Owner s Manual Parts manual TROOPER READ THIS MANUAL CAREFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION. MINIMUM RECOMMENDED OPERATOR AGE:

Transcription

1 Owner s Manual Parts manual TROOPER T2,T4 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. 1

2 INTRODUCTION Thank you for choosing JOYNER TROOPER. 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

3 CONTENTS Warranty policy... 6 Parts order form, warranty claim form Service record form Preventative maintenance and service log Location of warning labels and specification labels Safety information Are you ready to drive? Protective apparel Helmets and ayes protection Drive training Age recommendation No alcohol or drugs Is your vehicle ready to drive? Pre-drive Inspection Operation instruction Main switch Battery switch Gauges Switches Steering wheel Pedal Parking brake lever Drive select lever Differential control handle Fuel tank Seats and safety belts Safari bed Start engine Stop engine Passenger Break-in Starting and operating instructions Specifications Maintenance and adjustment Air Cleaner Engine Lubrication Transmission lubrication Differential lubrication Engine Coolant Idle Speed Spark plug inspection Wedge belt figure

4 Shift cable adjustment Parking brake cable adjustment Steering lubrication Throttle cable adjustment Differential lock cable adjustment Parking adjustment Gear shift adjustment Front Wheel Replacement Rear Wheel Replacement Clutch replacement Front Wheel Alignment Battery Fuse replacement Bulb replacement Shock adjustment Repair manual Chassis 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 Engine disassembly, installation and repair Timing Belt Camshaft Cylinder head Water pump Oil pump Crankshaft connecting rod mechanism Electric injection system PARTS MANUAL ENGINE COOLING SYSTEM CYLINDER BLOCK CRANKSHAFT EXHAUST MANIFOLD

5 5. INTAKE SYSTEM INTAKE SYSTEM LUBRICATING DEVICE CYLINDER HEAD CYLINDER HEAD COVER-VALVE CHAMBER OIL PAN VALVE MECHANISM VALVE MECHANISM VALVE MECHANISM IGNITION DEVICE PISTON AND CONNECTING ROD DEVICE OTHER ACCESSORY OTHER ACCESSORY T07D1 TRANSMISSION CASE&ACCESSORY CASE&ACCESSORY COUNTERSHAFT COUNTERSHAFT INPUT SHAFT ASSY INPUT SHAFT ASSY INPUT SHAFT ASSY SHIFT FORK&SHIFT-FORK SHAFT SHIFT FORK&SHIFT-FORK SHAFT SHIFT CONTROL MACHINSM DRIVEN GEAR ASSY CHASSIS HYDRAULIC PUMP ASSEMBLY OF FOOT BRAKE HYDRAULIC PUMP ASSEMBLY OF PARKING BRAKE CLUTCH HYDRAULIC ASSEMBLY DEALER PRE-DELIVERY INSPECTION

6 Warranty policy 6

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10 Parts order form, warranty claim form 10

11 Service record form 11

12 Preventative maintenance and service log 12

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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. 17

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21 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. 2. Always be sure the driver and passengers 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 schedules described in this manual. 11. Always keep both hands, arms, feet, and legs inside the vehicle at all times during operation. Keep your feet on the floorboard. Never hold onto the enclosure except when using the handgrip inside the enclosure. Otherwise, your hand could be injured if it is caught between the enclosure and an obstacle outside the vehicle. 12. Always keep both hands on the steering wheel when driving. 13. Never wrap your thumbs and fingers around the steering wheel. This is particularly important when driving in rough terrain. The front wheels will move right and left as they respond to the terrain, and this movement will be felt in the steering wheel. A sudden jolt could wrench the steering wheel around, and your thumbs or fingers could be injured if they are in the way of the steering wheel spokes. 14.Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when driving the vehicle. 15. Never operate on excessively rough, slippery, or loose terrain until you have learned and practiced the skills necessary to control the vehicle on such terrain. Always be especially cautious on these kinds of terrain. 16. Never turn at excessive speed. Practice turning at slow speeds before attempting to turn at faster speeds. Do not attempt turns on steep inclines. 17. Never operate the vehicle on hills that are too steep for it or for your abilities. Go straight up and down hills where possible. Maximum slope angle: 15º. 21

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. 19. Always follow proper procedures for going uphill. If you lose momentum and cannot continue up a hill, back down the hill with the engine in reverse gear. Use engine braking to help you go slowly. If necessary, use the brakes gradually to help you go slowly. 20. Always check terrain carefully before going down hills. Go as slowly as possible. Never go down a hill at high speed. 21. Always check for obstacles before operating in a new area. 22. Never operate the vehicle in fast flowing water or water deeper than the floorboards on this model. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply the brakes lightly while the vehicle is moving so the friction dries out the lining. 23. Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. Do not brake abruptly when carrying loads in the safari bed. 24. Always use the size and type of tires specified in this manual. 25. Always maintain proper tire pressure as described in this manual. 26. Never exceed the stated load capacity. Cargo should be as far forward in the bed as possible, and distributed evenly from side to side. Be sure cargo is secured so that it cannot move around during operation. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. 22

23 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. Before you drive your TROOPER for the first time, we urge you to: Read this owner s manual and the labels on your TROOPER carefully. Make sure you read and understand all the safety instruction before driving this vehicle. Know how to operate all the controls. Before each drive, be sure: You are wearing an approved motorcycle helmet (with chin strap tightened securely), eye protection, and other protective clothing. You don t have any alcohol or drugs. 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. Helmets and ayes protection Your helmet is your most important piece of driving gear because it offers the best protection against head injuries. A helmet should fit your head comfortably and securely. An open-face helmet offers some protection, but a full-face helmet offers more. Regardless of the style, look for a DOT (Department of Transportation) sticker in any helmet you buy. Always wear a face shield or goggles to protect your eyes and help your vision. Operating TROOPER without wearing an approved motorcycle helmet, eye protection, and protective clothing could increase your chances of head or eye injury, possibly death in the event of severe accident. Always wear approved motorcycle helmet that fits properly and wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket and long pants. 23

24 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. Practice driving TROOPER in a safe area to build your skills. Do not drive in rough terrain until you get accustomed to TROOPER s controls, and feel comfortable with its size and weight. Operating TROOPER without proper instruction could increase your risk of an accident which could lead to serious injury or death. Attempt supporting with your hands to the ground when the Off Highway Recreational vehicles turning over could lead to serious injury or death. Never support with your hands to ground when the Off Highway Recreational vehicles will turn over. Age recommendation It is strongly recommended that no one under the age of 16 permitted to ride the TROOPER without adult supervision. A child driving a TROOPER that is not recommended for his/her age could lose TROOPER control and result in severe injury or death. A child under 16 should have adult supervision when operate on TROOPER. No alcohol or drugs Alcohol, drugs and TROOPER don t mix. Even a small amount of alcohol can impair your 24

25 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. Never consume alcohol or drugs before or while operating TROOPER. Is your vehicle ready to drive? Before each drive, it is important to inspect your TROOPER and make sure any problems you find are corrected. A pre-drive inspection is a must, not only for safety, but because having a breakdown, or even a flat tire, can be a major inconvenience. If your TROOPER has overturned or has been involved in a collision, do not drive it until your TROOPER has been inspected by your dealer. There may be damages or other problems you cannot see. Improperly maintaining TROOPER or failing to correct a problem before driving can cause a crash in which you can be seriously hurt or even dead. Always perform a pre-drive inspection before every drive and correct any problems. Pre-drive Inspection Check the following items before you get on TROOPER: Engine Oil Check the level and add oil if needed. Check for leaks. Coolant With the engine cold, check the coolant and add if needed. Check for leaks Fuel Check the level and add fuel if needed. Also make sure the fuel 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. 25

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. Air Cleaner Check the air filter. Replace it if needed. Leaks, Loose Parts Walk around your TROOPER and look for anything that appears unusual, such as a leak or loose cable. 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. 26

27 Operation instruction Main switch Functions of the respective switch positions are as follows: ON 1 ON 2 OFF 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 taillights come on when the light switch is on. ON 2: The ignition system and fuel system are supplied with power. START: The electric starter is engaged by turning and holding the key in this position. Release the key when the engine starts. Do not operate the electric starter continuously for more than 5 seconds, or starter damage could occur. Wait at least 5 seconds between each operation of the electric starter to let it cool. Do not turn the key to the "START" position with the engine running, or damage to the electric starter can result. See starting instructions prior to starting the engine. Battery switch The battery connects battery to all of circuits. Turn off the battery switch when the vehicle is stored for a long time to save power. 1. Align the bulge on the key to the channel in the switch body. 2. Insert the key and turn clockwise. 3. So the battery is connected to other circuits, and the vehicle can work. 27

