Joyner JNSZ650DL, Owner'S Manual

Page 1: ...Owner s manual Parts manual READTHISMANUALCAREFULL Y ITCONTAINS IMPORTANTSAFETYINFORMATION MINIMUM RECOMMENDED OPERATOR AGE JNSZ650DL 0 ...

Page 2: ...e of improper maintenance improper assembly alterations abuse negligence or accident Should warranty service be required on your JNSZ650DL 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 ...

Page 3: ... 3 IMPORTANT SAFETY INFORMATION 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 PERIODICAL CHECK AND SERVICE 36 13 WIRING DIAGRAM 37 PARTS MANUAL PREPARATION ATTACH INSTRUCTIONS 2 ...

Page 4: ...ult 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 believes in conservation and protection of earth s natural resources To that end we encourage every vehicle owner to recycle trade in or properly dispose of as appropriate used motor oil coolant and ...

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 one of two signal words WARNING or CAUTION These signal words mean Physical harm may result from failure to adhere to the instructions that are described within the WARNING labels Safety Headings such...

Page 6: ...f road use only The tires are not made for pavement and the Go Kart does not have turn signals and other features required for use on public roads If you need to cross a paved or public road get off and walk your Go Kart across Take Time to Learn Practice Even if you have driven other Go Kart take time to become familiar with how this Go Kart works and handles Practice in a safe area until you bui...

Page 7: ...rs The exhaust from the engine contains a tasteless odorless and poisonous gas called carbon monoxide IMPORTANT SAFETY INFORMATION Keep away from moving parts of the Go Kart The operator of the Go Kart should never place their hands or other parts of their body near any moving part of the Go Kart Failure to adhere to this warning will cause physical harm to your body Skidding or Sliding The terrai...

Page 8: ...rmation 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 hard to read contact your dealer for warning labels replacements 7 ...

Page 9: ...get you prepared this section discusses how to evaluate your driving readiness what items you should check on your Go Kart and adjustments to make for your comfort convenience or safety Before you drive your Go Kart for the first time we urge you to Read this owner s manual and the labels on your Go Kart carefully 8 ...

Page 10: ...ffers 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 Go Kart without wearing an ...

Page 11: ...g over could lead to serious injury or death Never support with your hands to ground when the Go cat will turn over Age Recommendation It is strongly recommended that no one under the age of 16 be permitted this Go Kart without adult supervision A child driving a Go Kart that is not recommended for his her age could lose Go Kart control and result in severe injury or death A child under 16 should ...

Page 12: ...o Kart or failing to correct a problem before driving can cause a crash in which you can be seriously hurt or dilled Always perform a pre drive inspection before every drive and correct any problems Pre drive Inspection Check the following items before you get on the Go Kart Engine Oil Check the level and add oil if needed Check for leaks Coolant Check the coolant and add coolant if need Check for...

Page 13: ...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 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 tig...

Page 14: ...lision with other vehicle Never operate this Go Kart 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 Go Kart It is important to maintain your balance and control of the Go Kart Removing hands or feet away from the controls can reduce your ability to re...

Page 15: ...visibility Maintain a safe distance between your Go Kart and other off road vehicles Always exercise caution and use extra care on rough slippery and loose terrain Failure to use 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...

Page 16: ...l Coolant 4000ml Starting 5s Climbing 20 25 Battery 12V36Ah Head Light 12V 150W Both Tail Light 12V 80W Both Fuse 30A SPECIFICATIONS Brake Track 7m 20miles h Top speed 50 miles h or limited as customers require CHASSIS Front Rear brake Hydraulic disc right foot control Front tire 25 8 12 Rear tire 25 10 12 Front Suspension Independent Dual A Arm Rear Suspension Independent Dual A Arm Final Drive s...

Page 17: ...e 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 b Brake The brake is located on the middle of the three control pedals See Fig 1 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 kart c Clutch T...

Page 18: ...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 br...

Page 19: ...othly 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 12psi 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 ...

Page 20: ...mpting to adjust the seat ensure that engine of the Go Kart is stopped Never operate this Go Kart 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 Go Kart is stopped E Parking Adjustment Park brake OFF Park brake On Figure 6 a Pull the park brake lever u...

