Joyner TROOPER T2 Owner's Manual
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Joyner TROOPER T2 Owner's Manual

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Owner's Manual
Parts manual
READ THIS MANUAL CAREFULLY
IT CONTAINS IMPORTANT SAFETY INFORMATION.
MINIMUM
RECOMMENDED
OPERATOR AGE:
16
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 safety standards, and operation on public streets, roads,
or highways is illegal.
TROOPER
T2，T4
1

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Summary of Contents for Joyner TROOPER T2

  • Page 1 Owner’s Manual TROOPER Parts manual T2，T4 READ THIS MANUAL CAREFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION. MINIMUM RECOMMENDED OPERATOR AGE: 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 safety standards, and operation on public streets, roads, or highways is illegal.
  • Page 2 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.

  • Page 3: Table Of Contents

    CONTENTS   Warranty policy ............................6   Parts order form, warranty claim form ....................10   Service record form ..........................11   Preventative maintenance and service log..................12   Location of warning labels and specification labels ................. 17   Safety information ..........................21  ...
  • Page 4   Shift cable adjustment .......................... 47   Parking brake cable adjustment ......................48   Steering lubrication ..........................49   Throttle cable adjustment ........................49   Differential lock cable adjustment ....................... 49 Parking adjustment .......................... 49   Gear shift adjustment ........................50    ...
  • Page 5 5. INTAKE SYSTEM ........................143   5. INTAKE SYSTEM ........................144   6. LUBRICATING DEVICE ......................145   7. CYLINDER HEAD ........................146   7. CYLINDER HEAD ........................147   8. COVER-VALVE CHAMBER ..................... 148   9. OIL PAN ............................149   10.

  • Page 6: Warranty Policy

    Warranty policy...

  • Page 10: Parts Order Form, Warranty Claim Form

    Parts order form, warranty claim form...

  • Page 11: Service Record Form

    Service record form...

  • Page 12: Preventative Maintenance And Service Log

    Preventative maintenance and service log...

  • Page 17: Location Of Warning Labels 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.

  • Page 21: Safety Information

    Safety information THE SAFETY IS FIRST. 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 safari bed.
  • Page 22 18. Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of you. Never go over the top of a hill at speed if you cannot see what is on the other side.

  • Page 23: Are You Ready To Drive

    Are you ready to drive? Before each drive, you need to make sure you and your TROOPER are both ready to drive. To help get you prepared, this section discusses how to evaluate your driving readiness, what items you should check on your TROOPER, and adjustments to make for your comfort, convenience, and safety.

  • Page 24: Drive Training

    Additional Driving Gear In addition to a helmet and eye protection, we also recommend: Sturdy off-road motorcycle boots to help protect your feet, ankles, and lower legs. ■ Off-road motorcycle gloves to help protect your hands. ■ Drive training Developing your driving skills is an on-going process. Even if you have driven other TROOPER, take time to become familiar with how TROOPER works and handles.

  • Page 25: Is Your Vehicle Ready To Drive

    ability to operate a TROOPER safely. Likewise, drugs, even if prescribed by a physician, can be dangerous while operating a TROOPER. Consult your doctor to be sure it is safe to operate a vehicle after taking medication. Operating TROOPER after consuming alcohol or drugs can seriously affect your judgment, cause you to react more slowly, affect your balance and perception, and could result in serious injury or death.
  • Page 26 Nuts & Bolts ■ Check the wheels to see that the axle nuts are tightened, Use a wrench to make sure all accessible nuts, bolts, and fasteners are tight. 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 TROOPER.

  • Page 27: Operation Instruction

    Operation instruction Main switch Functions of the respective switch positions are as follows: ON 2 ON 1 START MAIN SWITCH OFF: All electrical components are switched off except for the turning signals. The ignition key can only be removed in the OFF position ON1: All electrical circuits are supplied with power, except the ignition system and fuel system, the headlights and...

  • Page 28: Gauges

    Bulg Channel Turn off the battery switch when the vehicle is stored for a long time to save power. Gauges 1. Fuel level gauge 2. Tachometer 3. Speedometer 4. Coolant thermometer 5. Voltmeter 6. Oil pressure gauge a fuel level gauge (which shows how much fuel you have in the fuel tank) a tachometer (which shows the engine rotate speed) a speedometer (This shows the riding speed in Km/MPH) a coolant thermometer (which shows the coolant temperature)
  • Page 29 Set the switch to “ ” to turn on the high beam and the taillights. Set the switch to “ ” to turn on the spotlights. Do not use the headlights with the engine turned off for an extended period of time. The battery may discharge to the point that the starter motor will not operate properly.

  • Page 30: Steering Wheel

    “ ” Oil pressure indicator light It indicates over low/over high oil pressure when illuminated, see authorized JOYNER dealer if necessary. Steering wheel Steering wheel is used to control the direction; it can be turned about third four rounds.

  • Page 31: Pedal

    If anyone of them can’t work well, please correct the problem before operating the engine .If you can’t find or solve the problem yourself, please get the help from your JOYNER dealer. Improper operation of the clutch will lead to excessive wear of the clutch friction surface.

  • Page 32: Drive Select Lever

    Adjust the parking cable if necessary. Be sure to fully release the parking brake lever before driving the vehicle. It is allowed use the parking lever as an emergency brake if the foot brake can’t work. Drive select lever The drive select lever is used to shift your vehicle into the 1,2,3,4,5 and R gear positions.

