FOR OFF-ROAD USE ONLY

Transcription

1 Owner s manual Parts manual JNSZ650DLB READ THIS MANUAL CAREFULLY. IT CONTAINS IMPORTANT SAFETY 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.

2 CONTENTS WARRANTY POLICY... 5 OWNER S MANUAL... 6 FOREWORD... 6 FOREWORD ABOUT SAFETY... 7 IMPORTANT SAFETY INFORMATION... 8 Follow the Age Recommendation... 8 Always Wear a Helmet... 8 Drive Off-Road Only... 8 Take Time to Learn & Practice... 8 Be Alert for Off-Road Hazards... 8 Drive within Your Limits... 8 Don t Drink and drive... 8 Never run your Go- Vehical indoors IMPORTANT SAFETY INFORMATION... 9 Keep away from moving parts of the Off Highway Recreational Vehicles... 9 Skidding or Sliding... 9 SAFETY LABLES... 9 ARE YOU READY TO DRIVE? PROTECTIVE APPAREL... 2 ADDITIONAL DRIVING GEAR... 2 DRIVE TRAINING... 2 Age Recommendation NO ALCOHOL OR DRUGS IS YOUR VEHICLE READY TO DRIVE? Pre-drive Inspection Engine Oil Coolant Fuel Tires Nuts & Bolts PRE-DRIVE INSPECTION Underbody & Exhaust System Air Cleaner Leaks, Loose Parts Lights Throttle Brakes Engine Stop Steering Wheel Cable Tie rod SAFE DRIVING PRECAUTIONS Off-road use only... 24

3 Keep Hands and Feet on Controls Control Speed Use Care on Unfamiliar or Rough Terrain Do Not Perform Stunts SPECIFICATIONS OPERATION Operation controls Engine stop key Pre-Drive Inspection Passengers Seat Parking Gear Shift Break-in Starting and Operating Instructions SERVICE INSTRUCTIONS Air filter Engine oil replacement Check engine oil and recharge Transmission lubrication Check transmission oil Engine Coolant Spark Plug Carburetor Adjustment Cleaning Instructions Vehicles Lubrication Storage Instruction REPAIR... 4 Front Wheel Replacement... 4 Rear Wheel Replacement... 4 Clutch replacement Timing setup and balancing shaft setup Water pump disassembly Distributor replacement WIRING DIAGRAM ELECTRICAL SCHEMATIC DIAGRAM PARTS MANUAL CYLINDER BLOCK PART SPROCKET COVER AND OIL PAN PART... 6 CYLINDER HEAD PART PISTON,CONNETING ROD AND CRANKSHAFT PART BALANCING SHAFT PART CAMSHAFT AND CHAIN TRAIN PART INTAKE MANIFOLD PART OIL FILTER AND OIL PUMP PART... 7

4 WATER PUMP AND FAN PART DISTRIBUTOR AND ITS LINE UNIT CARBURETOR PART AIR FILTER AND PIPE LINE PART STARTER, ALTERNATOR AND THEIR FASTENING PIECE TRANSMISSION TANK CLUTCH, SHIFTER SHAFT AND ROCKER ARM DIFFERENTIAL ONE SHAFT OUTPUT (OPTION)... 8 FIRST SHAFT AND COUNTERSHAFT GEAR SHIFTED GEAR FORK AIR FILTER FOR USA FRAME ENGINE MOUNT GEAR SHIFT STEERING ASSY PEDAL CONTROL AND PARK BRAKE PARKING BRAKE ASSY THROTTLE AND PARK ASSY FRONT HOUSING MUFFLER FUEL TANK AND GASOLINE PUMP REAR CARGO RACK AND ROLL BAR REAR HOUSING RADIATOR AND AIR CLEANER ELECTRIC APPLIANCE... 0 SEAT AND SAFETY BELT... 2 OTHER PARTS... 3 FRONT RACK OPTION... 4 REAR RACK OPTION... 5 PADDOCK ROOF RACK OPTION... 6 RIFLE ROOF RACK OPTION... 7 NERF ROOF RACK OPTION B WINCH OPTION... 9 SPOTLIGHT OPTION TOW BALL OPTION... 2 SAFTY BELT TUBE OPTION SHOCK ABSORBER COAT OPTION TOOLS AND BAG KIT OPTION ENVELOPMENT AND FOAM COVER OPTION PREPARATION ATTACH INSTRUCTION REMOVE PACKING INSTALL THE FRONT SUSPENSION ARM FRONT SHOCK ABSORBER, STUB AXLE ATTACH TIE ROD AND FRONT WHEES... 29

