Joyner JNSZ1600DL User manual

Owner’s manual JNSZ1600DL
Parts manual
READTHISMANUALCAREFULLY
ITCONTAINSIMPORTANTSAFETYINFORMATION.
MINIMUM
RECOMMENDED
OPERATOR AG
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for off-road use only.
USAonly;
It does not confirm to federal motor vehicle safety standards, and operation on public streets, roads, or
highways is illegal
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JNSZ1600DLLimited Warranty
The warranty policy applies to those cases where the new sold 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 sold was defective because of improper
maintenance, improper assembly, alterations, abuse, negligence or accident.
Should warranty service be required on your JNSZ1600DL 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 sold vehicle that has been subjected to:
a. This warranty does not cover any sold 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 sold 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 sold distributor or its authorized dealer.
Seller has the rights to make changes without notice.

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CONTENTS
OWNER’S MANUAL
Page
1. FOREWORD-----------------------------------------------------------------------------------------------3
2. AFEW WORDSABOUT SAFETY--------------------------------------------------------------------4
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 DRIVINGPRECAUTIONS-------------------------------------------------------------------- 12
8. SPECIFICATIONS----------------------------------------------------------------------------------------13
9. OPERATIONS -------------------------------------------------------------------------------------------- 14
10. SERVICE INSTRUCTIONS --------------------------------------------------------------------------- 20
11. REPAIR----------------------------------------------------------------------------------------------------- 26
12. ABOUT ENGINE------------------------------------------------------------------------------------------27
13. PERIODICALCHECKAND SERVICE-------------------------------------------------------------28
14. ENGINE MAINTENANCEAND SERVICE ------------------------------------------------------- 29
15. TRANSMISSION MAINTENANCEAND SERVICE---------------------------------------------128
16. WIRING DIAGRAM -------------------------------------------------------------------------------------151
PARTS MANUAL -----------------------------------------------------------------------------152

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SPECIFICATIONS
DIMENSIONS
Overall Length---------------------------------------------------------------------------------------128.5in. (3265mm)
Overall Width ---------------------------------------------------------------------------------------88.5 in. (2250mm)
Overall Height ----------------------------------------------------------------------------------------71.7 in. (1822mm)
Wheelbase ---------------------------------------------------------------------------------------------89.8 in. (2280mm)
Front Track ------------------------------------------------------------------------------------------- 68.8 in. (1748mm)
Rear Track --------------------------------------------------------------------------------------------72.4in. (1840mm)
Ground Clearance ------------------------------------------------------------------------------------ 14.2in. (360mm)
ENGINE
Type ---------------------------------------------------------------------------------4-Bore,4-Stroke, Liquid-cooled
Bore x Stroke --------------------------------------------------------------------------------------------79.94mm×79.52mm
Displacement ------------------------------------------------------------------------------------------------------1596 cc
Compression ratio-------------------------------------------------------------------------------------------------9 .75:1
Carburetor ---------------------------------------------------------------------------------------------Electric Fuel Injection
Max Power --------------------------------------------------------------------------------------------71kw/5500rpm
Maximum Torque ---------------------------------------------------------------------------135/2500~4000Nm/r/min
Starting ----------------------------------------------------------------------------------------------------------- Electric
Ignition ------------------------------------------------------------------------------------------------------------- C.D.I
Lubrication -------------------------------------------------------------------------------------------- Force & Splash
Transmission ----------------------------------------------------------------------- manual clutch, 4 shift/Reverse
Spark Plug -------------------------------------------------------------------------------------------------------K7RTC
Torque Of Spark Plug---------------------------------------------------------------------------------------- 17.0-30.0Nm
Fuel type --------------------------------------------------------------------------------------------- RQ90 (unleaded)
Lubricate oil ---------------------------------------------------------------------------------------------- SAE-10W/40
CAPACITIES
Maximum load -----------------------------------------------------------------------------------------------------300kg
Fuel tank ------------------------------------------------------------------------------------------------------------ 58.0L
Engine oil ----------------------------------------------------------------------------------------------------------3860ml
Coolant -------------------------------------------------------------------------------------------------------------6000ml
Starting ---------------------------------------------------------------------------------------------------------------- <5s
Climbing ---------------------------------------------------------------------------------------------------------- 20°-25°
Battery ---------------------------------------------------------------------------------------------------------- 12V45Ah
Head Light ----------------------------------------------------------------------------------------------12V 55/55W/Both
Tail Light ----------------------------------------------------------------------------------------------12V10W/5W/21W/Both
Spot light----------------------------------------------------------------------------------------------------12V35W/Four
Main Fuse ------------------------------------------------------------------------------------------------------------------50A
SPECIFICATIONS
Brake Track ----------------------------------------------------------------------------------------- < 7m @ 20miles/h
Top speed ------------------------------------------------------------100 miles/h (or limited as customers require)
CHASSIS
Front, Rear brake --------------------------------------------------------------- Hydraulic disc, right foot control
Front tire --------------------------------------------------------------------------------------------------------- 27×7.5-15
Rear tire -----------------------------------------------------------------------------------------------------------28×15.5-15
Front Suspension --------------------------------------------------------------------------- Independent Dual A-Arm
Rear Suspension ---------------------------------------------------------------------------Longitudenal Control Arm
Final Drive --------------------------------------------------------------------------------------------------- shaft driven
TIRE PRESSURE
Front ----------------------------------------------------------------------------------------- 115kpa 1.15kg/c ㎡16psi
Rear ------------------------------------------------------------------------------------------ 115kpa 1.15kg/c ㎡16psi
WEIGHT
Net Weight ---------------------------------------------------------------------------------------------------------750kg
WARRANTY
Parts and workmanship -------------------------------------------------------------------------------------- 90 Days

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A. Operation controls OPERATION
WARNING-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.
a. Throttle
The right foot pedal is the throttle that controls the ATV speed. To disengage the clutch at any time,
allow the throttle to return to the idle position. (See Fig. 1)
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.
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
The left foot pedal controls the clutch cable (See Fig. 1). With the pedal down, you can shift the
shift lever.
Improper operation of the clutch will lead to excessive wear of the clutch friction surface.
Fig. 1