  • Page 33: Fuel Tank

    will make the steering hard. Fuel tank Fuel tank locate under the passenger seat, and fuel tank cap locate behind the passenger seat. unlock Seat lock and turn passenger Seat over Seat lock before unscrew fuel tank cap. Fuel tank cap add gasoline to about 80% of fuel tank.
  • Page 34 Safety belts Cross above left This vehicle is equipped with five-point Cross above right shoulder seat belts for both driver and passenger. shoulder Always wear the seat belt while riding in the vehicle. To wear the seat belt properly, do the following: Cross above right leg 1.

  • Page 35: Safari Bed

    Cross above Cross above right leg 2. Push the latch plates into the buckle , use a right shoulder hook hook connects the end of the belt which crosses left leg and set level. Pull up on the latch plates to make sure it is secure (see right picture).

  • Page 36: Start Engine

    Start engine 1. Engage the parking brake if necessary. 2. Pressing down the clutch pedal can make starting easier, so do that if necessary. 3. Make sure the shift lever in neutral position. 4. Turn the key clockwise to the “start” position and hold it for less than 5 seconds, if engine not started.

  • Page 37: Passenger

    Passenger The vehicle allows for two riders only. The passenger should wear seat belt all the time. 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.

  • Page 38: Specifications

    Specifications Model TROOPER Dimensions: Overall length 3300mm/130 inch Overall width 1600mm/63 inch Overall height 1990mm/78 inch Seat height 800mm/34.6 inch Wheelbase 2470mm/97.2 inch Ground clearance 300mm/11.8 inch Minimum turning radius 6000mm/236 inch Basic weight: With oil and full fuel tank 780kg/1719 Ib Engine: Engine type...
  • Page 39 Transmission type Manual Operation Right hand operation (five shifts, one reverse) Chassis Frame type Steel tube frame Caster angle 3º Tire Type Tubeless Size front 27 inch rear 27 inch Brakes: System Front and rear unified Type front Dual disc brake rear Dual disc brake Operation...
  • Page 40 Indicator lights: Reverse indicator light Coolant temperature warning light Charge indicator light Four-wheel-drive indicator light...

  • Page 41: Maintenance And Adjustment

    Maintenance and adjustment Air Cleaner Clean air filter refer to Preventative maintenance and service log. Under dusty conditions Service more often Filter Cover Rubber bushing Remove filter cover; check the filter cover and the air filter, if dusty, blow off dust with clear and dry air.

  • Page 42: Transmission Lubrication

    measure Oil outlet With the engine warm, put the vehicle on the level ground. 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. Tighten the engine oil outlet plug.

  • Page 43: Differential Lubrication

    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 . Tighten the transmission oil outlet plug and the iron dust plug. Remove the plug, fill oil (API 80(75) W-90 GL-3 Gear Oil ) about 2.0 liters.
  • Page 44 a. Put the vehicle on level ground. b. Lift up the red release lever, release the pressure inside. c. Turn the coolant cap counterclockwise and open the cap. d. Pour fresh coolant to filler neck. Start the engine at idle. e.

  • Page 45: Idle Speed

    harm or damage may occur if use coolant that does not meet the specification.(50% standard green coolant and 50%distill water) Idle Speed Adjustment Never make unnecessary adjustments. The factory recommended settings are correct for most applications. It’s not necessary to disassemble the screw unless the idle speed needs to adjustment.
  • Page 46 Spark plug seat Special spanner 0.9～1.1mm 1. Unscrew 8 screws and take off spark plug plastic cover. 2. Clean the dust in the spark plug seat. 3. Pull off the high-voltage wire，remove the spark plug with a special spanner. 4. Insert a new spark plug or a cleaned spark plug, and turn a few rounds clockwise, if retarders happen, take it off and try it again to make sure screw engaged correctly.

  • Page 47: Wedge Belt Figure

    Wedge belt figure Correct installation and the proper tension will ensure electrical generator and air conditioner work well. If chap, tear, wear，or looseness happen, contact Joyner dealer and replace it immediately. Check the belt tension: Apply a pressure (about 100N) on the belt, if the movement is more than 10mm, it is necessary to replace the belt.

  • Page 48: Parking Brake Cable Adjustment

    Adjustment nuts Shift lever Transmission Adjustment nuts Parking brake cable adjustment After a long time use, more and more free play of parking brake cable make parking brake power decrease, so adjust the shift cable refer to Preventative maintenance and service log. 1.

  • Page 49: Steering Lubrication

    Adjustment nut Parking brake lever Adjustment nut Steering lubrication After a long time use, more and more free play of parking brake cable make parking brake power decrease, so adjust the shift cable refer to Preventative maintenance and service log. Throttle cable adjustment Differential lock cable adjustment Parking adjustment...

  • Page 50: Gear Shift Adjustment

    Pull the park brake lever up so that the unit can engage park brake. To release the unit, press button on front end of parking lever then push the parking lever to the bottom. Adjust the parking cable if necessary. Gear shift adjustment Before operating the vehicle, check the shift lever as to change gearshift from 1 to 5 and...

