coolant let out from the reserve tank, add some coolant to the tank
slowly.
49
Spark Plug
a. Remove the spark plug and inspect it
each time you change the oil.
(Use a spark plug wrench) The electrodes
should be kept clean and free of carbon.
The presence of carbon or excess oil will
greatly reduce proper engine performance.
If possible, check the spark plug gap
(area between electrodes) using a wire feeler
gauge. This specification is 0.025”~0.030”.
b. Before installing spark plug coat threads
lightly with graphite grease if possible,
to ensure easy removal next time the spark plug
needs inspection.
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 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 turns counterclockwise.
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 observe the RPM of the engine,
stop adjusting as the RPM reaches the top speed.
e. Adjust the screw and adjust the idle speed to an ideal value.
f. Repeat step d and e until the rotate speed of engine stables.
50
REPAIR
Front Wheel Replacement
Do not disassemble 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.
51
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.
1. Remove bolt M14
2. Remove two bolts (M12) on the starter (See Fig. 23), Remove the starter
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.
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
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.
55
11.Fix pressure plate of clutch. Two bolts with “Y.G” mark must be inserted into two
anchor hole. Tighten six bolts with torque 30 N•m .
12. Fix upper mud plate
13. Fix parts according to reverse operation to the disassembly.
Timing setup and balancing shaft setup
1. When the first piston locates top dead center, make sure the mark on
camshaft timing sprocket wheel in the position shown as the following
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 beginning of this step.
3. Fix guide plate, and tension plate
4. Fix the sprocket. Mark on the sprocket must be in straight line to the single
white link on the timing chain. (See Figure 4)
Torque 30 N•m
56
Figure 1
Figure 2
Camshaft timing sprocket wheel
Mark
Right balancing
shaft sprocket
Left balancing shaft
sprocket
Crank shaft
Mark here
Left balancing shaft
sprocket
Mark
57
Figure 3
Water pump disassembly
1. Take off fan belt and loosen 4 bolt tightening water pump pulley.
Figure 4
2. Loosen the 6 bolts shown as the Figure 5.
Left balancing shaft
sprocket
Mark
Make a Mark
30mm above the
bolt
30mm
Fan belt
Water pump
pulley
Bolt
58
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.
Figure 6
Bolts
Bolts
Clamp Bolts Water pipes
59
Figure 7
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
60
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.
3. Insert the screwdriver into the hole, turn the drive of oil pump shaft until parallel
61
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.
62
7.Fix the cover of the distributor.
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.
Front Wheel Alignment
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.
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.
63
The USING，MAINTENANCE AND
REPAIR OF THE FRONT/REAR
REDUCER
Before install the front/rear main reducer to the vehicle, we have done accurate test to
64
each one, and don’t open them in normal. But please 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?
b. Dismantle the bolt M6(PIC.01)/M8(PIC.02) from the main case of front/rear
main 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 .
65
e. The final , screw the bolt “4” and washer “3” properly(PIC.03).
2. When driving in rough terrain , I suggest consumingly that you’d better set your
vehicle on 4WD. Changing 2WD to 4WD,do the following:
a. To change from 2WD to 4WD, the vehicle should stop fully. It will make some
parts of the electric locker can’t work that changing from 2WD to 4WD when the
vehicle is moving.
b. To change from 2WD to 4WD successfully, you should try more times, and then
start the engine slowly back and forth.
c. You should try again if there is some nonnormal noise when the speed is about
20Km after changing from 2WD to 4WD.
3. Check the oil leaking before each using , please do the following:
a. If there is some oil leaking out from the seal, maybe the seal 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 some important parts in them can’t work, then you
must do the following:
a. Never start the vehicle again.
b. Dismantle the reducer from the vehicle, then open it and change a new part from
66
your JOYNER dealer.
c. When you assemble the part, all the bolts and nuts should be screwed with the
rated Torque.
5. If it is too high about the temperature of the oil in the reducer, please stop using
the vehicle and get help from your JOYNER dealer.
6. For some special reasons, you have to dismantle the drive halfshaft or change a
new one , please do the following:
a. Use a special tool to dismantle the drive halfshaft.
b. After dismantling, you must make sure that the circlip of the drive halfshaft 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 vehicle .If you have some problems
which you can’t resolve by yourself, please get help from your JOYNER dealer.