28 Bulg Channel Key Key Off On 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) 2. a tachometer (which shows the engine rotate speed) 3. a speedometer (This shows the riding speed in Km/MPH) 4. a coolant thermometer (which shows the coolant temperature) 5. a voltmeter (which shows the battery charge capacity) 6. a oil pressure gauge (which shows oil pressure) Switches Light switch / / Set the switch to and the taillights. to turn on the low beam 28

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. If this should happen, remove the battery and recharge it. Turning light switch / Set the switch to Set the switch to when turn left when turn right Four-wheel drive switch 2WD/4WD Front diff lock handle Rear diff lock handle This vehicle is equipped with an on-command four-wheel switch "2WD/4WD" and 2 differential gear lock handles. Select the appropriate drive according to terrain and the conditions ( 2WD ) Power is routed to the back wheels only ( 4WD ) Power is delivered to both the front and the back wheels. Front free: the vehicle working with front differential. Front lock: the vehicle working with front differential locked. Rear free: the vehicle working with rear differential. Rear lock: the vehicle working with rear differential locked. To change from 2WD to 4WD bring the vehicle to a complete stop set the gear in neutral press the 4WD button and wait for the 4WD button to light up. After the button lights up you can continue in four wheel mode. Injury or death may occur if change differential to differential locked at a high speed. Injury or death may occur if drive the vehicle at a high speed with both front differential locked and rear differential locked 29

30 Winch switch in/out Set the winch to IN to reel the cable in Set the winch to OUT to reel the cable out. Indicator lights Reverse indicator light R This indicator light comes on when the drive select lever is R reverse position. Battery charging indicator light This indicator light comes on when the generator of the engine can t electricize the battery. You should check the generator and battery or get help from your JOYNER dealer. Coolant temperature indicator light It indicates the temperature of coolant. if the temperature is above C/215 0 F, stop engine immediately. Check coolant lever and add if low, see authorized JOYNER dealer if temperature indicator stay on and overflow tank is full of coolant. 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. Be familiar with the steering wheel before driving, and slow down less than 20 km/h when turn a direction, or turning over may occur. Check the steering wheel before driving, and make sure it can work well, and front wheels can turn according to the steering wheel. Steering wheel 30

31 Pedal Clutch pedal The left foot pedal controls the clutch cable. With the pedal down, you can shift the shift lever Brake pedal The brake is located in the middle of the three control pedals.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 vehicle. Throttle pedal Press the accelerator pedal down to increase engine rpm. Clutch Pedal Brake Pedal throttle Pedal Before start the engine, you should check the three pedal to be they are operating smoothly. Before start the engine, you must make sure that the spring pressure can returns the three pedals to the rest position fully when released. 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. When operating the vehicle, if it does not feel comfortable about clutch or throttle pedal, adjust the position of the pedal location sheet 1 and the pedal location sheet 2, tighten the nut until it feels very comfortable. Parking brake lever Park brake not engaged Park brake engaged Pull the parking lever up so that the unit can engage park brake. To release the unit, press button in the front end of parking lever, then push the parking lever to the bottom. 31

32 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. Never start the vehicle at 3, 4 or 5 gear Stop the vehicle fully before shifting to reverse. When reversing, the reverse indicator R comes on. Differential control handle Moving the differential control handle up and down to make the differential work and locked, 2 handles control front differential and rear differential respectively. Choose the work mode that you need according to the terrain situation. The following work mode is available: 2DW(2 driven wheels): 1. Rear differential. 2. Rear differential locked 4DW(4 driven wheels): 1. Rear differential and front differential. 2. Rear differential locked and front differential. 3. Rear differential locked and front differential locked Shift the handles right side and pull down, then stop the handle in the differential locked position. Front diff lock handle Rear diff lock handle Never use 4DW with both front differentials locked and rear differential locked at a high speed, because the work mode of 4DW with both front differentials locked and rear differential locked 32

33 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 before unscrew fuel tank cap. add gasoline to about 80% of fuel tank. Fuel tank cap Seat lock Never overfill the gas tank. Keep the fuel tank cap clean. Make sure to cover the key hole back after use to prevent dirt from entering the lock mechanism Fuel tank Seats and safety belts Seats Left seat To slide the seat back and forwards on the Trooper, pull the lever located in the front of the seat upward, hold the lever in that position and adjust the seat to the desired position. Be sure the adjustment lever is back on its full lock position and the seat is locked in place. 1. Pull seat lock lever under left leg upward. 2. Move the Seats backwards or forwards As your need. 3. Release the lock lever, so the Seat is locked in the position you want. To access the battery compartment the compartment is located underneath the passenger seat the seat can be lifted in the same manner the cargo bed. Just unlock the quick release latches located in the back of the seat. 1. Remove the safety belt hooks connecting to the hoops bolted on the frame. a) Press the limiting rock, make a space between the hook and the hoop. b) Take off the hook. 2. Repeat step 1, take off these hooks behind seat and both sides of seat. 3. Unlock the seat locker under the seat. 4. Turn the seat until it is stopped by steering wheel. 33

34 Safety belts This vehicle is equipped with five-point seat belts for both driver and passenger. Always wear the seat belt while riding in the vehicle. To wear the seat belt properly, do the following: Cross above right shoulder Cross above right leg Cross above left shoulder 1. Hold the latch plates as you pull the belts across above right shoulder, left shoulder, right leg, left leg and among two legs. Make sure the belt is not twisted and is not caught on any portion of the vehicle, your clothing, or any equipment you are carrying (see right picture). Cross between 2 legs Cross above left leg 34

35 2. Push the latch plates into the buckle, use a 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). 3. Position the shoulder belt over your shoulder and the leg belt over your leg. The shoulder belt should fit against your shoulder and the leg belt should fit against your leg. If it is loose, pull the belt out all the way and then let it retract. 4. To release the buckle, lift and release the hook. Cross above right leg hook Cross above right shoulder Cross above left shoulder Before attempting to adjust the seat ensure that engine of TROOPER is stopped. Never operate TROOPER when the seat is not securely fastened, or may result in a strong possibility of severe personal injury or loss of life. Before attempting to adjust the seat ensure that TROOPER is stopped. Safari bed Safari bed can be lift up. 1. Pull up the release lever on the both side of the vehicle, 2. Lift up the safari bed slowly until it stops. 3. Lower the safari bed slowly to its original position and make sure it is locked tightly. Before closing the bed, be sure others are standing away from the vehicle. Keep hands and fingers away from the pinch points between the bed and frame. The max load is 150Kg/330Ib.never exceed the stated maximum load limit for this safari bed. or injury or Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo. Allow greater distance for braking. 35

36 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. Repeat it until the engine is started. Release the key and the clutch pedal when the engine starts. Keep engine running for 1-2 minutes before driving. 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. 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. 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 5 seconds, a second attempt to start the engine can be allowed. Improper operation will damage the engine. Stop engine 1. It is strongly recommended to stop vehicle before stop engine. 2. Make sure the shift lever in neutral position. 3. Turn the key clockwise to the off position. Before driving this vehicle, test the Engine Stop key to assure that it is operating properly. 36

37 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. 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. The speed of vehicle Max speed in each gear The first 1000 km 1st Gear 12.4 MPH 2nd Gear 24.8 MPH 3rd Gear 37.2 MPH 4th Gear 52.7 MPH 5th Gear 65.1MPH Starting and operating instructions Before starting the engine, be sure that the driver is seated properly in TROOPER and tighten the seat belts. Testing TROOPER in a open place at the beginning to learn how to start, turn and stop. Operate TROOPER slowly until you are familiar with it. The turning radius of TROOPER is small and agile, so the centrifugal force is very high when turning at high speed. Slow down to a more controllable speed when turning to prevent TROOPER from rolling over. To prevent vehicle from rolling over, be sure to only turn the vehicle at a slow more controllable speed. 37