  • Page 51: Clutch Replacement

    Clutch replacement 1. Remove two bolts, and demount Starter-assembly carefully. Q1840845 Q1841245 S11-37081 2. Remove four bolts on the transmission case, lay down these carefully. Caution: When fix the four bolts in the transmission case; you must tighten them according to the prescribed torque 45-55N.M.
  • Page 52 3. Remove upper steel cushions and lower steel cushion. 372-100203 S11-170010 4. Insert a spine-shaft into the hole of the Clutch assy , remove the six bolts on the Clutch pressure plate, now It’s clear. Caution: When fix the six bolts in the Clutch pressure plate; You must tighten them according to the prescribed torque 28 N.M.
  • Page 53 S11-1601020 S11-1601030 FIGURE 1 5. Insert a spline-shaft into the hole of the Clutch assy , fix the six bolts on the Clutch pressure plate , tighten them according to the prescribed torque 28 N.M . 6.Fix parts according to reverse operation to the disassembly.

  • Page 54: Front Wheel Alignment

    Front Wheel Alignment a. Put the vehicle on level ground. b. The “toe-in” of the front wheels should be 0.98 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 0.98 inches greater than dimension B.

  • Page 55: Repair Manual

    Repair manual Chassis wiring diagram...

  • Page 56: Engine Wiring Diagram

    Engine wiring diagram Chassis disassembly, installation and repairment Front suspension Rear suspension Driven system Coolant system Fuel system Steering box Shift Brake Parking brake clutch...

  • Page 57: Engine Disassembly, Installation And Repair

    Engine disassembly, installation and repair Timing Belt 1. Configuration diagram 1 Water pump pulley 2 Timing belt cover. upper 3 Timing belt cover. Lower 4 Torsion shock absorber 5 Timing pulley damper 6 Tensioner 7 Crankshaft timing pulley .8 Timing belt...
  • Page 58 2. Disassembly 2.1. According the right picture, remove water pump pulley Torque: 25±1.5 N.m 2.2. Removing timing belt cover Torque: 6±1N.m 2.3. Remove tensional vibration damper 2.3.1. Fix the flywheel and prevent the gear ring from rotating, 2.3.2. Remove bolt of tensional vibration damper.
  • Page 59 2.5. Remove the tensioner 2.5.1. Carry out the operation at the upper thrust point of compression of the first cylinder piston 2.5.2. After removing the timing cover cap, turn the bolt and rotate the timing gear clockwise with wrench, align timing mark of camshaft timing gear with the cam mark of camshaft cover cap;...
  • Page 60 2.7. Remove the crankshaft timing gear 2.8. Make careful and detailed checks on the timing belt. Replace with new parts if any of the conditions shown in the figure occurs. 2.8.1. Cracks on the backside rubber; 2.8.2. Cracks of teeth roots, cracks clearing off the fabric lining layer; 2.8.3.
  • Page 61 Specifications and model of clockwise pulley Model ＥＦ Item ＧＬ、ＺＬ、ＧＳ、ＺＳ Diameter of camshaft +0.1 φ110.7 -0.2 timing gear （mm） Diameter crankshaft +0.7 φ54.65 -0.13 timing gear（mm） Baffle of crankshaft timing gear Check to see if there is any deformation Standard size of crankshaft timing gear： Wide 28.6mm 3.
  • Page 62 3.3.2. Turn the crankshaft for two circles towards the engine rotating direction, so that the camshaft pulley and the crankshaft pulley match the clockwise marks respectively. 3.3.3. Use hands to press down for about 5mm. The force for pressing the clockwise belt is about: ［Reference］...
  • Page 63 3.5.2. When there is a flying wheel, 3.5.2.1. Fix the flywheel to prevent the tooth ring from turning 3.5.2.2. Then tighten bolt of tensional vibration damper. 3.6. Install timing belt cover Install seal strip in the position shown as right figure.

  • Page 64: Camshaft

    Camshaft 1. Configuration diagram ※:Non-reusable part Unit: N*m (kg*cm) (1) Valve cage cover (2) Valve cage cover gasket (3) Camshaft timing pulley (4) Camshaft cover (5) Circular plug (6) Camshaft bearing cap (7) Exhaust camshaft,(8) Intake camshaft,(9) Oil seal(10) Spring retainer(11) Wave washer(12) Intake camshaft sub-gear(13) Snap ring(14) Lock nut(15) Flange...
  • Page 65 2. Removal 2.1. 1) Cover-valve chamber 2) Disassembly order of Cover-valve chamber 2.2. Dismount the timing belt sprocket with a special tool. Attention: Manufacture a special tool according the right figure The special is necessary to prevent the camshaft to rotate Timing mark 2.3.
  • Page 66 2.3.2. Use bolt to position the master and slave Screw gears on the air inlet camshaft, as shown in the right figure. Attention In order to eliminate the radial force, keep the camshaft in the leveled position before dismounting it (to avoid possible damages caused by excessive radial forces) 2.4.
  • Page 67 2.7. Camshaft 2.7.1. Use the caliper to measure the height of the camshaft. If it is below the specified limits, make roper replacement. Camshaft Unit：mm Model ZL、 GL、GS、 Item φ23.0-0.02 -0.033 Standard φ23.0-0.02 -0.033 φ22.9 Limit φ22.9 2.7.2. Checks on camshaft axial clearance (1)、When the axial spacing is measured with a clipper to be larger than the benchmark value, the camshaft is to be replaced.
  • Page 68 3.2. When no using a special tool Screw bolt m6 as the right figure, and then insert a screwdriver between the bolt m6 and camshaft, and rotate driven-gear right to match the mark on both of gears, or keep the gear-top of 2 gears Air outlet camshaft gear consistent, then...
  • Page 69 3.6. Installation of camshaft head cap Smear the fluid sealant on the camshaft head Sealing line cap section (With oil groove) shown as the right figure. 3.6.1. Tighten the bolts according to the sequences shown as the right figure with the specified torques.
  • Page 70 Attention: process the special tool according the right figure. 3.9. Installation of cylinder head gasket 3.9.1. Clean the the used cylinder head gasket 3.9.2. Put new one into the groove on the timing-belt cover accurately 3.9.3. Cover the cylinder head with cylinder head cover;...
  • Page 71 4.4. Rotate camshaft a round, keep the position as the right figure, measure the clearance again. First Second Third Fourth cylinder cylinder cylinder cylinder — — — — If exceed the standard of valve clearance, replace a adjusting washer to get a proper clearance Attention: record the position where valve clearance exceed the standard and the...
  • Page 72 4.4.3.3. Select proper separation cushion on the basis of the throttle thrusting rod benchmark values. (1). IN Selected cushion thickness = removed cushion thickness + (measured throttle spacing – 0.18mm) (2). EX Selected cushion thickness = removed cushion thickness +(measured throttle spacing –0.25mm) [Reference] there are 32 kinds of shim’s thickness Shown as the illustration 2.18...