Ref Bolt or Nut Torque （N·m）
1 Nut M27*1.5 for the driven gear 170~230
2 Bolt M8*25 for the driven gear 80~90
3 Bolt M8*16 for venting oil 20~28
4 Hex M8*40 for the enter cover 17~25
5 Hex M8*40 for the out cover 17~25
6 Bolt M18×1.5 for adding oil 45~55
67
PERIODIC MAINTENANCE
The maintenance intervals in the following table are based upon average driving
conditions. Driving in unusually dusty areas, require more frequent servicing.
Time of service
Item Initial
service Monthly Quarterly Yearly
Engine
1. driven belt I I R
2. Tighten bolts on engine. I I
3. Engine oil I I
4. Coolant I
5. Coolant hose and joints I I R
6. Exhaust I I
7. Transmission oil I R
Ignition
8. Coil I
9. Distributor for 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
68
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. Tighten nuts on the hub and wheel I I I
24. Shocks I
25. Driven shaft I I
26. All nuts and bolts I I I I
27. Steering wheel, steering I I
28. Test vehicle I I I I
A: adjust C: clean I: inspect, clean or replace if necessary. L: lubricate R: replace
69
WIRING DIAGRAM
green
Turn signal
switch
RLyellow
red
Reve
rse
indic
atio
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harg
e
indic
atio
n
OFF
2W
D/4
WD
R
reve
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wa
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Sp
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d-
me
ter
Co
mp
ou
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me
ter
Wire's
co
lou
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mb
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---r
ed
/gre
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B--
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R
---r
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U--
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RU
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ed
/blu
e
P--
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S
---g
rey
W
---w
hite
Y
G--
-ye
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en
L
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am
brid
ge
blu
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row
n K
---p
ink
N
B--
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R--
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d
UW
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lue
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ite R
B--
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d/b
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G
Y--
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S
B--
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B
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ed
Y
---y
ello
w W
G--
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n G
B--
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R--
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B
W--
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hite
M
Re
ctifi
er,
reg
ula
tor
14V
Fuse 5AFu
el p
um
pHigh beam
switch
ON
blue
ON
green
Spotlight
switch
Dipped beam
switch
ON
t°
Th
erm
om
ete
r
Sw
ich
（8
2 o
C）
Alte
rna
tor
14
V 3
5A
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12
Ba
tte
ry
12
V3
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pe
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sen
sor
Ra
dia
tor
fa
nF
lash
er
Bra
kes
ligh
t
switc
h
Ho
rn
Igni
tion
swi
tch
Dis
trib
uto
rco
il,i
gn
Horn
button
Fuse
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70
JNSZ650UV LIMITIED WARRANTY
The warranty policy applies to those cases where the new seller vehicle is unloaded
from its shipping container, set up and delivered by authorized dealer, and under
normal use and service is found to have defects in parts or workmanship under the
following terms and conditions. This warranty covers the engine and engine related
components for a period of 90 days.
This warranty does not apply to any part, which in opinion of seller was defective
because of improper maintenance, improper assembly, alterations, abuse, negligence
or accident.
Should warranty service be required on your JNSZ650UV 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 so as to adversely
affect its safety or reliability.
d. Competition or racing
The warranty does not cover loss of use of the seller vehicle, loss of time,
inconvenience, or other consequential damage which includes, but is not limited to,
loss or damage to persons or property or any expense of returning any damaged
units to the seller distributor or its authorized dealer.
Seller has the right to make changes without notice.
157
DEALER PRE-DELIVERY INSPECTION
158
_______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. I further understand that cosmetic damage is NOT covered by any factory
warranties and unless noted here are deemed accepted by me.
_______Sand dunning or desert riding is dangerous. Death or injury could occur. The
seller is not liable for injury or death.
_______I understand all sales are final and that there is no right of rescission, no option
for return or exchange for any vehicle purchased, and that the titled and registered
machines were effectively purchased when I signed the title application.
