JNSZ 650 DL
JNSZ 650 DL
JNSZ650DL
.
MINIMUM
RECOMMENDED
OPERATOR AGE.
TION.
Specifications ........................................................................................................................................ 28
Operation ............................................................................................................................................... 29
Operation controls ............................................................................................................................ 29
Engine stop key ................................................................................................................................ 31
Pre-Drive Inspection ......................................................................................................................... 31
Passengers......................................................................................................................................... 33
Seat ................................................................................................................................................... 33
Parking .............................................................................................................................................. 34
Gear Shift .......................................................................................................................................... 35
Break-in ............................................................................................................................................ 35
Starting and Operating Instructions .................................................................................................. 35
Repair .................................................................................................................................................... 42
Front Wheel Replacement ................................................................................................................ 42
Rear Wheel Replacement.................................................................................................................. 42
Clutch replacement ........................................................................................................................... 43
Timing setup and balancing shaft setup ............................................................................................ 47
Water pump disassembly .................................................................................................................. 49
Distributor replacement .................................................................................................................... 51
Be sure to follow the recommended maintenance schedule and service your Off
Highway Recreational Vehicle accordingly. Preventative maintenance is
extremely important to the longevity of your Off Highway Recreational Vehicles.
To help you make informed decisions about safety, we have provided operating
procedures and other information on labels and in this manual. This information
alerts you to potential hazards that could hurt you or others.
It is not practical or possible to warn you about all hazards associated with
operating or maintaining a Off Highway Recreational Vehicle. You must use your
own good judgment.
Physical harm may result from failure to adhere to the instructions that are
described within the WARNING labels.
Instructions --- how to use this Off Highway Recreational Vehicles correctly
and safely.
There is a lot you can do to protect yourself when you drive. You‘ll find many
helpful recommendations throughout this manual. The following are a few that
we consider most important.
Skidding or Sliding
The terrain surface can be a major factor affecting turns, Skidding a turn is
more likely to occur on slippery surfaces such as snow, ice, mud and loose
gravel. If you skid on ice, you may lose all directional control. To avoid skidding
on slippery terrain, keep you speed low and drive carefully.
Before you drive your Off Highway Recreational Vehicles for the first time, we
urge you to do following:
■ Read this owner‘s manual and the labels on your Off Highway Recreational
Vehicles carefully.
■ Make sure you understand all the safety messages.
■ Know how to operate all the controls.
■ Never drive this Off Highway Recreational Vehicles if under 16 years old.
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 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.
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, date 070202.
Drive Training
Developing your driving skills is an on-going process. Even if you have driven
other Off Highway Recreational Vehicless, take time to become familiar with how
this Off Highway Recreational Vehicles works and handles. Practice driving the
Off Highway Recreational Vehicles in a safe area to build your skills. Do not drive
in rough terrain until you get accustomed to the Off Highway Recreational
Vehicles‘s controls, and feel comfortable with its size and weight.
Attempt supporting with your hands to the ground when the Vehical
turning over could lead to serious injury or death.
Never support with your hands to ground when the Vehicles will turn over.
Age Recommendation
It is strongly recommended that no one under the age of 16 be permitted this
Off Highway Recreational Vehicles without adult supervision.
No Alcohol or Drugs
Alcohol, drugs and Off Highway Recreational Vehicles don‘t mix. Even a
small amount of alcohol can impair your ability to operate a Off Highway
Recreational Vehicles safely. Likewise, drugs, even if prescribed by a physician,
can be dangerous while operating a Off Highway Recreational Vehicles. Consult
your doctor to be sure it is safe to operate a vehicle after taking medication.
Pre-drive Inspection
Check the following items before you get on the Off Highway Recreational
Vehicles:
Engine Oil
Check the level and add oil if needed. Check for leaks.
Coolant
Check the coolant and add coolant if need. Check for the leaks.
Fuel
Check the level and add fuel if needed. Also make sure the fuel fill 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.
Pre-drive Inspection
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 Off Highway
Recreational Vehicles.
Air Cleaner
Check the air filter. Replace it if needed.
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 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.
When driving off-road, also remember to always obey local off-road driving
laws and regulations. Obtain permission to drive on private property. Avoid
posted areas and obey ―no trespassing‖ signs.
You should never drive your Off Highway Recreational Vehicles 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 Off Highway Recreational Vehicless on public
streets, roads and highways.
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 Off
Highway Recreational Vehicles, the terrain, visibility and other operating
conditions, plus your own skills and experience.
Failure to use extra care when Operating this Off Highway Recreational
Vehicles on unfamiliar terrain could result in the Off Highway Recreational
Vehicles 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 Off
Highway Recreational Vehicles.
Never drive past the limit of visibility. Maintain a safe distance between your
Off Highway Recreational Vehicles and other off-road vehicles. Always exercise
caution and use extra care on rough, slippery and loose terrain.