  • Page 73: Cylinder Head

    Cylinder head 1. Configuration diagram （1） Spark plug20±1Nm（2） Cylinder head（3） Weather seal I（4） Cylinder head gasket （5） Adjust shim（6） Valve lifter（7） Keeper（8） Valve spring seat（9） Valve spring （10） Intake valve（11） Exhaust valve（12） Valve oil seal（13） Valve seat（14） Valve guide 2. Dismounting 2.1.
  • Page 74 2.2. There are 8 cylinder cover bolts. In the process of removing the cylinder, please follow the sequences shown as the right illustration, loosen the bolts one by one evenly and gently.。 2.3. Removal of the cylinder dustproof sealing and cylinder cover base. Attention The cylinder cushion cannot be used repeatedly.
  • Page 75 spring if it fails to meet the specifications. [Limit] 1.2mm 3.2.2. Measure the free state of spring [Benchmark value] 37mm 3.3. Routine checks on throttles 3.3.1. Check to see if there are some deformations, obvious tears and wears Check list on valve Unit: mm item standard limit...
  • Page 76 3.3.3.2. Use special tools to drive in the valve-guiding pipe to the position as shown in the right figure from the side of the combustion chamber. Attention The removed guiding pipe cannot be used repeatedly. The air intake and exhaust valve guiding pipes should not be mixed up in installation.
  • Page 77 benchmark value. 3.3.4.4. Check the mating position of the throttle. If it is in the center of the valve, the position is the best one. If not, proper corrections have to be made. 3.3.4.5. Make conic cutting at the center of the mating position with 70 degrees toward inwards and 30 degrees outwards.
  • Page 78 3.4.3.2. Installation of IN and EX 3.4.3.2.1. Assembling of valve springs Attention It is for you to distinguish the different suppliers by means of paintings on the valve spring, valve spring of same engine should have the same identification paint marking. 3.4.3.3.

  • Page 79: Water Pump

    torque for the third tightening operation is 70±3.5 Nm. 3.4.4.3. Installation of the spark plug [Torque] 20±1Nm Attention: The tools should be placed vertically, so as not to make the spark plug insulator become deformed, otherwise it is easy to leak oil.

  • Page 80: Oil Pump

    3. Clearing 3.1. Clearing of the mating surface of the water pump 4. Routine checks 4.1. Check to see if there are any deformation or damages 4.2. Use a hand wrench to see if the turning is OK, and if it is smoothly lubricated? 5.
  • Page 81 Non-reusable part ① Oil pan， tighten bolt： 8±2 Nm② Oil strainer③ Oil collector gasket④ Oil pump⑤ Oil pump gasket⑥ Rear oil seal bracket 2. Dismounting 2.1. The engine being turned upside down on the dismounting frame, take off the bolts. Remove the oil pan from the cylinder body.
  • Page 82 Attention The filter flange is not reusable. 2.3. Dismount the oil pump assembly and oil pump cushion 2.4. Dismounting of oil seal stand 3. Clearing 3.1. For the mating surfaces of the oil bottom case, oil pump and oil seal stands, For the mating surfaces of the rear oil seal stand and oil pump scraper and chipping chisel or some other tools may be used to clear the...
  • Page 83 ※:Non-reusable part Unit: N*m (kg*cm) 1 Weather seal2 Oil pump cover plate3 Driven rotor4 Drive rotor5 Split pin6 Relief valve spring seat7 Relief valve spring8 Relief valve9 Crankshaft front oil sealing10 Oil pump body 4.2. Disintegration 4.2.1. Weather seal Attention The weather seal are not reusable. 4.2.2.
  • Page 84 suddenly, while taking off the open pins. 4.2.5. Removal of the oil pump pressure relief valve spring stand, spiral spring, oil pump pressure relief valve 4.2.6. Removal of the front oil seal of the crankshaft Attention The removed oil seals are not reusable.
  • Page 85 should be no visible tears, wears and scrapes on the pressure relief valve 4.4. Installation After smearing lubricating oil on the lips of 4.4.1. the new T-shaped oil seals, use SST to make the assembly. Attention ·Use new oil seal.. ·The exposed part of the outer edge of the oil seal after being pressed in should be less than 0.5mm.
  • Page 86 5. Disintegrating and assembling of oil seal 5.1. Configuration diagram ※:Non-reusable part Unit: N*m (kg*cm) 5.2. Disintegration 5.2.1. Use a flat screwdriver to remove the rear oil seal. Attention The oil seals are not reusable. 5.3. Checks Check to see if the tears and wears of the lip section of the oil seals are within the normal...
  • Page 87 conditions, and if there are any damages in outer appearance. Oil sealing lip 5.4. Assembling 5.4.1. Smear lubricating oil on the new oil seal lip section. Install the oil seal shown as the right 5.4.2. figure. 6. Assembling 6.1. Assembling of the oil sealing stands Smear oil sealing silica on the oil sealing Seal line stands shown as the right figure.