38 Specifications Model Dimensions: Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system Engine oil Type Recommended engine ail classification Quantity: With oil filter cartridge replacement Final gear case oil: Type Quantity Radiator capacity(including all routes): Air filter: Engine Intake duct Fuel: Type Fuel tank capacity Fuel system: Type Spark plug: Type/manufacturer Clutch type: Transmission: 3300mm/130 inch 1600mm/63 inch 1990mm/78 inch 800mm/34.6 inch 2470mm/97.2 inch 300mm/11.8 inch 6000mm/236 inch 780kg/1719 Ib TROOPER Liquid cooled 4stroke Upstanding double cylinder 1080cc 72mm 66.5mm/2.83 inch x2.62 inch 9.5:1 Electric starter Wet sumb >0 SE15W/40, <0 SE15W/30 3.0L/3.17qt SAE85 API GL-5 gear oil 1.8L/1.9 qt 5.0L/5.28 qt Wet element Dry element Unleaded gasoline only 30L EFI S / Chery Dry, diaphragm spring 38

39 Transmission type Operation Chassis Frame type Caster angle Tire Type Size Brakes: System Type front rear front rear Operation Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capacity Specified fuses: High beam fuse Low beam fuse Turning light fuse Tail light fuse Brake light fuse Reverse light Gauge light Engine main fuse Fuel pump fuse Fan fuse Bulb voltage, wattage x quantity: Headlight Tail/brake light Spotlight Manual Right hand operation (five shifts, one reverse) Steel tube frame 3º Tubeless 27 inch 27 inch Front and rear unified Dual disc brake Dual disc brake Foot operation Independent Dual A-Arm Longitudinal Control Arm Coil spring/oil damper Coil spring/oil damper 120mm 150mm Distributor block AC magneto Lead acid storage battery 12V 45Ah 7.5A 7.5A 5A 5A 5A 5A 7.5A 20A 15A 25A 12V 35W/35W 2 12V 5W/21W 2 12V 35W/35W 4 39

40 Indicator lights: Reverse indicator light Coolant temperature warning light Charge indicator light Four-wheel-drive indicator light LED LED LED LED 40

41 Maintenance and adjustment Air Cleaner Clean air filter refer to Preventative maintenance and service log. Under dusty conditions Service more often Cover Filter Rubber bushing Remove filter cover; check the filter cover and the air filter, if dusty, blow off dust with clear and dry air. If necessary, replace with a new one. Engine Lubrication 1. Engine oil replacement You must change the oil in the crankcase refer to Preventative maintenance and service log. That will insure proper lubrication of internal parts and prevent costly repairs due to excessive wear. Oil inlet Oil inlet plug Oil measurer 41

42 Oil measure Oil outlet a. With the engine warm, put the vehicle on the level ground. b. Shut down the engine; put a collecting oil plate under the engine oil outlet. Loosen the oil outlet plug in the warm engine. Let the engine oil out fully. c. Tighten the engine oil outlet plug. d. Remove the oil filler cap, fill oil (SAE 10W/30-50) about 3.86 liters to the engine. e. Pull out the engine oil dip stick; confirm the corrective oil level in the crankcase. 2. Check engine oil and recharge If the color of engine oil changes, you need to replace the engine oil as above. Check the engine oil level; charge if the oil level is lower than L. Transmission lubrication Oil replacement You must change the oil in the transmission refer to Preventative maintenance and service log. That will insure proper lubrication of internal parts and prevent costly repairs due to excessive wear. Oil outlet Oil inlet 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. 42

43 c. Remove the iron dust plug, this plug has a magnet on it. Iron dust caused by moving parts will stick to the plug. Clean the iron dust from this dust plug. d. Tighten the transmission oil outlet plug and the iron dust plug. e. Remove the plug, fill oil (API 80(75) W-90 GL-3 Gear Oil ) about 2.0 liters. Differential lubrication Oil replacement You must change the oil in differential refer to Preventative maintenance and service log. That will insure proper lubrication of internal parts and prevent costly repairs due to excessive wear. Oil inlet Oil outlet plug a. Put the vehicle on the level ground. b. Shut down the engine; put an oil container under differential oil outlet plug. Loosen the oil outlet plug in the differential. Let the oil out fully. 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 differential oil outlet plug e. Remove the oil inlet plug; fill oil (API 80(75) W-90 GL-3 Gear Oil) about 0.4 liters. f. Replace the oil inlet plug, and tighten with 30N*m torque. g. Change the oil in front differential with the same steps. Engine Coolant Add Coolant You must check the coolant for level and leaks. If it is low, you need to refill coolant into the radiator (approximately 6000 ml). 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. 43

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. Increase the engine rev s a few times. f. Repeat 2, 3, and 4 till the coolant is at neck and no bubbles come up. g. Refit the coolant cap, turn it clockwise and tighten it. h. Turn the reserve coolant case cap counterclockwise and open the cap. i. 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. j. Close the reserve coolant case cap, turn it clockwise and tighten it. Opening the radiator cap while the engine is hot can be hazardous. Opening the radiator cap can spray the high temperature coolant in your eyes, face and any parts of your body. This can result in severe injury. Never open the radiator cap while the engine is hot. Children and pets may be harmed by coolant. Keep coolant away from the children and pets. Continuous or brief contact with coolant may be dangerous for your health. Wear a long sleeve shirt and moisture-proof gloves (such as dishwashing gloves) when you change coolant. If coolant contacts your skin, wash thoroughly with soap and water. Wash any clothing or rags if wet with coolant. Recycle or properly dispose of used coolant. 44

45 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. Warm up the engine (5~10min) a. Connect the tachometer; adjust the throttle to limit the idle speed. The standard value is (900±RPM). b. Adjust the screw and adjust the idle speed to an ideal value. c. Repeat step b until the RPM of engine stables. Spark plug inspection Adjustment screw and nut Clean spark plug Check spark plug refer to Preventative maintenance and service log, if too much carbon adhered, which will weaken the spark. Clear the carbon adhered with a dry brush, and scratch the carbon adhered to insulating lay carefully with a file. And blow of dust with dry and clear air. And adjust the space to 0.9~ 1.1mm. Spark plugs replacement The spark plugs should be replaced every 30000km, or 18 months. Screws Screws Plastic cover Plastic cover Spark plug seat 45

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. 5. Tighten spark plug with a special spanner (torque:25n*m ) 6. Connect high-voltage wire in order. Engine damage or working unsteadily may occur if: 1. Not install the spark plug correctly. 2. Use a forbidden spark plug. To avoid damage, follow the following items 1. Tighten spark plug to a required torque (25N*m), over tightening will damage the screw. 2. Removing or installing a spark plug, make sure the slot aligned. 3. Do not pull the high-voltage wire, pulling the tube wrapping the high-voltage wire is allowed. 4. Other brands of spark plug are forbidden. 5. Make sure spark plugs hole lip is clear. 46

47 6. The spark plugs is hot after a long-time driving, make sure the spark plugs is not hot before operation. 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. 10mm When checking the wedge belt, never start engine, or body injury even death may occur. Shift cable adjustment After a long time use, more and more free play of shift cable make gear position is not accurately or shift lever in a wrong position, so adjust the shift cable refer to Preventative maintenance and service log. 1. Loosen the adjustment nuts, move the cable forwards or backwards according situation, repeat it until find a position where gear shift work correctly and the shift lever work in a proper position. 2. Repeat step 1 with another shift cable. 3. Tighten all of the adjustment nuts. 47

48 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. Loosen the adjustment nuts, move the cable forwards or backwards according the situation, repeat it until find a position where free play is gone. 2. Tighten all of the adjustment nuts. 48

49 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 49

50 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 reverse smoothly. The shift lever should be vertical when the gear is in neutral.if not,adjust the shift cable Thin nut and then tighten the nuts of the shift cable. Front Wheel Replacement Do not disassemble the center castle nuts when you replace the front wheels.tighten the nuts after replacing the wheels. Rear Wheel Replacement Do not disassemble the center castle nuts when you replace the rear wheels. Tighten the nuts after replacing the wheels. 50

51 Clutch replacement 1. Remove two bolts, and demount Starter-assembly carefully. Q Q S 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. Q Q218B1245 Q

52 3. Remove upper steel cushions and lower steel cushion S 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. Spline-shaft 52

53 S S 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. 53

54 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. c. To adjust the alignments, loose the lock nuts on both sides of Front Tie Rods. To make Dimension B smaller, turn the rod to the left. Turn the rod to the right to make Dimension B larger. After adjusted to desired length, tighten the lock nut against the rod end. Recheck the dimensions for proper alignment. Battery Fuse replacement Bulb replacement Shock adjustment 54

55 Repair manual Chassis wiring diagram 55

56 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 56

57 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 57

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 Fix the flywheel and prevent the gear ring from rotating, Remove bolt of tensional vibration damper Ensure the mark on the timing belt match the mark on the oil pump 2.4. Remove timing belt covers 58