ENGINE
Type --------------------------------------------------------------------------------- 2-Bore,4-Stroke,
Liquid-cooled
Bore x Stroke -------------------------------------------------------------------------------------------- 76mm×71mm
Displacement ------------------------------------------------------------------------------------------------------ 644 cc
Compression ratio ------------------------------------------------------------------------------------------------8.4:1
Carburetor ------------------------------------------------------------------------------------ BJH101E or CSH101E
Max Power --------------------------------------------------------------------------------------------20.6kw/5300rpm
Maximum Torque ---------------------------------------------------------------------------44/2700~3300Nm/r/min
Starting -----------------------------------------------------------------------------------------------------------
Electric
Ignition ------------------------------------------------------------------------------------------------------------- C.D.I
Lubrication -------------------------------------------------------------------------------------------- Force & Splash
Transmission ----------------------------------------------------------------------- manual clutch, 4 shift/Reverse
Spark Plug ---------------------------------------- --------------------------------------------------------F6T or F6TC
Plug gap ---------------------------------------------------------------------------------------------------- 0.7±0.1mm
Fuel type --------------------------------------------------------------------------------------------- RQ93 (unleaded)
Lubricate oil ---------------------------------------------------------------------------------------------- SAE-15W/30
CAPACITIES
Maximum load ---------------------------------------------------------------------------------- -----------------200kg
Fuel tank ------------------------------------------------------------------------------------------------------------ 23.0L
Engine oil ----------------------------------------------------------------------------------------------------------2900ml
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 --------------------------------------------------------------------------------------------------------- 25×10-12
Rear tire ----------------------------------------------------------------------------------------------------------- 25×8-12
Front Suspension --------------------------------------------------------------------------- Independent Dual A-Arm
Rear Suspension --------------------------------------------------------------------------- Independent Dual A-Arm
Final Drive --------------------------------------------------------------------------------------------------- shaft driven
TIRE PRESSURE
Front ----------------------------------------------------------------------------------------- 70kpa 0.7kg/c ㎡ 10psi
Rear ------------------------------------------------------------------------------------------ 70kpa 0.7kg/c ㎡ 10psi
WEIGHT
Net Weight ---------------------------------------------------------------------------------------------------------460kg
WARRANTY
Parts and workmanship -------------------------------------------------------------------------------------- 90 Days
Throttle
The right foot pedal is the throttle that controls the Off Highway Recreational
Vehicles 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.
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 vehical.
Clutch
The left foot pedal controls the clutch cable (See Fig. 1). With the pedal down,
you can shift the shift lever.
Clutch pedal
[5pedl]
Figure 1 Shift n.踏板
lever
v.踩...的踏板
Speedome Tachomet Horn Fuel level gauge
ter er button
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 Coolant temperature Voltmete Combination switch
Ignition-switch
indicator r
Figure 2
If the engine is cold
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 runs smooth without choke.
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 10 seconds, a second attempt to start
the engine can be allowed. Improper operation will damage the engine.
1. Check for Engine Oil Level. Check for transmission Oil Level. Check for leaks,
add oil if required. (See page 36, Engine oil replacement, and page
37Transmission lubrication)
2. Check the coolant. Check for leaks, add the coolant if required. (See page38
Engine Coolant)
Brake light
Fuel tank
Figure 3
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.
Clutch cable
Brake pedal
Figure 4
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. (See Figure 4)
6. Check Tires. Check tires condition and pressure. The pressure on both Front
and Rear tire is 12psi.(see Figure 5)
Rear tire
Front tire
Figure 5
Axile nuts
Steering wheel
Figure 6
Passengers
The vehicle allows for two riders only.
Combined maximum weight of driver
and the passenger should not exceed 180kg
or 400Ibs.
Seat
The seat must always be securely
fastened in the position which best
allows the operator control of the foot
pedals, steering wheel, and the remote
stop key. Figure 7
Before attempting to adjust the seat ensure that engine of the Off
Highway Recreational Vehicles is stopped.
Parking
a. Pull the park brake lever up so that the unit can engage park brake.
b. To release the unit, press button on front end of parking lever then push the
parking lever to the bottom.
c. Adjust the parking cable if necessary. As the figure shown, adjust the
adjustment nuts to make sure the cable tight, and then tighten lock nuts.
Lock nuts
Figure 12
Figure 11
1. Operate the gear shift as the picture shown. and the max speed in every
gear position is shown as the following form(see Figure 11)
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
Service instructions
Air filter
Service air cleaner every 80 hours
NOTE: Service more often under dusty conditions.
Remove filter cover,
Check the filter cover and the air filter for dusty,
If necessary, clear the filter cover and the filter with special liquid or replace them
with a new one. (See Figure 15)
Filter cover
Figure 15 Filter
Figure 17 Figure 16
Figure 19
With the engine warm, put the vehicle on the level ground.
a. 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
Figure 17).
b. Tighten the engine oil outlet plug.
c. Remove the oil filler cap (see Figure 16), fill oil (SAE 10W/10~50) about 2.8
liters to the engine.
d. Pull out the engine oil dip stick (see Figure 16), confirm the corrective oil
level in the crankcase (see Figure 19).