  • Page 88: Crankshaft Connecting Rod Mechanism

    6.4.1. Clear the mating surface with the cylinder body 6.4.2. Apply sealing silica before assembling [Grease] Letai 5699 Attention ·The liquid cushion with silica line diameter of ф3-4mm, without any broken section ·Make the assembly in 15 minutes after the Front Rear application of silica...
  • Page 89 ※:Non-reusable part Unit: N*m (kg*cm) (1) Connecting rod cover(2) Connecting rod bearing bush(3) Piston and connecting rod assembly(4) Main bearing cover(5) Crankshaft(6) Crankshaft bush(7) Thrust washer(8) Cylinder block(9) No.1 compression ring(10) No.2 compression ring(11) Oil ring(12) Piston(13) Connecting rod(14) Piston pin 2.
  • Page 90 [Benchmark]:0.15-0.24mm [Limit]:0.30mm 2.2. Check the connecting rod bush vertical clearance 2.2.1. Remove the bush cover Attention: Parts and components of various cylinders should be placed in good order. Clean the bush and axle diameter 2.2.2. 2.2.3. Place clearance gauge on the connecting bearing diameter.
  • Page 91 2.2.5. Replace the bush if width is beyond the limit. Attention: ·In replacing the bushes, you should use the products Connecting of same brand and from the same manufacturer, which rod bush Connecting can accord with the request of clearings. rod cover 2.2.6.
  • Page 92 damages. 2.4.3. Use a clearance+6 gauge to adjust the radial clearance of the crankshaft; tighten the bolts of bearing bush cover with specified torque. [Torque] 70±3.5N.m Attention Tighten the bolts of the crankshaft bearing cover in three times to the regulated value, in the sequence as shown in the right figure.
  • Page 93 ① Remove the piston pin to take off the piston and the connecting rod by using SST. Clearing 3.1. Cylinder body Warning Wear eyeglasses during the clearing operation to protect your eyes. Use flat chisel to clear the cylinder body, 3.1.1.
  • Page 94 4.2. Piston 4.2.1. Check the clearance between the piston pinholes. Use a caliper to measure the positions of the piston shown in the following figure, with the maximum value as the size of the piston pin diameter. 4.2.2. Use the inner diameter centimeter to measure the positions of the piston hole diameter shown as the following figure, take the minimum value as the size of the...
  • Page 95 4.2.6. Check the clearance of piston ring ends 4.2.6.1. Put the piston ring i n the position which is 45 mm under the cylinder hole top surface, in order to make the piston ring keep flattened, you can press the piston ring with piston top surface, then use a piston gauge to measure the open clearance.
  • Page 96 Replace the crankshaft if the measurement result exceeds t he limit. [Limit] 0.03mm Attention: The bending value should be 1/2 of the fluctuation for one circle of turning the crankshaft. 4.3.2. Check the tears and wears of the crankshaft 4.3.2.1. Use a caliper to measure the shaft diameter, and work out the circularity and cylindricity.
  • Page 97 procedures. 5.2.1. Install gas ring Side face with marks should be upright, install primary ring with piston ring tool. Install oil ring (gasket ring, down scraper 5.2.2. and upper scraper) firstly, then install the secondary ring, then install the primary ring, Open degree of every ring is shown as the illustration: Oil groove...
  • Page 98 Attention:· The torque of crankshaft rotating should be less than 1Nm;(The torque is for installing the crankshaft only, not for installing the piston connecting rod) 5.4. Assemble the piston connecting rod Ay, connecting rod bush and connecting rod bearing cover according to the following instructions.

  • Page 99: Electric Injection System

    Electric injection system...

  • Page 139: Parts Manual

    PARTS MANUAL 1. ENGINE 1. COOLING SYSTEM Part number Name Quantity Q1400612 HEXAGON HEAD BOLT 372-1307014 WATER PUMP PULLEY Q1840840 HEXAGON FLANGE BOLT Q1840855 BOLT（M8X55） Q1840865 HEXAGON FLANGE BOLT 372-1307010 WATER PUMP SET 372-1307015 ‘O’ RING 372-1307041 WATER PUMP WASHER 372-1307018 SEAL STRIP 2 Q1840825...

  • Page 140: Cylinder Block

    2. CYLINDER BLOCK Part number Name Quantity 472-1002010 CYLINDER BLOCK ASSY 372-1002037 POSITION PIN 372-1002046 CRANKCASE VENTILATION PIPE 372-1002044 CYLINDER HEAD SEAL PLUG Q1840830 HEXAGON FLANGE BOLT 372-1002060 KNOCK SENSOR 372-1002036 POSITION PIN S11-3810010 OIL PRESSURE SWITCH 11G10GB308 BALL 372-1002024 PLUG 372-1002023 BOLT...