59 2.5. Remove the tensioner Carry out the operation at the upper thrust point of compression of the first cylinder piston 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; Attention: You can rotate the engine clockwise only, after installing the pulley; before removal, make a arrow mark on the position of timing mark, assemble according to original state Make sure that the crankshaft timing pulley wheel mark is aligned with the mark of the oil pump. Timing mark Remove the tensioner bolt, and take off the tensioner 2.6. Remove the timing belt. [Caution] It is absolutely not allowed to use screw driver or some other sharp-edged tools to remove the belt. Attention: Pay attention to the following points while using timing belt: - Don t bend the belt even at a small angle, otherwise it will result in rope fracture inside the belt. - - Service life of belt is short, don t pollute the belt with grease and water. - You have no choice but rotate 59

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 Cracks on the backside rubber; Cracks of teeth roots, cracks clearing off the fabric lining layer; Tears and wears of fabric lining layer, missing rear teeth, broken teeth, etc. Chap Tears and wears Chap Abnormal tears and wears on belt sides MIS Abnormal Tears and wears Drop-off of belt core Even if the damages on the outer appearance can not be confirmed, the belt should be replaced under any of the following circumstances: If the water in the water pump is leaked, which makes it necessary to refill the water continuously; There are much oil stains on the belt, the belt should be replaced for the rubber will be damaged when it is expanded; Specifications and model of the timing belt Part number Belt wide 27.0mm Timing belt tensioner Turn the belt tensioner supporting stand bolts to see if there is any abnormal sound. Check to see if there are any damages on the contacting surface of the belt. Specifications and model of the timing belt tensioner Part number Wide 27.0mm Outside diameter φ50mm Check to see if there are any damages on the outer appearance 60

61 Specifications and model of clockwise pulley Model EF Item GL ZL GS ZS Diameter of camshaft φ timing gear (mm) Diameter of crankshaft φ 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. Installation 3.1. Installation of crankshaft timing gear 3.2. Installation of timing belt On the upper thrust point of the first cylinder Compression Place the camshaft timing gear around the front end of the air exhaust camshaft so as to make the positioning groove on the gear be aligned with the positioning pin on the end surface of the camshaft. Then use screws to fix the clockwise gear, with the torque of 100 ± 5N.m Make sure that the punched mark on the crankshaft clockwise pulley is aligned with the mark of the oil pump Install the tensioner Adjust the tension of the timing belt As shown in the figure, make the space between the edge of the stretching wheel and the water pump case arc to be about 8mm;Tighten the bolt of the stretching wheel with a torque of 25 ± 3N.m. Use a screwdriver to swing the stretcher toward the right.. 61

62 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 Use hands to press down for about 5mm. The force for pressing the clockwise belt is about: [Reference] 20~30 N Notice: When the deflection of the timing belt fails to meet the specifications, the key is to adjust the above-mentioned stretcher fastening bolt by widening he spacing. tighten the S/A fixing bolt of the stretcher with the specified torque of 25 ± 3N.m 3.4. Install the baffle of the crankshaft-timing pulley [Attention] Install the baffle towards the direction shown in the right figure Install the tensional vibration damper (use SST) When there is not a flying wheel, Fix a part of the crankshaft pulley Pay attention not to make the gear belt moving, tighten the bolt according to the specified torque :98.0±10N.m{10±1kgm} 62

63 When there is a flying wheel, Fix the flywheel to prevent the tooth ring from turning Then tighten bolt of tensional vibration damper Install timing belt cover Install seal strip in the position shown as right figure. Install the position 1 and position 2 before cylinder head assembly; install position 3 before tighten water pump. Install the timing belt cover, screw the bolt manually, and then tighten them with a tool. Torque: 6±1N.m 3.7 Install water pump pulley Torque: 6±1N.m 63

64 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 64

65 2. Removal ) 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. Removal of camshaft bearing cover Align the marks on the camshaft gears as shown in the right figure. Air outlet camshaft gear Air inlet camshaft gear 65

66 Use bolt to position the master and slave 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) Screw 2.4. Remove bolts according the right figure, remove camshaft bearing cover 2.5. Remove the spark plug 2.6. Remove the camshaft slave gear Use the special tool as shown in the right figure. Clip the camshaft tightly, and turn the gear, to keep the bite state of master and slave gear; remove the fixing bolts of slave gear. Attention: Do not damage the surface of the camshaft. Bolt Fixer Don t Use the special tool (1). Screw bolt M6 on the camshaft slave gear as the right figure show (2). Rotate the gear with a screwdriver; remove the bolt fixing slave gear Attention: Do not damage the surface of the camshaft. (3). Remove retainer for shaft with tensionor, remove waveform washer, driver ring and saddle flip washer. 66

67 2.7. Camshaft Use the caliper to measure the height of the camshaft. If it is below the specified limits, make roper replacement. Camshaft Unit:mm Model EF Item ZL RL GL GS ZS Standard IN φ EX φ IN φ22.9 Limit EX φ 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. The air inlet camshaft axial clearance is 0.1~0.170mm The air exhaust camshaft axial spacing is 0.1 ~ 0.173mm Limits for operation:0.18mm Checks on camshaft meshing clearance (1). Put camshaft into cylinder head (2). Make sure the front mark on bearing cover and shaft number is ok, and then tighten bolt. (3). Fix air inlet camshaft, and then measure the clearance with dial indicator. Attention: measure 4 points around gear use a special tool to rotate air inlet camshaft. under the condition that the mark on drive-gear match the mark on driven-gear 3. Installations 3.1. When using a special tool Fix the two φ6 holes of the camshaft gear S/A Turn the slave gear to the right, match the mark hole on the slave gear with the mark on the master gear, or align the marks on the slave gear with the mark on the master gear; then fix the slave gear with bolt.(thread: M5; pitch: 0.8) Fixer Bolt 67

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 consistent, and then fix driven-gear with bolt(m5 0.8). Attention: Do not damage the surface of the camshaft. Air outlet camshaft gear 3.3. Installation of the camshaft Attention: Size of the axial clearance of the camshaft Smear lubricating oil at the camshaft gear section and the cylinder cover axial diameter section Fix the camshaft slave gear by roughly adjusting on the cylinder cover Install camshaft, the timing mark must be aligned shown as the right figure Smear lubricating oil on the camshaft assembly, the gears and the cylinder head axial diameter section Tighten the camshaft-bearing cap shown as right figure Remove the bolt for fixing the slave gear of the camshaft assembly. Timing mark Fixer Air inlet camshaft gear 68

69 3.6. Installation of camshaft head cap Smear the fluid sealant on the camshaft head cap section (With oil groove) shown as the right figure. Sealing line Tighten the bolts according to the sequences shown as the right figure with the specified torques After smearing oil in the plug cap hole and assembling surface of the plug, use SST to press the plug lid Attention: Install the plug lid shown as the right Illustration. Keep unbiased with cylinder head end surface after pressing.1±1mm 3.7. Smear engine oil on the oil seal installation port of cylinder head, camshaft oil seal edge of blade and outside ring, use M10 bolt (length mm) and SST press the cylinder, lower 1mm than the end surface of the cylinder4 head. Attention Under the condition of use the oil seal repeatedly, press here with engine oil adhesive agent - The oil seal should not be pressed inclining to one side. Outside 3.8. Installation of the timing gear of camshaft After smearing the fluid sealant, use SST to prevent rotating, tighten the timing gear bolt of camshaft according to regulated torque of 100±5N.M. 69

70 Attention: process the special tool according the right figure Installation of cylinder head gasket Clean the the used cylinder head gasket Put new one into the groove on the timing-belt cover accurately Cover the cylinder head with cylinder head cover; tighten the bolts according the right figure. Torque: 6±1N.m. 4. Routine check Timing mark 4.1. Standard of valve clearance: valve clearance IN 0.18±0.05 EX 0.25±0.05 Air outlet camshaft gear Air inlet camshaft gear 4.2. Align the timing marks on the drive-gear and driven-gear Use a plug gauge to measure the clearance according the right figure 一缸二缸三缸四缸 IN EX IN EX IN EX I E N X O O O O 70