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.
Figure 21 Figure 20
a. Put the vehicle on the level ground.
b. 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 (see Figure 20).
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.
Engine Coolant
You must check the coolant for level and leaks. If it is low, you need to refill
coolant into the radiator (approximately 4L). 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 22 Figure 23
Put the vehicle on level ground.
1. Turn the coolant cap counterclockwise and open the cap (see Figure 22
Figure 23).
2. Pour fresh coolant to filler neck.
3. Start the engine at idle.
4. Increase the engine rev‘s 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 (see
Figure 22 Figure 23).
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
Harm or damage may occur if use coolant that does not meet the
specification 50% standard green coolant and 50%distill water.
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 0.025‖~0.030‖. Figure 24
b. Before installing spark plug coat threads
lightly with graphite grease if possible,
to ensure easy removal next time the spark plug
needs inspection (see Figure 24).
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
Figure 25
Cleaning Instructions
Keep your vehical clean. With a clean rag, wipe off and dirt and oil from
around controls. Wipe off any spilled fuel and oil. Keep the engine clean of
foreign object and be sure to check that air intake fan is free of debris for proper
cooling.
Vehicles Lubrication
Lubricate vehicle every 90 days of use, Apply several drops of oil in specific
points shown as following picture
Do not drain fuel while engine is hot. Be sure to move Off Highway
Recreational Vehicles outside before draining fuel.
Figure 26
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 (See Figure 28)
Bolt M14
Figure 28
2. Remove two bolts (M12) on the starter (See Figure 30), Remove the starter
(See Figure 29)
Bolt M12
Starter
Figure 30 Figure 29
Bolt M14
Bolt M14
Figure 32 Figure 31
1. Remove two bolts(M8) on the lower mud plate of transmission (See Figure
33,Figure 34)
Bolt M8
Figure 34 Figure 33
Figure 35
Transmission Engine
Figure 37 Figure 36
Figure 38
5. Insert the aligning shaft into hole (See Figure 40). Remove six bolts on the
pressing plate of clutch (See Figure 39)
Bolt
Bolt
Aligning shaft
Bolt Aligning shaft
Figure 40 Figure 39
6. Remove the pressure plate (See Figure 42).
Remove the friction disc of clutch (See Figure 41,Figure 43)
Figure 42 Figure 41
Figure 43
10. Insert the aligning shaft into the hole; align new friction plate to the flywheel
of engine (See Figure 44,Figure 45).
Figure 45 Figure 44
10. Fix pressure plate of clutch. Two bolts with ―Y.G‖ mark must be inserted into
two anchor holes. Tighten six bolts with torque 30 N.m (See Figure 46,Figure
47).
Torque 30 N*M
Figure 47 Figure 46
12. Fix upper mud plate (See Figure 48,Figure 49Figure 49)
Figure 49 Figure 48
Mark
Crank shaft
Figure 50
Mark
Left balancing
shaft sprocket
Figure 51
Make a Mark
30mm above
the bolt
30mm Mark
Left balancing
shaft sprocket
Figure 52
Fan belt
Bolt
Water pump
pulley
Figure 53
Bolts
Bolts
Figure 54
3. Loosen the clamp bolts shown as Figure 55, and disconnect two peace of
water pipe, and take off the water pump. The engine without water pump is
Clamp Bolts
Water pipes
Figure 55
Figure 56
Distributor replacement
1) Turn around the crank shaft, align the line on the pulley of crankshaft straight
to the 0 degree line on the cover of engine (See Figure 57,Figure 58,Figure
Figure 58 Figure 57
Figure 59
2) Remove the rocker cover of head by removing two bolts (See Figure 60)
Figure 60
3) Check the anchor hole, if it is not on the direction shown by Fig. Repeat
4) Insert the screwdriver into the hole, turn the drive of oil pump shaft until
parallel to the crankshaft (See Figure 62,Figure 63)
Figure 62 Figure 61
5) Align the mark 2 on the shaft of distributor to the mark 1 on the aluminum
housing (See Figure 63)
Figure 63
6) Insert the distributor slowly to the hole (See Figure 64). Confirm the direction
of distributor is as per the figure (See Figure 65,Figure 66). Tighten the nut of
distributor housing.
Figure 64
Figure 67
A. Gear shift
Short crank
Shifter shaft
Shifter shaft
Figure 68 Figure 69
Washer
Short crank
Figure 70 Figure 71
2) Install thin pivot plate and long crank. (see Figure 72
Figure 73
Figure 72 Figure 73
Step 2 finished
3) Install the shifter shaft ASSY finished above to transmission. (See Figure 74)
Bolt M10x1.5x20
Figure 74
B. Front Wheel Alignment
Figure 75
BR
R
U
SB
L L SR
S
WG
W W
W WB
Spot switch 1
Dipping switch 2
Charge indicator
NR
G
K
3~
Alternator
RB 14V 35A
Charge indicator
Charge indicator GR
Distributor coil,ign
block
NB
U
P
UW
Figure 76