  • Page 141: Crankshaft

    3. CRANKSHAFT Part number Name Quantity 372-1005031 PULLEY BOLT 372-1005040 TORSION SHOCK ABSORBER ASSY 372-1005018 CRANKSHAFT TIMING GEAR 372-1005017 TOOTHED BELT BAFFLE 372-1005015 CRANKSHAFT FRONT OIL SEAL 372-1005033 NEEDLE BEARING 372-1005032 WOODRUFF KEY 472-1005010 CRANKSHAFT ASSY 372-1005016 STOPPER PLATE S11-1601101 COVER SET BOLT 372-1005036 PIN - DOWEL...

  • Page 142: Exhaust Manifold

    4. EXHAUST MANIFOLD Part number Name Quantity 472-1008033 GASKET-EXHAUST MANIFOLD 472-1008031 EXHAUST MANIFOLD Q1200825F3 STUD Q33008 HEXAGON NUT 472-1008044 HEAT INSULATOR Q1460612 HEXAGON HEAD BOLT S11-1205110JA OXYGEN SENSOR Q1200835F3 STUD S11-3724863 OXYGEN SENSOR BRACKET...

  • Page 143: Intake System

    5. INTAKE SYSTEM Part number Name Quantity Q1420625 HEXAGON HEAD BOLT S11-1129010JA THROTTLE S11-1129021JA GASKET-THROTTLE Q1840620 HEXAGON FLANGE BOLT 372-1008043 ACCELERATOR PULLING WIRE BRACKET S11-1109411 INTAKE TEMPERATUREAND PRESSURE SENSOR Q1400416 HEXAGON HEAD BOLT 472-1008011 UPPER INTAKE MANIFOLD Q1420645 HEXAGON HEAD BOLT S11-1121012JA OIL GUIDE 480EF-1112010...

  • Page 144: Intake System

    5. INTAKE SYSTEM Part number Name Quantity 372-1008042 INTAKE MANIFOLD REAR BRACKET 472-1014110 BRACKET Q1400612 HEXAGON HEAD BOLT 472-1014122 CRANKCASE VENTILATION PIPE (2) 481H-1014030 OIL AND AIR SEPARATOR 472-1014121 CRANKCASE VENTILATION PIPE (1) Q1840816 HEXAGON FLANGE BOLT 372-1014130 CRANKCASE VENTILATION PIPE (3) Q1840820 HEXAGON FLANGE BOLT S11-1108210DA...

  • Page 145: Lubricating Device

    6. LUBRICATING DEVICE Part number Name Quantity 372-1012010 OIL FILTER ASSY 372-1009130 OIL DIP STICK ASSY 372-1009120 OIL DIP STICK PIPE ASSY 372-1011055 SEAL STRIP 372-1011021 OIL PUMP WASHER 372-1011030 OIL PUMP ASSY Q1840825 BOLT BOLT（M8X55） Q1840855 Q1420612 HEXAGON HEAD BOLT 372-1010017 OIL STRAINER WASHER Q1200616...

  • Page 146: Cylinder Head

    7. CYLINDER HEAD Part number Name Quantity 372-1003074 SPARK PLUG SLEEVE Q1400638 HEXAGON HEAD BOLT 372-1003051 CYLINDER HEAD BOLT 372-1003052 CYLINDER HEAD BOLT WASHER S11-3808013 WATER TEMP. SENSOR S11-1003069 CAMSHAFT POSITION SENSOR Q1400816 HEXAGON HEAD BOLT 372-1003023 GUIDE - VALVE 372-1003022 EXHAUST VALVE SEAT INSERT 372-1003021...

  • Page 147: Cylinder Head

    7. CYLINDER HEAD Part number Name Quantity 372-1003063 CAMSHAFT BEARING CAP POSITION COVER S11-3808010 WATER TEMP. SENSOR SET 372-1003201BA REAR HINGER 372-1003026 PLUG 372-1003024 PLUG 372-1003028 PLUG 372-1003038 STUD 372-1003076 SLEEVE 372-1003025 PLUG...

  • Page 148: Cover-Valve Chamber

    8. COVER-VALVE CHAMBER Part number Name Quantity 372-1003090 OILING PORT COVER ASSY Q2540616 SCREW 472-1003075 COVER 472-1003030 VALVE CHAMBER 472-1003036 GASKET-VALVE CHAMBER Q1460625 HEXAGON HEAD BOLT...

  • Page 149: Oil Pan

    9. OIL PAN Part number Name Quantity 472-1009010 OIL PAN ASSY Q1420612 HEXAGON HEAD BOLT 372-1009017 SEAL WASHER-OIL DRAIN THREADED PLUG 372-1009014 MAGNET PLUG...

  • Page 150: Valve Mechanism

    10. VALVE MECHANISM Part number Name Quantity 372-1007030 TENSIONING PULLEY ASSY Q1401045 HEXAGON HEAD BOLT Q1400616 HEXAGON HEAD BOLT 372-1007040 TIMING GEAR COVER ASSY Q1460625 HEXAGON HEAD BOLT Q1460650 HEXAGON HEAD BOLT Q43140 SHIELD-SHAFT SPRING RING 372-1006032 SADDLE FLIP WASHER 372-1006031 DRIVE RING 372-1006040...