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 IN EX IN EX IN EX IN EX O O O O 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 result Rotate camshaft to make the cam-top (valve clearance exceed the standard) upwards, and gap of valve lifter towards inside Rotate camshaft and the cam press valve lifter down Load the special tool at the top of the valve lifter around the valve lifter, and then rotate camshaft to make the cam-top upwards, press valve lifter down with a special tool, and hold it Move the adjusting washer out with a screwdriver, and then remove the washer with a magnet iron wire from inside Use a caliper to measure and adjust the thickness of the separation cushion. 71

72 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 Underside Use the selected adjusting gasket to adjust the throttle clearance. Attention Install the feeler with the identification mark facing downwards Rotate camshaft to make cam-top downwards, and the throttle to be pressed down, and then take special tool out Rotate camshaft 2-3 round, and then recheck the valve clearance, if valve clearance can t get to the standard, repeat to adjust the valve clearance. 72

73 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. Removal of spark plug 73

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 Removal of the cylinder dustproof sealing and cylinder cover base. Attention The cylinder cushion cannot be used repeatedly Removal of throttle adjusting separation cushion and valve thrusting rod 2.5. Use special tools to remove the valve spring locking block, throttle spring stand, valve spring, IN valve and EX valve 2.6. Removal of valve oil seal and valve spring washer 2.7. Clearing (1). The accumulated carbon residue covered on the valve must be cleared. (1). Use scraper to clear the cylinder cover, the air inlet and exhaust branching pipe surfaces and bottoms Attention Do not damage the cylinder cover surface by scraping During the process of clearing. Do not drop filth into the air inlet and the water channel. 3. Routine checks 3.1. Cylinder cover Use the straight knife sharp edge ruler to measure the levelness at various points as shown in the figure. Cylinder cover 0.10mm Air inlet branching pipe surface 0.10 mm 3.2. Valve spring Use a square ruler to measure the right angle of the valve spring. Replace the 74

75 spring if it fails to meet the specifications. [Limit] 1.2mm Measure the free state of spring [Benchmark value] 37mm 3.3. Routine checks on throttles Check to see if there are some deformations, obvious tears and wears Check list on valve Unit: mm item standard limit IN 0.85~1.41 wide EX 1.07~1.36 IN 1.0± Width of valve top EX 1.0± Checks on the clearance between the throttle guiding pipe and throttle thrusting rod Use a dial gauge to measure the inner diameter of the throttle-guiding pipe, and use a caliper to measure the outer diameter Work out the differences of the measured values. If it is above the specified limits, the throttle or the guiding pipe must be replaced. Attention The measurement points are shown as the figure. Work out the clearance of the final torn and worn section item standard limit Valve guide Inside diameter(mm) φ5.0 Valve stem outside diameter (mm) φ ~ 0.07 IN Spacing 0.020mm (mm) ~ EX 0.030mm Replacement of valve guide Heat the cylinder cover to degrees C with hot water 75

76 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 Use special tools to drive in the new valve-guiding pipe to the position as shown in the right figure. Attention In the process of driving in the guiding pipe into the cylinder cover, the operation should be carried out slowly until the pipe gets to the proper position. No excessive driving should be exerted. Pay attention to the specifications in the operation. Driving in depth of throttle guiding pipe For IN For EX model item Height(mm) EF GL,ZL,RL,GS,ZS IN 13.71±0.25 EX 12.11± Use reamer to grind the inner diameter to achieve the standard value of the clearing Valve mating surface Smear thin layer of red lead powder on the valve-mating surface. Do not turn the valve, and gently drive it in. Check the mating condition and the width of mating line Correction of valve base stand ring Attention Signs of breaking or cracking should not appear on the correction surface. Take it out slowly after the correction is completed Use a 45 degree cone as the mating 76

77 benchmark value 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 Make conic cutting at the center of the mating position with 70 degrees toward inwards and 30 degrees outwards Use polishing agent to grind and polish the throttle sealing Assemble of cylinder head Cylinder head Pay attention to the following instructions in the process of assembling for the other accessories on the cylinder cover Spark plug insulator 1 Put the spark plug insulator in the corresponding hole on the cylinder head with special use auxiliary tools, smear fluid sealant before pressing, pressing height is shown as the illustration: Attention Pay attention that the vertical degree of its pressing depth and the cylinder head top surface; The insulator should not be deformed while being pressed; Otherwise, it is easy for the valve chamber cover cap to lea Spark plug insulator Sub stool Installation Installation of valve spring washer and valve oil sealing Cover auxiliary tools on the valve rod head, smear oil on the outer circle of the auxiliary roundness and inside of new valve oil seal, install it on the illustrated position, pull out the auxiliary tools of valve oil seal. [Reference] Insert the oil sealing up to the dimension as shown in the right figure. Spring bottom plate Oil sealing Valve 77

78 Installation of IN and EX 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 Install the locking blocks for the valve spring stands. Warning Protective eye glasses must be worn in the process of this operation to protect the eyes. Beware of the flying spring and other objects Upon completion of the installation of the throttle springs and throttle spring stands, use special tools to install the locking blocks for the throttle spring stands Installation of the throttle thrusting rod and throttle spacing by adjusting the separation cushions Install the cylinder cover base, make identification of the marks for the front and rear directions Assembling of dustproof sealing strip and cylinder cover Apply lubricating oil at the threads and grooves of the bolts The tightening of the cylinder bolts should follow the sequence as shown in the right figure. The tightening is to be carried out in 2 3 operations till the torque meets the specifications. The torque for the first tightening operation is 30±2N.m; the torque for the second tightening operation is 50±3N.m; and the 78

79 torque for the third tightening operation is 70±3.5 Nm 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. Water pump 1. Configuration diagram (the dismounting and assembling of the cylinder body should be done in the following procedures) 1 O ring, non-reusable2 Oil pump body3 Weather seal :Non-reusable part Unit: N*m (kg*cm) 2. Dismounting 2.1. Dismounting and removal of O-shaped ring Attention: These rings are not reusable Removing the three bolts and dismount the water pump principal body Removal of the dustproof sealing stripe 79

80 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. Installation 5.1. Install the dustproof sealing stripes 5.2. Install the water pump principal body Tighten with a torque of 25±1.5N.m 5.3. Install the new O-rings Oil pump 1. Configuration diagram (The dismounting and installation of the lubricating oil pump should be carried out according to the following procedures). 80

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. Attention: Do not make the oil pan flange section to be deformed Remove the oil collecting filter and its flange 81

82 Attention The filter flange is not reusable 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 used ones. Attention Do not drop the residues into the cylinder body. 4. Disintegration and assembling of oil pump 4.1. Configuration diagram 82

83 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 Weather seal Attention The weather seal are not reusable. :Non-reusable part Unit: N*m (kg*cm) Remove the oil pump cover Attention: The bolt is assembled with glue, loosen it with screw driver according to the illustrations Remove the driven and drive rotor of the oil pump Take off the split pin Attention The split pins are not reusable. Attention: Pay attention not to make the spring and spring seat sending forth and ropping 83

84 suddenly, while taking off the open pins Removal of the oil pump pressure relief valve spring stand, spiral spring, oil pump pressure relief valve Removal of the front oil seal of the crankshaft Attention The removed oil seals are not reusable Routine checks Checks on lubricating oil pump spacing Follow the mark on the interior and exterior gears of the oil pump to place it into the lubricating oil pump body on the cylinder body Use a feeler to measure the clearance between the interior gear and the exterior gear [Benchmark] mm(average of 9 points) [Limit] 0.35 mm MARK Use a feeler to measure the clearance between the rotator and the pump body [Benchmark] mm [Limit] 0.25mm Routine checks on the pressure relief valve Remove the pressure relief valve, there 84

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 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 Assembling of the oil pump pressure relief valve and split pins Attention The split pins are not reusable The marks of the exterior and interior gears of the lubricating oil pump should be on the visible side when being assembled into the pump body. Mark The new weather seal should be put inside the oil pump cover groove. 85

86 5. Disintegrating and assembling of oil seal 5.1. Configuration diagram :Non-reusable part Unit: N*m (kg*cm) 5.2. Disintegration Use a flat screwdriver to remove the rear oil seal. Attention The oil seals are not reusable Checks Check to see if the tears and wears of the lip section of the oil seals are within the normal 86

87 conditions, and if there are any damages in outer appearance Assembling Smear lubricating oil on the new oil seal lip section Install the oil seal shown as the right figure. 6. Assembling 6.1. Assembling of the oil sealing stands Smear oil sealing silica on the oil sealing stands shown as the right figure. [Grease] Letai 5699 Oil sealing lip SST SST Seal line Attention The liquid sealing silica is to be smeared to the mating section of the oil seal stands and cylinder body surface, with a width of 3 4mm. [Torque] 25±1.5N.m 6.2. Assembling of new oil pump washer, oil pump assembly [Torque] 20±1.5N.m 6.3. Installation of new lubricating oil collecting and filtering device, oil pump collecting and filtering device [Torque] 6±1N.m 6.4. Assembling of oil pan 87

