Joyner JNSZ650UV4S User manual

Owner’s manual
Parts manual
JNSZ650UV4S

1
INTRODUCTION
Thank you for choosing JOYNER JNSZ650UV4S. 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
CONTROLFUNCTIONS....................................................................................................................21
MAIN SWITCH......................................................................................................................................21
MULTI-FUNCTION METER UNIT............................................................................................................22
SWITCHES ...........................................................................................................................................22
PEDAL.................................................................................................................................................23
PARKING BRAKE LEVER.......................................................................................................................24
DRIVE SELECT LEVER..........................................................................................................................25
FUELTANK CAP ...................................................................................................................................25
SEATS AND SAFETY BELTS ...................................................................................................................25
GLOVE COMPARTMENT........................................................................................................................26
ARE YOU READY TO DRIVE...........................................................................................................27
PROTECTIVE APPAREL.........................................................................................................................28
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.......................................................................................................................30
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

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GEAR SHIFTADJUSTMENT ..................................................................................................................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 SETUPAND BALANCING SHAFT SETUP .....................................................................................55
WATER PUMP DISASSEMBLY.................................................................................................................58
DISTRIBUTOR REPLACEMENT ..............................................................................................................61
FRONT WHEELALIGNMENT ................................................................................................................65
THE USING，MAINTENANCE AND REPAIR OF THE FRONT/REAR REDUCER...............66
PERIODIC MAINTENANCE.............................................................................................................69
WIRING DIAGRAM ...........................................................................................................................71
JNSZ650UV4S LIMITIED WARRANTY..........................................................................................72
PARTS MANUAL ................................................................................................................................73
1CYLINDER BLOCK PART............................................................................................................73
2SPROCKET COVER AND OIL PAN PART..................................................................................76
3CYLINDER HEAD PART..............................................................................................................78
4PISTON ，CONNETING ROD AND CRANKSHAFT PART......................................................82
5BALANCING SHAFT PART .........................................................................................................84
6CAMSHAFT AND CHAIN TRAIN PART.....................................................................................85
7INTAKE MANIFOLD PART .........................................................................................................87
8OIL FILTER AND OIL PUMP PART.............................................................................................88
9WATER PUMP AND FAN PART..................................................................................................89
10 DISTRIBUTOR AND ITS LINE UNIT ........................................................................................90
11 CARBURETOR PART .................................................................................................................91
12 AIR FILTER AND PIPE LINE PART...........................................................................................92
13 STARTER ，ALTERNATOR AND THEIR FASTENING PIECE...........................................93
14 TRANSMISSION TANK..............................................................................................................94
15 CLUTCH，SHIFTER SHAFT AND ROCKER ARM................................................................97
16 FIRST SHAFT AND COUNTERSHAFT .....................................................................................98
17 GEAR SHIFTED GEAR FORK..................................................................................................103
18 FRAME..........................................................................................................................................106

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19 ROLL BAR.....................................................................................................................................107
20 FRONT PROTECT BAR AND ELECTRICAL WINCH ............................................................................108
21 CARGO BED ..................................................................................................................................110
23 DRIVEN SYSTEM...........................................................................................................................114
24 FRONT MAIN REDUCER（FRONT DIFFERENTIAL）.......................................................................121
25 REAR MAIN REDUCER...................................................................................................................126
26 FRONT SUSPENSION SYSTEM.........................................................................................................131
27 REAR SUSPENSION SYSTEM...........................................................................................................132
28 GEAR-SHIFT MECHANISM .............................................................................................................133
29 STEERING ASSY ............................................................................................................................136
30 RADIATOR ASSY ...........................................................................................................................139
31 THROTTLE AND PARK BRAKING....................................................................................................141
32 FUEL TANK AND GASOLINE PUMP .................................................................................................144
33 SEAT AND SAFETY BELT ...............................................................................................................147
34 ELECTRICAL APPLIANCE AND OTHER PARTS .................................................................................149
35 PLASTIC PARTS .............................................................................................................................154
36ACCESSORIES（OPTION）............................................................................................................156
37 SNOW SCRAPER（OPTION）.........................................................................................................157
DEALER PRE-DELIVERY INSPECTION.....................................................................................159

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.
WARNING
The 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)

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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
WARNING
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.
S650.09.04.00.06(1)
JOYNER
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.
S650.09.04.00.07
WARNING
This off-highway utility vehicle will
handle and maneuver differently from
an ordinary passenger car or other
ALWAYS
wear a seat belt when riding in the
vehicle.
Improper use can result in Severe INJURY or DEATH.

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S650.09.04.00.11(3)
JOYNER
MAX . LOAD:
JOYNER CHINA
VIN/NIV:
NW:
MANUFACTURER:
TYPE:
S650.09.04.00.12(1)
JOYNER

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Note:
WARNING
The 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