  • Page 151: Valve Mechanism

    10. VALVE MECHANISM 9 10 Part number Name Quantity 372-1006063 COUPLING FLANGE 372-1006062 EXHAUST CAMSHAFT GEAR 472-1006060 EXHAUST CAMSHAFT GEAR 372-1007017 ADJUSTMENT WASHER 372-1007018 VALVE LIFTER 372-1007019 VALVE LOCK BLOCK 372-1007021 EDDY SLEEVE 372-1007014BA VALVE SPRING UPPER SEAT 372-1007013 SPRING - VALVE 372-1007020 VALVE SEAL 372-1007016...

  • Page 152: Valve Mechanism

    10. VALVE MECHANISM Part number Name Quantity 372-1007014 VALVE SPRING UPPER SEAT Q673B155 CLAMP 472-1007042 LOWER COVER-TIMING GEAR 480-1011062 BOLT...

  • Page 153: Ignition Device

    11. IGNITION DEVICE Part number Name Quantity S11-3705110JA IGNITION COIL Q2320525 SCREW AND WASHER UNIT S11-3705001CA BRACKET-IGNITION COIL S11-3707100 SPARK PLUG ASSY Q1460820 HEXAGON HEAD BOLT S11-3707020BA HI.TENSION CORD NO.1 S11-3707030BA HI.TENSION CORD NO.2 S11-3707040BA HI.TENSION CORD NO.3 S11-3707050BA HI.TENSION CORD NO.4 S11-3724183 CLIP...

  • Page 154: Piston And Connecting Rod Device

    12. PISTON AND CONNECTING ROD DEVICE Part number Name Quantity 372-1004031 PISTON PIN 372-1004021AC PISTON 372-1004110 CONNECTING ROD ASSY 372-1004116 BEARING-CONNECTING ROD...

  • Page 155: Other Accessory 1

    13. OTHER ACCESSORY 1 Part number Name Quantity S11-3724180CS Engine Harness S11-3605010JA-1 472 ECU Shifter soft shaft bracket SV1100.05.02.01.00 S11-1208210JA carbon can PCV S11-3708110GA Starter assembly S11-1700103 lower Steel cushion S11-1200011BA Single Exhaust Gasket 6170-M12*1.75 Hex nut M12*1.75 93-SW12 Spring Washerφ12 97.1 -W12 Washerφ12 70.1- M12*1.75*75*25...

  • Page 156: Other Accessory 2

    14. OTHER ACCESSORY 2 Part number Quantity Name S11-3701110BB Alternator Alternator bracket S11-3701211BA S11-1001415BA Rear bracket S11-3701315 V-ribbed belt...

  • Page 157: 5T07D1 Transmission

    5T07D1 TRANSMISSION 1 CASE&ACCESSORY Part No. Part Description Comments QR512－1701101 Clutch case 4T08A1－1701111 Transmission case 5T07－1701020 Side cover 5T07－1702010 Declutch bearing 5T07－1702020A Declutch fork 5T07－1702004 Clutch fork 2 sleeve 5T07－1702030 Clutch fork seal 5T07－1702001 Clutch fork 1 sleeve QR512－1701103 Double－screw rod 5787－M8x40 Flange bolt M8x40...

  • Page 158: Case&Accessory

    1 CASE&ACCESSORY Part No. Part Description Comments 5T07－1701001 Locating pin 5T07－1701002 Oil plug screw 5T07－1701003 Screw plug washer 5T07－3729010 Back－up light switch 5T07－1701058A Double－screw rod 5T07－1701009 Bearing stop plate 5T07－1701004 Oil－stop plate 5787－AM6X12 Flange bolt M6x12 7246－W6 Flat washer 6 5T07－1701400 Oil groove S800.04.01.02.01－R2...

  • Page 159: Countershaft

    2 COUNTERSHAFT Part No. Part Description Comments QR512－1701401 Output shaft QR512－1701410 First gear assy QR512－1701420 Second gear assy QR512－1701441 Third gear QR512－1701461 Fourth gear 5T07－1701610 Front bearing of output shaft 5T07－1701240 Needle bearing of 1 &2 gear QR512－1701439 Synchronizer out ring of 1 &2 gear Synchronizer middle ring of 1...

  • Page 160: Countershaft

    2 COUNTERSHAFT Part No. Part Description Comments QR512－1701433 Synchronizer spring of 1 &2 gear Synchronizer gear － hub of 1 &2 QR512－1701434 gear Synchronizer gear-sleeve of 1 &2 QR512－1701431 gear Synchronizer gear block of 1 &2 QR512－1701432 gear 5T07－1701205 Synchronizer retainer of 1 &2 gear 5T07－1701202...

  • Page 161: Input Shaft Assy

    3 INPUT SHAFT ASSY Part No. Part Description Comments QR512－1701201 Input shaft 5T07－1701080 Input shaft seal 4T08－1701130 Bearing 6204/YA/P63 QR512－1701240 gear assy 5T07－1701150 Needle bearing of 3 &4 gear QR512－1701257 Synchronizer ring of 3 &4 gear ＆5 QR512－1701250 Synchronizer assy of 3 &4 QR512－1701252 Synchronizer gear－hub of 3...

  • Page 162: Input Shaft Assy

    3 INPUT SHAFT ASSY Part No. Part Description Comments 5T07－1701103 Synchronizer retainer of 3 &4 gear QR512－1701258 Synchronizer waveform washer ring QR512－1701260 gear assy 5T07－1701110 Back bearing of input shaft QR512－1701285 Spacer of 5 gear QR512－1701200 Input shaft assy QR512－1701287 Adjusting washer of rear bearing Demand QR512－1701280 5...