Page 21: ... speed on the below schedule The speed of vehicle The first 1000 km 1st Gear 15 km h 2nd Gear 25km h 3rd Gear 40 km h Max speed in each gear 4th Gear 70km h H Starting And Operating Instructions a Before starting the engine be sure that the driver is seated properly in the Go Kart and tighten the seatbelt b Testing the Go Kart in a open place at the beginning to learn how to start turn and stop c ...

Page 22: ...ue to excessive wear Figure 10 Figure 11 Figure 12 Figure 13 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 see Fig 10 c Tighten the engine oil outlet plug d Remove the oil filler cap see Fig 11 fill oil SE 15W 40 or SF 15W 40 about 2 ...

Page 23: ...ne Let the transmission oil out fully see Fig 15 c Remove the iron dust plug this plug has a magnet on it Iron dust caused by moving parts will stick to the plug Clean the iron dust from this dust plug d Tighten the transmission oil outlet plug and the iron dust plug e Remove dipstick of transmission see Fig 14 fill oil GL 4 85W 90 about 1 9 liters f Insert the transmission dipstick check the oil ...

Page 24: ...cified 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 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 ...

Page 25: ...mage may occur if you use coolant that does not meet the specifications E 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 gaug...

Page 26: ...ure to check that air intake fan is free of debris for proper cooling H Kart Lubrication Lubricate vehicle every 90 days of use Apply several drops of oil in specific points I Storage Instruction In the event your kart is not to be operated for periods in excess of 30 days or at the end of each driving season prepare for storage as follows a Drain fuel tank and carburetor by allowing engine to run...

Page 27: ...Rear Wheel Replacement Do not disassemble the center castle nuts when you replace the front wheels See Fig 21 Tighten the nuts after replacing the wheels Figure 21 REPAIR C Clutch replacement Do not remove the whole engine from vehicle when you replace the clutch but 26 ...

Page 28: ... and rubber cushion that is in the middle of transmission and frame 1 Remove bolt M14 See Fig 22 Figure 22 2 Remove two bolts M12 on the 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 27 ...

Page 29: ...gure 25 Figure 26 5 Remove two bolts M8 on the low mud plate of transmission See Fig 27 28 Figure 27 Figure 28 6 Remove the mud plate See Fig 21 Figure 29 REPAIR 7 Remove the transmission See Fig 30 31 28 ...

Page 30: ...Figure 30 Figure 31 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 29 ...

Page 31: ... Figure 34 10 Remove the pressure plate 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 30 ...

Page 32: ...wo bolts with Y G mark must be inserted into two anchor hole See Fig 40 Tighten six bolts with torque 30 N m See Fig 41 Figure 40 Figure 41 12 Fix upper mud plate See Fig 42 43 Figure 42 Figure 43 13 Fix parts according to reverse operation to the disassembly REPAIR 31 ...

Page 33: ...shaft Mark A on the sprocket of crankshaft must be in the middle of double white links of timing chain 2 Fix the guide plate 3 Fix the tensional plate 4 Fix the sprocket Mark on the sprocket must be in straight line to the single white link on the chain REPAIR 32 ...

Page 34: ...he 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 Figure 44 Figure 45 Figure 46 2 Remove the rocker cover of head by removing two bolts See Fig 47 Figure 47 33 ...

Page 35: ...s to obtain the hole direction shown by Fig 3 Insert the screwdriver into the hole turn the drive of oil pump shaft 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 34 ...

Page 36: ...r slowly to the hole See Fig 51 Confirm the direction of distributor is as 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 35 ...

Page 37: ...e 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 c 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 adjuste...

Page 38: ...or ignition I 10 Air cleaner C I 11 Throttle cable and choke I A L I R A 12 Fuel tank cover Breathe hose and joint I I R 13 Idle I 14 Breathe hose I 15 Fuel hose and joints I I I R Control system 16 Wire and plugs I 17 The free display of clutch pedal I I R 18 Brake fluid hose joints I 19 The free display of brake pedal Brake I I I I 20 Parking I 21 Brake shoes and disc I I R Chassis 22 Tires I R ...

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