88 Clear the mating surface with the cylinder body 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 application of silica Front Tighten in the sequence shown in the right figure with the torque of 6±1N.m from the center to the two sides Rear Crankshaft connecting rod mechanism 1. Configuration diagram (Dismount and assemble the oil pump in the follow sequence) 88

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. Disintegration of crankshaft connecting rod mechanism 2.1. Check the connecting rod axial clearance Use centimeter or feeler to measure axial spacing 89

90 [Benchmark]: mm [Limit]:0.30mm 2.2. Check the connecting rod bush vertical clearance Remove the bush cover Attention: Parts and components of various cylinders should be placed in good order Clean the bush and axle diameter Place clearance gauge on the connecting bearing diameter. Tighten bush cover according to regulated torque torque: 40±2N.m Attention Do not turn the crankshaft Remove the bush cover, measure the maximum width of the spacing ruler [Benchmark]: mm [Limit]: 0.07 mm 90

91 Replace the bush if width is beyond the limit. Attention: In replacing the bushes, you should use the products of same brand and from the same manufacturer, which can accord with the request of clearings. Connecting rod bush Connecting rod cover Removal of connecting rod bearing cover and Connecting rod bush The threaded section of the connecting rod bolt is to be equipped with protective sleeve to prevent from scraping the cylinder hoe and crankshaft connecting rod axle diameter. Then knock the piston connecting rod out with the handle of a hammer. Attention Put the parts and components of various cylinders in good order. Lagging cover 2.3. Use a caliper to measure the crankshaft axial clearance. If the axial clearance is above the limits, it is needed to replace the axial thrust washer or the crankshaft. [Benchmark]: mm [Limit]:0.30mm item Thickness of thrust face Benchmark value Check the radial clearance of the crankshaft Remove the crankshaft bearing cover; use a resin hammer to knock the bearing cover off gently Clean the inside of the bushes, the inside of the bearing cover, the cylinder walls, the axle diameter, etc. Make thorough checks for any tears and wears as well as other 91

92 damages 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. Attention: Don t turn the crankshaft after tightening,because of the clearance gauge Remove the bearing cover and measure the maximum width of the spacing. If it goes beyond the limit, replace the bush. [Benchmark]: mm [Limit]:0.10mm Remove Main bearing cover, Crankshaft, Crankshaft bush, Thru st washer Attention: tighten the bolts fixing bearing cover according the order show as right figure Disassembling of connecting rod assembly of the piston Use the piston ring pliers to remove the primary ring, the secondary ring and the oil ring Attention Do not mix up the pistons and piston rings for each unit of assembly. Clearance gauge Use SST to remove the piston, connecting rod and piston pin 92

93 1 Remove the piston pin to take off the piston and the connecting rod by using SST. 3. Clearing 3.1. Cylinder body Warning Wear eyeglasses during the clearing operation to protect your eyes Use flat chisel to clear the cylinder body, the cylinder cover, the oil bottom casing, the oil pump and the oil seal Piston Warning Wear eye glassed in the process of cleaning to protect your eyes Use the old ring to clean the accumulated carbon in the ring groove Clean the accumulated carbon at various parts with detergents. Attention Do not use metal brush or some other hard substance to do the cleaning. 4. Routine checks 4.1. Cylinder block Checks on the levelness of cylinder top surface (1). Use a ruler and feeler to do the measurements of the six parts as shown in the right figure. [Limit] 0.08mm The use of cylinder meter: Measure the values at the parts as shown in the right figure and work out the maximum value and the minimum value. Replace the cylinder body or do the boring of the cylinder if the values exceed the limits. [Limit] 0.03mm [ Reference] Circularity:A-B or a-b Cylindricity: A-a or B-b [Reference] Cylinder standard diameter: Φ mm Top dead center Bottom dead center Measure point 93

94 4.2. Piston 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 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 pinhole diameter Work out the clearance on the basis of the size difference between the hole diameter and the pin diameter. Replace the piston pin or the piston if the result exceeds the benchmark value. [Benchmark] mm [Limit] 0.015mm Measurement of the piston diameter Make the measurement at the position 11mm below the piston skirt and along the vertical direction of the piston pin. [Benchmark] Check the clearance between the piston ring and the ring groove Use a feeler to measure the rings Benchmark(mm) Limit (mm) Primary ring 0.03~ Secondary ring 0.03~

95 Check the clearance of piston ring ends 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. Primary ring Benchmark(mm) Limit (mm) Secondary ring 0.35~ Oil ring 0.20~ Check the clearance between the piston and the cylinder wall The positions for measuring the inner diameter of the cylinder and the piston skirt are as shown in the right figure. Replace and repair the piston or the cylinder body, or bore the Inside diameter cylinder if the measured results exceed Measure position the limits [Benchmark] 0.018~0.03 [Limit] 0.10 [Reference] The clearance between the piston and the cylinder hole is subject to the innermost diameter of cylinder in vertical direction minus the maximum outer diameter of the piston After the replacement of the piston or the cylinder body, it is needed to confirm the clearance of the replaced cylinder once again. Datum: 0.018~ Crankshaft Check the coaxiality of the main shaft diameter Use the centimeter to measure the coaxiality. Outside diameter Measure position 95

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 Check the tears and wears of the crankshaft Use a caliper to measure the shaft diameter, and work out the circularity and cylindricity. [Limit] 0.005mm Use a caliper to measure the connecting rod diameter, and work out the circularity and cylindricity. [Limit] 0.004mm the measuring position is shown as the figure, 5. Assembling of the crankshaft connecting rod mechanism 5.1. Assembly of the piston and connecting rod Use special tools to assemble the piston, connecting rod and piston pin in the following specified procedures Smear lubricating oil to the connecting rod pin hole, and make the assembly according to the marks for the same unit and in the indicated direction Make the installation shown as the right figure Make adjustments and installation of the piston and the connecting rod shown as the right figure. After smearing lubricating oil to the piston pin, use pressurizing device to assemble the piston and the connecting rod. Attention Pay attention to the assembling direction when pressing in the piston pin; The small bit of connecting rod should be heated to 300 while pressing the piston pin in the piston. Exert pressure in the process of pressing to assure the alignment of the pin Install Primary ring, the secondary ring and the oil ring in the following specified 96

97 procedures Install gas ring Side face with marks should be upright, install primary ring with piston ring tool Install oil ring (gasket ring, down scraper and upper scraper) firstly, then install the secondary ring, then install the primary ring, Open degree of every ring is shown as the illustration: 5.3. Assemble the crankshaft main bearing cover, the crankshaft, shaft bush, shaft body and thruster according to the following instructions The protruding thrust block on the bush should match the groove on the cylinder body for installation.. Attention Use the bush made by the same manufacturer. Outward Smear lubricating oil on this side (upper side) of the crankshaft before installing it The side thrust chip with oil sink should face outward (crankshaft handle) for installation on the cylinder body-bearing stand. Attention Smear lubricating oil on the side of the oil sink. The bush (lower) installed in bearing cover must match thruster groove Smear lubricating oil on the friction side opposite to the contact of the bush lower parts. Install the parts according to the forward induction mark on the crankshaft bearing cover After applying the lubricating oil, tighten the bolts in the sequence shown as the right figure for 2 3 cycles with the specified torque. [Torque] 70±3.5N.m Rotate the crankshaft after assembling, you should rotate it with ease, the torque should be less than 1Nm Oil groove Thruster Apply Oil Outwards Direction mark Diameter mark 97

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 The openings of the air ring and oil ring should match the specified direction Use nylon sleeves for the bolts of the connecting rod to prevent from scraping the cylinder hole and axial diameter Apply lubricating oil to the piston, the connecting rod and the surfaces of the other related moving parts Make sure the frontward indication mark on the piston. Should be frontward and assemble the piston connecting rod Ay with SST. Attention The cylinder number on the piston connecting rod should be identical to the cylinder number Assemble the connecting rod bearing cover and bush according to the following instructions Smear a little lubricating oil on the bolt and screw nut stand before they are mounted according to the indication mark Tighten the left and right screw nuts alternately for a couple of times with the specified torque. [Torque]: 40±2N.m Attention The connecting rod and the rod bush should be bought from the same supplier 98