  • Page 163: Input Shaft Assy

    3 INPUT SHAFT ASSY Part No. Part Description Comments QR512－1701254 Synchronizer spring of 5 gear QR512－1701293 Synchronizer gear block of 5 gear QR512－1701292 Synchronizer gear－hub of 5 gear Synchronizer gear － sleeve of 5 QR512－1701291 gear QR512－1701294 Synchronizer ring of 5 gear QR512－1701298 Nut of 5...

  • Page 164: Shift Fork&Shift-Fork Shaft

    4 SHIFT FORK&SHIFT-FORK SHAFT Part No. Part Description Comments QR512－1702311 Shift fork of 1 &2 gear 5T07－1702041A Shift fork of 3 &4 gear 308－7.9375 Steel ball 7.9375 5T07－1702042A Shift fork of 5 gear 5T07－1702061A Shift fork of 3 &4 gear 4T08A－1702042A Stop block QR512－1702231...

  • Page 165: Shift Fork&Shift－Fork Shaft

    4 SHIFT FORK&SHIFT－FORK SHAFT Part No. Part Description Comments QR512－1702431 Shift－fork shaft of 5 gear QR512－1702441 Shift－fork shaft of reverse gear 5T07－1702234 Shift－fork shaft screw plug 5T07－1702233 Washer of screw plug QR512－1702341 Shift fork pin of reverse gear 5T07－1702068 Shift block spring 5T07－1702050A Shift arm 93－W8...

  • Page 166: Shift Control Machinsm

    5 SHIFT CONTROL MACHINSM Part No. Part Description Comments 5T07－1702100A Shift－select shaft assy 5T07－1702101A Shift－selecting shift QR512－1702214 Snap ring of shift interlock 5T07－1702102 Release－sprig seat of 1 &2 gear Part No. Part Description Comments...
  • Page 167 5T07－1702103 Release sprig of 1 &2 gear 5T07－1702104 Spring－stop plate 5T07－1702107A Stop plate of shift interlock 5T07－1702105A Shift－select arm. QR512－1702113 Spring pin 3.5x28 5T07－1702106 Pin of shift－select arm 5T07－1702114A Release spring of 5 & reverse gear Release－spring seat of 5 &...

  • Page 168: Driven Gear Assy

    6 DRIVEN GEAR ASSY Part No. Part Description Comments 5T07D1--1701600 Driven gear assy 5T07-1701310 Front bearing of differential QR512-1701604 Driving gear of odometer 4T08A-1701602 Front bearing of output shaft 4T08A-1701601 Output shaft 4T08A-1701603 Connecting disc QR512-1701611 Driven gear of speed reducer 4T08A-1701605 Rear bearing of output shaft 5T07-1701320...

  • Page 169: Chassis

    CHASSIS...

  • Page 199: Hydraulic Pump Assembly Of Foot Brake

    18 HYDRAULIC PUMP ASSEMBLY OF FOOT BRAKE Part No. Part Description Comments ZJ509.05-00L Left caliper assembly TROOPER.07.01.01. Left inlet hose of front caliper S800.07.01.01.01-R2 Outlet hose of master cylinder ZJ609.F02-01 “T” connection TROOPER.07.01.01. Right inlet hose of front caliper ZJ509.05-00R Right caliper assembly TROOPER.07.01.01.

  • Page 200: Hydraulic Pump Assembly Of Parking Brake

    19 HYDRAULIC PUMP ASSEMBLY OF PARKING BRAKE Part No. Part Description Comments ZJ610.04-00/14 Master cylinder assembly TROOPER.07.02.01. Outlet hose of master cylinder TROOPER.07.02.01. Right outlet hose of “T” connection ZJ509.05-00R Right caliper assembly ZJ609.F02-01 “T” connection TROOPER.07.02.01. Left outlet hose of “T” connection ZJ509.05-00L Left caliper assy ZJ509.03-04...

  • Page 201: Clutch Hydraulic Assembly

    20 CLUTCH HYDRAULIC ASSEMBLY Part No. Part Description Comments ZJ610.05-00/19 cylinder Lower of clutch TROOPER.07.04.01. Outlet hose of Master cylinder ZJ709.04-00/16 Master cylinder ZJ610.05-05 Ripple boot ZJGS.01-02 Hose bolt M10x1.25 ZJGS.01-01 Seal washer TROOPER.07.04.01. Clutch hydraulic pump assembly...

  • Page 202: Dealer Pre-Delivery Inspection

    DEALER PRE-DELIVERY INSPECTION...
  • Page 203 _______Jumping the vehicle can cause serious damage to the drive train (axle, transmission, suspension). _______Injury or death can result from jumping vehicle. Do Not Jump. _______I understand that the roll bars are cosmetic and a roll over could cause death or serious injury.
  • Page 204 5. ATTORNEYS FEES. If it is necessary for Seller to take legal action to enforce any of seller’s rights under this contract, Buyer agrees to pay to the extent permitted by law, the seller‘s reasonable attorneys fees and court costs. 6.
  • Page 205 6. GENERAL. This contract is governed by applicable federal law and the laws of the State of Arizona. Any provisions found to be invalid shall not invalidate the remainder hereof. Waiver of any default shall not constitute waiver of any subsequent default. All words used herein shall be construed to be of such gender and number as the circumstances require.

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