Owner s manual JNSZ650UV

Transcription

1 Owner s manual JNSZ650UV

2 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. 1

3 CONTENTS WARRANTY POLICY... 5 LOCATION OF THE WARNING AND SPECIFICATION LABELS SAFETY INFORMATION CONTROL FUNCTIONS MAIN SWITCH MULTI-FUNCTION METER UNIT SWITCHES PEDAL PARKING BRAKE LEVER DRIVE SELECT LEVER FUEL TANK CAP SEATS AND SAFETY BELTS GLOVE COMPARTMENT ARE YOU READY TO DRIVE PROTECTIVE APPAREL HELMETS AND EYES PROTECTION DRIVE TRAINING AGE RECOMMENDATION NO ALCOHOL OR DRUGS IS YOUR VEHICLE READY TO DRIVE PRE-DRIVE INSPECTION SAFE DRIVING PRECAUTIONS OFF-ROAD USE ONLY KEEP HANDS AND FEET ON CONTROLS CONTROL SPEED DO NOT PERFORM STUNTS SPECIFICATIONS OPERATION OPERATION CONTROLS BRAKE CLUTCH START ENGINE ENGINE STOP KEY PRE-DRIVE INSPECTION PASSENGER SEAT ADJUSTMENT PARKING ADJUSTMENT

4 GEAR SHIFT ADJUSTMENT BREAK-IN STARTING AND OPERATING INSTRUCTIONS SERVICE INSTRUCTION SERVICE AIR CLEANER ENGINE LUBRICATION TRANSMISSION LUBRICATION ENGINE COOLANT SPARK PLUG CARBURETOR ADJUSTMENT REPAIR FRONT WHEEL REPLACEMENT REAR WHEEL REPLACEMENT CLUTCH REPLACEMENT TIMING SETUP AND BALANCING SHAFT SETUP WATER PUMP DISASSEMBLY DISTRIBUTOR REPLACEMENT FRONT WHEEL ALIGNMENT THE USING,MAINTENANCE AND REPAIR OF THE FRONT/REAR REDUCER PERIODIC MAINTENANCE WIRING DIAGRAM JNSZ650UV LIMITIED WARRANTY DEALER PRE-DELIVERY INSPECTION

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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. WARNING The enclosure cannot protect occupants in all foreseeable accidents,including rollover. JOYNER JOYNER!! S (2) WARNING Keep hands,body,other persons away when closing bed. Do not operate the vehicle with bed up. S (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 S (1) 16

17 ! 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. JOYNER S (1) WARNING JOYNER MAX3.9INCH (100MM) S (1) WARNING Turning 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. Improperly 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. JOYNER S JOYNER S (1) WARNING Improper use can result in Severe INJURY or DEATH. This off-highway utility vehicle will handle and maneuver differently from an ordinary passenger car or other vehicle. ALWAYS wear a seat belt when riding in the vehicle. keep your hands and feet 17

18 JOYNER S (3) TYPE: MANUFACTURER: NW: VIN/NIV: JOYNER JOYNER CHINA MAX. LOAD: S (1) 18

19 Note:! WARNING The enclosure cannot protect occupants in all foreseeable accidents,including rollover. JOYNER S (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 19

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. 20

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 21

22 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 Set the switch to when turn left 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 22

23 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 Accelerator pedal Clutch pedal Brake 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. 23

24 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 24

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 25

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, 26

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 27

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. 28

29 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. 29

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. 30

31 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 31

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 32

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. 33

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. 34

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 Dimensions: Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore stroke Compression ratio JNSZ650UV 2980mm 1435mm 1820mm 770mm 1980mm 280mm 4500mm 645kg Liquid cooled 4stroke Upstanding double cylinder 644cc 76mm 71mm 8.4:1 35