_______I understand the warranty is 90 day manufacture defect only with the following
not covered: axles, electrical batteries, light bulbs, clutches, turbo cartridges, carburetor
cleaning, piston rings that are scorched from one revving, rims/tires, bearings.
_______I understand that although some lending institutions do not require insurance,
state law DOES require liability insurance and a driver‘s license. I also understand that
none of the products offered by the dealer constitutes insurance and a separate policy
would have to 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. Both tires turn equally, this is not a limited slip differential. Injury or death can
occur form operating a non DOT vehicle on public roads.
_______Turbo systems, system lessen life of engine, over revving the engine to increase
boost of turbo can cause engine damage. This will not be covered under warranty.
ADDITIONAL 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
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‖ provision.
3. NOTICE. Any notice required to be given to Buyer shall be deemed reasonable
notification if
(Ⅰ)mailed by ordinary mail, postage prepaid, to Buyer‘s mailing address as shown on
this contract or to Buyer‘s most recent address as shown by a ―notice 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
159
reason, Seller may at Seller‘s sole option, terminate this contract and retake the
vehicle, or make claims against Buyer on the check. In addition, Seller will charge
Buyer a $25 returned check charge plus any actual charges assessed 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, Buyer agrees to pay to the extent permitted by law,
the seller‗s reasonable attorneys fees and court costs.
6. GENERAL. This contract is governed by applicable federal law and the laws of the
State of Arizona. Any provisions found to be invalidate the remainder hereof, Waiver of
any default shall not constitute waiver of any subsequent default. All words used
herein shall be construed to be of such gender and number as the circumstances
require. The contract shall be binding upon Buyer‘s heirs, personal representatives,
successors and assigns and shall inure to the benefit of Seller‘s successors and
assigns. This contract constitutes the entire agreement between the parties with
respect to the subject matter herein, and may not be altered or amended unless made
in writing and duty 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 reimburse
Seller for any expenses and losses Seller incurs or suffers as a result of Buyer ‘s
failure or refusal to accept 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 LOSS, INSURANCE. The risk of loss to the Vehicle or any other items
covered by this invoice passes to Buyer upon delivery of the Vehicle or other goods to
Buyer at the address set forth on this invoice for shipment to Buyer or such other place
of receipt designated by Buyer. Buyer is responsible for maintaining its own theft and
liability insurance coverage for the Vehicle.
10. AGE. Buyer represents and warrants to Seller that Buyer is over the age of majority
and is fully competent to enter into this contract. Buyer acknowledges that Seller is
relying on this representation in entering into and performing this contract.
ADDITIONAL 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, Seller‘s 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‖ provision.
3. NOTICE. Any notice required to be given to Buyer shall be deemed reasonable
notification if(Ⅰ)mailed by ordinary mail, postage prepaid, to Buyer‘s mailing address
as shown on this contract or to Buyer‘s most recent address as shown by a ―notice of
change of address‖ on file with Seller, whether or not such notice is actually received
160
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. In addition, Seller will charge
Buyer a $25 returned check charge plus any actual charges assessed 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. Buyer agrees to pay to the extent permitted by law,
the seller‘s reasonable attorney‘s fees and court costs.
6. GENERAL. This contract is governed by applicable federal law and the laws of the
State of Arizona. Any provisions found to be invalid shall not invalidate the remainder
hereof. Waiver of any default shall not constitute waiver of any subsequent default. All
words used herein shall be construed to be of such gender and number as the
circumstances require. The contract shall be binding upon Buyer‘s heirs, personal
representatives, successors and assigns and shall inure to the benefit of Seller‗s
successors and assigns. This contract constitutes the entire agreement between the
parties with respect to the subject matter herein, and may not be altered or amended
unless made in writing and duly 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 the Vehicle or product or to comply with
this contract. Such expenses and losses may include Seller‘s reasonable and loses
Seller incurs or suffers as a result of Buyer‘s failure or refusal to accept delivery 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 LOSS: INSURANCE. The risk of loss to the vehicle or any other items
covered by this invoice passes to Buyer upon delivery of the vehicle or other goods to
Buyer at the address set forth on this invoice for shipment to Buyer or such other place
of receipt designated by Buyer. Buyer is 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.