Joyner Go-kart JNSZ650DS, Owner'S Manual

Page 1: ...TYINFORMATION MINIMUM RECOMMENDED OPERATOR AGE JNSZ650DS FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only USA only It does not confirm to federal motor vehicle saf...

Page 2: ...DS during the 90 days warranty period please contact your nearest authorized dealer for repairs What is not covered under this warranty This warranty does not cover any seller vehicle that has been su...

Page 3: ...TION 5 4 SAFETY LABELS 7 5 ARE YOU READY TO DRIVE 8 6 IS YOUR VEHICLE READY TO DRIVE 10 7 SAFE DRIVING PRECAUTIONS 12 8 SPECIFICATIONS 14 9 OPERATIONS 15 10 SERVICE INSTRUCTIONS 20 11 REPAIR 24 12 PER...

Page 4: ...lt in serious injuries Be sure to follow the recommended maintenance schedule and service your kart accordingly Preventative maintenance is extremely important to the longevity of your Go Kart JOYNER...

Page 5: ...Kart You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels On the Go Kart Safety Messages Preceded by a safety alert symbol and o...

Page 6: ...rt take time to become familiar with how this Go Kart works and handles Practice in a safe area until you build your skills and get accustomed to this Go Kart s size and weight Because many accidents...

Page 7: ...Kart Failure to adhere to this warning will cause physical harm to your body Skidding or Sliding The terrain surface can be a major factor affecting turns Skidding a turn is more likely to occur on s...

Page 8: ...mation and recommendations to help you drive your Go Kart safely please take a few moments to read these pages The labels are considered permanent parts of the Go Kart If a label comes off or becomes...

Page 9: ...otorcycle helmet eye protection boots gloves long pants and long sleeved shirt or jacket whenever you drive Although complete protection is not possible wearing proper gear can reduce the chance of in...

Page 10: ...lls Do not drive in rough terrain until you get accustomed to the Go Kart s controls and feel comfortable with its size and weight Operating Go Kart without proper instruction could increase your risk...

Page 11: ...t not only for safety but because having a breakdown or even a flat tire can be a major inconvenience If your Go Kart has overturned or has been involved in a collision do not drive it until your Go K...

Page 12: ...f 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...

Page 13: ...of street vehicles may have difficulty seeing and avoiding you which could lead to a collision In many states it is illegal to operate Go Karts on public streets roads and highways Operating this Go K...

Page 14: ...Kart 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 Go Kart Never drive past...

Page 15: ...ug F6T or F6TC Plug gap 0 7 0 1mm Fuel type RQ93 unleaded Lubricate oil 00 C SAE 15W 40 00 C SAE 10W 30 CAPACITIES Maximum load 200kg Fuel tank 27 0L Engine oil 2900ml Coolant 4000ml Starting 5s Climb...

Page 16: ...s 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 probl...

Page 17: ...engine is not smooth pull out the choke to find the best running position and keep running for a while long until the engine ryns smooth without choke If the engine is warm Press the throttle slightly...

Page 18: ...rive Inspection 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 tr...

Page 19: ...lmet OPERATION C Passengers The vehicle allows for two riders only Combined maximum weight of driver and the passenger should not exceed 180kg or 400Ibs D Seat Adjustment The seat must always be secur...

Page 20: ...th thread glue Then second tighten bolt 2 with thread glue See Fig 7 Figure 7 G Break in The first month is most important in the life of your vehicle Proper operation during this break in period will...

Page 21: ...vent vehicle from rolling over be sure to only turn the vehicle at a slow more controllable speed SERVICE INSTRUCTIONS A Service Air Cleaner Service air cleaner every 80 hours NOTE Service more often...

Page 22: ...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 C Transmission lubrication You must cha...

Page 23: ...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 Figure 16 Figure 17 Put...

Page 24: ...ontinuous 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...

Page 25: ...re 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 counter clockwise see Fig 19 c Connect the tachometer adjust the throttle to li...

Page 26: ...he spark plug hole into the cylinder Crank the engine slowly to spread oil and replace spark plug c Do not save or store gasoline over winter Using old gasoline which has deteriorated from storage wil...

Page 27: ...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 transmiss...

Page 28: ...e starter See Fig 23 Remove the starter See Fig 24 Figure 23 Figure 24 REPAIR 3 Remove two nuts M14 on two side of transmission See Fig 25 26 Figure 25 Figure 26 5 Remove two bolts M8 on the low mud p...

Page 29: ...Figure 27 Figure 28 6 Remove the mud plate See Fig 21 Figure 29 REPAIR 7 Remove the transmission See Fig 30 31 Figure 30 Figure 31 28...

Page 30: ...8 Remove upper mud plate See Fig 32 Figure 32 REPAIR 9 Insert a shaft into the hole See Fig 33 Remove six bolts on the pressing plate of clutch See Fig 34 Figure 33 Figure 34 29...

Page 31: ...te See Fig 35 Remove the friction disc of clutch See Fig 36 37 Figure 35 Figure 36 Figure 37 REPAIR 10 Insert a special shaft into the hole fix new friction plate on the flywheel of engine See Fig 38...

Page 32: ...Figure 42 Figure 43 13 Fix parts according to reverse operation to the disassembly REPAIR D Timing chain 1 Fix the timing chain n the sprocket of crankshaft Mark A on the sprocket of crankshaft must...

Page 33: ...REPAIR E Distributor replacement turn around the crank shaft See Fig 44 direct the line on the pulley of crankshaft straight to the 0 degree line on the cover of engine See Fig 46 32...

Page 34: ...gure 46 2 Remove the rocker cover of head by removing two bolts See Fig 47 Figure 47 REPAIR 3 Check the anchor hole if it is not on the direction shown by Fig Repeat above 1 as to obtain the hole dire...

Page 35: ...aft untill parallel to the crankshaft See Fig 48 49 Figure 48 Figure 49 4 Align the mark 2 on the shaft of distributor to the mark 1 on the aluminum housing See Fig 50 Figure 50 REPAIR 5 Insert the di...

Page 36: ...per the figure See Fig 52 53 Tighten the nut of distributor housing Figure 51 Figure 52 Figure 53 6 Fix the cover of the distributor See Fig 44 Figure 42 REPAIR 7 Check the spark timing Adjust if need...

Page 37: ...ont 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...

Page 38: ...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...

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