36 Starting system Lubrication system Engine ail Type Recommended engine ail classification Quantity: With oil filter cartridge replacement Final gear case oil: Type Quantity Radiator capacity(including all routes): Air filter: Engine Intake duct Fuel: Type Fuel tank capacity Carburetor: Type Spark plug: Type/manufacturer Spark plug gap Clutch type: Transmission: Crank to primary shaft Primary to secondary Final Transmission type Operation Chassis Tire Frame type Caster angle Type Size front rear Electric starter Wet sumb >0 SE15W/40, <0 SE15W/30 2.9L SAE85 API GL-5 hypoid gear oil 0.7L 1.4L Wet element Dry element Unleaded gasoline only 28L P32Q-1 T4196J 0.7±0.1mm Dry,digphragm spring 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: Two:2.559 Three:1.654 Four:1 Reverse:4.271 Manual Right hand operation Steel tube frame 6º Tubeless 25 inch 25 inch 36

37 Tire (option) Type Size front rear Brakes: System Type front rear Operation Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shack absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capacity Specified fuses: Main fuse Headlight fuse Signaling system fuse Tubeless 27 inch 27 inch Front and rear unified Dual disc brake Dual disc brake Foot operation Double wishbone Double wishbone Coil spring/oil damper Coil spring/oil damper 120mm 120mm Distributor block AC magneto Lead acid storage battery 12V 36Ah 35A 20A 15A Bulb voltage, wattage quantity: Headlight Tail/brake light Indicator lights: Reverse indicator light Coolant temperature warning light Parking brake indicator light Four-wheel-drive indicator light 12V 35W/35W 2 12V 5W/21W 2 LED LED LED LED 37

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. 38

39 Accelerator pedal Clutch pedal Brake pedal 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. 39

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. 40

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 41

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 UV 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. 42

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 43

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 Max speed in each gear The first 1000 km 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. 44

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. 45

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. 46

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 47

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. 48

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 ~ 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. 49

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. 50

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 51

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. 52

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 53

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. 54

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. 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) 55

56 Camshaft timing sprocket wheel Mark Left balancing shaft sprocket Right shaft sprocket balancing Figure 1 Crank shaft Mark here Mark Left balancing shaft sprocket Figure 2 56

57 Make a Mark 30mm above the bolt 30mm Mark Figure 3 Left balancing shaft sprocket Water pump disassembly 1. Take off fan belt and loosen 4 bolt tightening water pump pulley. Fan belt Bolt Figure 4 2. Loosen the 6 bolts shown as the Figure 5. Water pulley pump 57

58 Bolts Bolts 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. Clamp Bolts Water pipes Figure 6 58

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 59

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 60

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. 61

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. 62

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 63

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 ml. 64

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 65

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 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 M for adding oil 45~55 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. 66

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. Item Time of service 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 67

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, I I I I Brake 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 68

69 WIRING DIAGRAM Distributor coil,ign Ignition switch Turning signal,before R NR 2WD/4WD Spotlight switch ON green ON High beam switch blue ON Dipped beam switch green Turn signal switch Reverse indication L yellow red OFF Charge indication Horn button SB RS R U SR S oil warninig indication GY W B YW NB U U Fuse 20A U Turning signal indication, R YG Compounding meter Turning signal indication, L Speedmeter Fuel meter Thermometer Tachometer Fuse 35A Fuse 15A Headlight WG Headlight Turning signal,before L P UW B NB B N R RB t R GY B Y GB o C B B R R Wire's colour symbol Brakes light switch Horn Flasher Radiator fan Thermometer Swich (82 o C) RS---red/grey B---black R---red U---blue RU---red/blue P---purple S---grey W---white YG---yellow/green L---Cambridge blue N---brown K---pink NB---brown/black NR---brown/red UW---blue/white RB---red/black GY---green/yellow SB---grey/black BR---black/red Y---yellow WG---white/green GB---green/black WR---white/red BW---black/white Speed sensor Rectifier, regulator 14V Alternator 14V 35A reverse switch Oil sensor water temperature sensor Start motor( take the electromagnetism switch) 12 Battery 12V35Ah Fuel sensor Fuel pump M WG Fuse 5A Turning signal,rear R B NR NR K L B P R R W L YG W L K B G G R 3 ~ OP S M - + YG UW Tail lamp/ the brake light K Turning signal,rear L R reverse warn R 69

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. 70

71 DEALER PRE-DELIVERY INSPECTION 157