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139 PARTS MANUAL 1. ENGINE 1. COOLING SYSTEM No Part number Name Quantity 1 Q HEXAGON HEAD BOLT WATER PUMP PULLEY 1 3 Q HEXAGON FLANGE BOLT 1 4 Q BOLT(M8X55) 3 5 Q HEXAGON FLANGE BOLT WATER PUMP SET O RING WATER PUMP WASHER SEAL STRIP Q BOLT SEAL STRIP SEAL STRIP 'O' 'O' RUBBER RING SEAT - THERMOSTAT OUTER THERMOSTAT ASSY THERMOSTAT ASSY 1 17 Q HEXAGON FLANGE BOLT INNER SEAT-THERMOSTAT ASSY OUTER SEAT-THERMOSTAT ASSY PIPE 1 139

140 2. CYLINDER BLOCK No Part number Name Quantity CYLINDER BLOCK ASSY POSITION PIN CRANKCASE VENTILATION PIPE CYLINDER HEAD SEAL PLUG 4 5 Q HEXAGON FLANGE BOLT KNOCK SENSOR POSITION PIN 2 8 S OIL PRESSURE SWITCH G10GB308 BALL PLUG BOLT COVER-OIL CONTROL TIE-IN-OIL FILTER VENT PIPE 1 140

141 3. CRANKSHAFT No Part number Name Quantity PULLEY BOLT TORSION SHOCK ABSORBER ASSY CRANKSHAFT TIMING GEAR TOOTHED BELT BAFFLE CRANKSHAFT FRONT OIL SEAL NEEDLE BEARING WOODRUFF KEY CRANKSHAFT ASSY STOPPER PLATE 2 10 S COVER SET BOLT PIN - DOWEL REAR OIL SEAL REAR OIL SEAL BRACKET 1 15 Q HEXAGON FLANGE BOLT FLYWHEEL ASSY LOCK-FLY WHEEL BOLT 6 18 S CRANKSHAFT POSITION SENSOR 0 19 S CA COVER-CLUTCH 1 20 S CA DRIVEN DISK ASSY 1 141

142 4. EXHAUST MANIFOLD No Part number Name Quantity GASKET-EXHAUST MANIFOLD EXHAUST MANIFOLD 1 3 Q F3 STUD 6 4 Q33008 HEXAGON NUT HEAT INSULATOR 1 6 Q HEXAGON HEAD BOLT 4 7 S JA OXYGEN SENSOR 1 8 Q F3 STUD 1 9 S OXYGEN SENSOR BRACKET 1 142

143 5. INTAKE SYSTEM No Part number Name Quantity 1 Q HEXAGON HEAD BOLT 4 2 S JA THROTTLE 1 3 S JA GASKET-THROTTLE 1 4 Q HEXAGON FLANGE BOLT ACCELERATOR PULLING WIRE BRACKET 1 6 S INTAKE TEMPERATUREAND PRESSURE SENSOR 1 7 Q HEXAGON HEAD BOLT UPPER INTAKE MANIFOLD 1 9 Q HEXAGON HEAD BOLT 2 10 S JA OIL GUIDE EF INJECTOR (1.6L) 4 12 Q F3 STUD 3 13 Q F3 STUD GASKET-INTAKE MANIFOLD 1 15 Q F3 STUD INTAKE MANIFOLD FRONT BRACKET 1 143

144 5. INTAKE SYSTEM No Part number Name Quantity INTAKE MANIFOLD REAR BRACKET BRACKET 1 19 Q HEXAGON HEAD BOLT CRANKCASE VENTILATION PIPE (2) H OIL AND AIR SEPARATOR CRANKCASE VENTILATION PIPE (1) 1 23 Q HEXAGON FLANGE BOLT CRANKCASE VENTILATION PIPE (3) 1 25 Q HEXAGON FLANGE BOLT 2 26 S DA CABLE-ACCL GASKET-INTAKE MANIFOLD INTAKE MANIFOLD LOWER TIE-IN PIPE S BA TUBE 1 144

145 6. LUBRICATING DEVICE No Part number Name Quantity OIL FILTER ASSY OIL DIP STICK ASSY OIL DIP STICK PIPE ASSY SEAL STRIP OIL PUMP WASHER OIL PUMP ASSY 1 7 Q BOLT 1 8 Q BOLT(M8X55) 2 9 Q HEXAGON HEAD BOLT OIL STRAINER WASHER 1 11 Q STUD 2 12 Q33006 HEXAGON NUT OIL STRAINER ASSY 1 14 Q HEXAGON FLANGE BOLT 1 15 Q HEXAGON FLANGE BOLT 4 145

146 7. CYLINDER HEAD No Part number Name Quantity SPARK PLUG SLEEVE 4 2 Q HEXAGON HEAD BOLT CYLINDER HEAD BOLT CYLINDER HEAD BOLT WASHER 10 5 S WATER TEMP. SENSOR 1 6 S CAMSHAFT POSITION SENSOR 1 7 Q HEXAGON HEAD BOLT GUIDE - VALVE EXHAUST VALVE SEAT INSERT INTAKE VALVE SEAT INSERT AB GASKET-CYLINDER HEAD RA HANGER - FRONT ENGINE 1 13 Q HEXAGON FLANGE BOLT BLOCK COVER CAMSHAFT OIL SEAL CYLINDER HEAD 1 146

147 7. CYLINDER HEAD No Part number Name Quantity CAMSHAFT BEARING CAP POSITION COVER S WATER TEMP. SENSOR SET BA REAR HINGER PLUG PLUG PLUG STUD SLEEVE PLUG 1 147

148 8. COVER-VALVE CHAMBER No Part number Name Quantity OILING PORT COVER ASSY 1 2 Q SCREW COVER VALVE CHAMBER GASKET-VALVE CHAMBER 1 6 Q HEXAGON HEAD BOLT 5 148

149 9. OIL PAN No Part number Name Quantity OIL PAN ASSY 1 2 Q HEXAGON HEAD BOLT SEAL WASHER-OIL DRAIN THREADED PLUG MAGNET PLUG 1 149

150 10. VALVE MECHANISM No Part number Name Quantity TENSIONING PULLEY ASSY 1 2 Q HEXAGON HEAD BOLT 1 3 Q HEXAGON HEAD BOLT TIMING GEAR COVER ASSY 1 5 Q HEXAGON HEAD BOLT 9 6 Q HEXAGON HEAD BOLT 2 7 Q43140 SHIELD-SHAFT SPRING RING SADDLE FLIP WASHER DRIVE RING GEAR (DERIVEN) - INTAKE CAMSHAFT GEAR (MAIN ) - INTAKE CAMSHAFT GEAR (MAIN ) - INTAKE CAMSHAFT HEXAGON FLANGE BOLT TIMING BELT SPROCKET LOCK-CLUTCH HUB NUT 1 16 Q INNER HEXGON HEAD BOLT 4 150

151 10. VALVE MECHANISM No Part number Name Quantity COUPLING FLANGE EXHAUST CAMSHAFT GEAR EXHAUST CAMSHAFT GEAR ADJUSTMENT WASHER VALVE LIFTER VALVE LOCK BLOCK EDDY SLEEVE BA VALVE SPRING UPPER SEAT SPRING - VALVE VALVE SEAL LOWER VALVE SPRING SEAT EXHAUST VALVE TOOTHED TIMING BELT INLET VALVE PIN PIN 1 151

152 10. VALVE MECHANISM No Part number Name Quantity VALVE SPRING UPPER SEAT 1 34 Q673B155 CLAMP LOWER COVER-TIMING GEAR BOLT 1 152

153 11. IGNITION DEVICE No Part number Name Quantity 1 S JA IGNITION COIL 1 2 Q SCREW AND WASHER UNIT 3 3 S CA BRACKET-IGNITION COIL 1 4 S SPARK PLUG ASSY 4 5 Q HEXAGON HEAD BOLT 3 6 S BA HI.TENSION CORD NO S BA HI.TENSION CORD NO S BA HI.TENSION CORD NO S BA HI.TENSION CORD NO S CLIP 1 153

154 12. PISTON AND CONNECTING ROD DEVICE No Part number Name Quantity PISTON PIN AC PISTON CONNECTING ROD ASSY BEARING-CONNECTING ROD 8 154

155 13. OTHER ACCESSORY No Part number Name Quantity 1 S CS Engine Harness 1 2 S JA ECU 1 3 SV Shifter soft shaft bracket 1 4 S JA carbon can PCV 1 5 S GA Starter assembly 1 6 S lower Steel cushion 1 7 S BA Single Exhaust Gasket M12*1.75 Hex nut M12* SW12 Spring Washerφ W12 Washerφ M12*1.75*75*25 Hex socket head bolt M12*1.75*75* Q218B1245 Bolt 12* Q Bolt 12* Upper steel cushion 1 15 S locating dowel 2 16 Q Bolt 8* Q Bolt 8* S Electric odometer sensor assy 1 155

156 14. OTHER ACCESSORY No Part number Name Quantity 1 S BB Alternator 1 2 S BA Alternator bracket 1 3 S BA Rear bracket 1 4 S V-ribbed belt 1 156

157 5T07D1 TRANSMISSION 1 CASE&ACCESSORY Ref Part No. Part Description Qty Comments 1 QR Clutch case 1 2 4T08A Transmission case 1 3 5T Side cover 1 4 5T Declutch bearing 1 5 5T A Declutch fork 1 6 5T Clutch fork 2 sleeve 1 7 5T Clutch fork seal 2 8 5T Clutch fork 1 sleeve 1 9 QR Double-screw rod M8x40 Flange bolt M8x

158 1 CASE&ACCESSORY Ref Part No. Part Description Qty Comments 11 5T Locating pin T Oil plug screw T Screw plug washer T Back-up light switch T A Double-screw rod T Bearing stop plate T Oil-stop plate AM6X12 Flange bolt M6x W6 Flat washer T Oil groove 1 21 S R2 Clutch rocker AM8X35 Flange bolt M8x Flange nut M T Side cover bolt 8 25 QR Declutch release spring 1 26 S R2 5T07D1 Transmission assy 1 158

159 2 COUNTERSHAFT Ref Part No. Part Description Qty Comments 1 QR Output shaft 1 2 QR First gear assy 1 3 QR Second gear assy 1 4 QR Third gear 1 5 QR Fourth gear 1 6 5T Front bearing of output shaft 1 7 5T Needle bearing of 1 ST &2 ND gear 2 8 QR Synchronizer out ring of 1 ST &2 ND gear 2 9 QR Synchronizer middle ring of 1 ST &2 ND gear 2 10 QR Synchronizer inner ring of 1 ST &2 ND gear 2 11 QR Synchronizer of 1 ST &2 ND gear 1 159

160 2 COUNTERSHAFT Ref Part No. Part Description Qty Comments 12 QR Synchronizer spring of 1 ST &2 ND gear 2 13 Synchronizer gear-hub of 1 ST &2 ND QR gear 1 14 Synchronizer gear-sleeve of 1 ST &2 ND QR gear 1 15 Synchronizer gear block of 1 ST &2 ND QR gear T Synchronizer retainer of 1 ST &2 ND gear T Spacer of 3 RD &4 TH gear T Rear bearing of output shaft 1 19 QR Adjusting washer of rear bearing Demand 20 4T08A Countershaft sleeve 1 21 MQC Countershaft nut T08A Countershaft assy 1 160

161 3 INPUT SHAFT ASSY Ref Part No. Part Description Qty Comments 1 QR Input shaft 1 2 5T Input shaft seal 1 3 4T Bearing 6204/YA/P QR TH gear assy 1 5 5T Needle bearing of 3 RD &4 TH gear 2 6 QR Synchronizer ring of 3 TH &4 TH &5 TH gear 1 7 QR Synchronizer assy of 3 TH &4 TH 1 8 QR Synchronizer gear-hub of 3 TH &4 TH gear 1 9 QR Synchronizer gear-sleeve of 3 TH &4 TH gear 1 10 QR Synchronizer spring of 3 TH &4 TH &5 TH gear 1 11 QR Synchronizer gear block of 3 TH &4 TH gear 3 161

162 3 INPUT SHAFT ASSY Ref Part No. Part Description Qty Comments 12 5T Synchronizer retainer of 3 TH &4 TH gear 1 13 QR Synchronizer waveform washer ring 1 14 QR TH gear assy T Back bearing of input shaft 1 16 QR Spacer of 5 TH gear 1 17 QR Input shaft assy 1 18 QR Adjusting washer of rear bearing Demand 19 QR TH gear assy 1 20 Synchronizer ring of 3 TH &4 TH & 5 TH QR gear 1 21 QR Synchronizer waveform washer ring 1 22 QR Synchronizer assy of 5 TH gear 1 162

163 3 INPUT SHAFT ASSY Ref Part No. Part Description Qty Comments 23 QR Synchronizer spring of 5 TH gear 2 24 QR Synchronizer gear block of 5 TH gear 1 25 QR Synchronizer gear-hub of 5 TH gear 1 26 Synchronizer gear-sleeve of 5 TH QR gear 1 27 QR Synchronizer ring of 5 TH gear 1 28 QR Nut of 5 TH gear synchronizer 1 29 QR Reverse gear T Ring of reverse gear T A Shaft of reverse gear T Washer of reverse gear shaft T A Bolt of reverse gear shaft 1 163

164 4 SHIFT FORK&SHIFT-FORK SHAFT Ref Part No. Part Description Qty Comments 1 QR Shift fork of 1 ST &2 ND gear 1 2 5T A Shift fork of 3 RD &4 TH gear Steel ball T A Shift fork of 5 TH gear 1 5 5T A Shift fork of 3 RD &4 TH gear 1 6 4T08A A Stop block 1 7 QR PIN 4.5x QR Shift-fork shaft of 1 ST &2 ND gear 1 9 5T Shift-fork shaft spring 3 10 QR Shift-fork shaft of 3 RD &4 TH gear 1 164

165 4 SHIFT FORK&SHIFT-FORK SHAFT Ref Part No. Part Description Qty Comments 11 QR Shift-fork shaft of 5 TH gear 1 12 QR Shift-fork shaft of reverse gear T Shift-fork shaft screw plug T Washer of screw plug 3 15 QR Shift fork pin of reverse gear T Shift block spring T A Shift arm W8 Flat washer T A Bolt of shift arm 2 165

166 5 SHIFT CONTROL MACHINSM Ref Part No. Part Description Qty Comments 1 5T A Shift-select shaft assy 1 2 5T A Shift-selecting shift 1 3 QR Snap ring of shift interlock 3 4 5T Release-sprig seat of 1 ST &2 ND gear 1 Ref Part No. Part Description Qty Comments 166

167 5 5T Release sprig of 1 ST &2 ND gear 1 6 5T Spring-stop plate 2 7 5T A Stop plate of shift interlock 1 8 5T A Shift-select arm. 1 9 QR Spring pin 3.5x T Pin of shift-select arm T A Release spring of 5 TH & reverse gear 1 12 Release-spring seat of 5 TH & reverse 5T gear P3x22 Pin 3x T A Seat of reverse gear spring T A Limiting spring reverse gear 1 16 QR A Limiting cam of reverse gear x22 Pin 5x QR Guide case assy of shift-select shaft 1 19 QR Guide case of shift-select shaft T Stop plate of release spring Mx12 Flange bolt M6x QR SHIFT-SELECT SHAFT OIL SEAL T Anti-dust cover of shift-select shaft T Limiting bolt of reverse gear 1 25 QR Washer of limiting bolt P6x12 Pin B 6x M8x20 BOLT AM 8x T A Limiting bolt of shift 1 29 QR Washer of limiting bolt M8x75 Flange bolt M8x T Shift pushing block T Anti-dust cover M8 Nut M SW8 Spring washer T Big washer of shift arm T Small washer of shift arm 1 37 S R2 Gear changing arm 1 38 SV Cuprum bush T Anti-dust washer of shift arm 1 40 S R2 Choosing gear arm mount 1 41 S R2 Gear changing arm P5x28 PIN 5x S R2 Gear cable mount 1 167

168 6 DRIVEN GEAR ASSY Ref Part No. Part Description Qty Comments 1 5T07D Driven gear assy 1 2 5T Front bearing of differential 1 3 QR Driving gear of odometer 1 4 4T08A Front bearing of output shaft 1 5 4T08A Output shaft 1 6 4T08A Connecting disc 1 7 QR Driven gear of speed reducer 1 8 4T08A Rear bearing of output shaft 1 9 5T Rearing bearing of differential T Flange bolt 8 11 MQC Retaining ring T Right seal of differential T Left seal of differential 1 14 QR Right seal adjusting washer of differential Demand 168

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