5 ATTACH THE REAR SUSPENSION ARM... 3 ATTACH PROPELLER SHAFT AND SHAFT CARRIER ATTACH REAR SHOCK ABSORBER AND REAR WHEEL ATTACH REAR SHOCK ABSORBER AND REAR WHEEL ATTACH REAR BUMPER BAR ATTACH ROLL BAR ATTACH RADIATOR AND COVER ATTACH MUFFLER ATTACH SEATS AND SAFETY BELT CHECK VEHICAL... 4 DEALER PRE-DELIVERY INSPECTION... 42

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17 Owner s manual Foreword Thank you for choosing JOYNER off Highway Recreational Vehicle. We hope you will have fun with it. Before you start to operate the Vehicle, please read through this Owner s Manual carefully as it contains important safety and maintenance information. Failure to follow the warnings contained in this manual can result in serious injuries. Be sure to follow the recommended maintenance schedule and service your Off Highway Recreational Vehicle accordingly. Preventative maintenance is extremely important to the longevity of your Off Highway Recreational Vehicles. JOYNER believes in conservation and protection of earth s natural resources. To that end, we encourage every vehicle owner to recycle, trade in, or properly dispose of, as appropriate, used motor oil, coolant, and other fluids, batteries, and tires. We hope you will have a pleasant experience with our products.

18 Foreword about safety In order to keep everyone safe, you must take responsibility for the safe operation of your Off Highway Recreational Vehicles. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others. It is not practical or possible to warn you about all hazards associated with operating or maintaining a Off Highway Recreational Vehicle. You must use your own good judgment. You will find important safety information in a variety of forms, including: Safety labels - On the Vehicles. Safety Messages Preceded by a safety alert symbol words: WARNING, or CAUTION. and one of two signal These signal words mean: Physical harm may result from failure to adhere to the instructions that are described within the WARNING labels. Safety Headings --- such as Important Safety Reminders or Important Safety Precautions. Safety Section --- such as Off Highway Recreational Vehicles Safety. Instructions --- how to use this Off Highway Recreational Vehicles correctly and safely. This entire manual is filled with important safety information----please read it carefully.

19 Important safety information Your Vehicle will provide you with many years of service and pleasure. Providing you take responsibility for your own safety and understand the challenges you can meet while driving. There is a lot you can do to protect yourself when you drive. You ll find many helpful recommendations throughout this manual. The following are a few that we consider most important. Follow the Age Recommendation It is strongly recommended that no one under the age of 6 be permitted to drive this Off Highway Recreational Vehicles without adult supervision. Always Wear a Helmet It s a proven fact: helmets significantly reduce the number and severity of head injuries. Always wear an approved motorcycle helmet. We also recommend that you wear eye protection, sturdy boots, gloves, and other protective gear. Drive Off-Road Only Your Off Highway Recreational Vehicles is designed and manufactured for off-road use only. The tires are not made for pavement, and the Off Highway Recreational Vehicles does not have turn signals and other features required for use on public roads. Take Time to Learn & Practice Even if you have driven other Off Highway Recreational Vehicles, take time to become familiar with how this Off Highway Recreational Vehicles works and handles. Practice in a safe area until you build your skills and get accustomed to this Off Highway Recreational Vehicles s size and weight. Because many accidents involve inexperienced or untrained drives, we urge all drivers to take a training course approved by the Off Highway Recreational Vehicles Safety Institute. Check with your dealer for more information on training courses. Be Alert for Off-Road Hazards The terrain can present a variety of challenges when you drive off-road. Continually read the terrain for unexpected turns, drop-offs, rocks, ruts, and other hazards. Always keep your speed low enough to allow time to see and react to hazards. Drive within Your Limits Pushing limits is another major cause of Off Highway Recreational Vehicles accidents. Never drive beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, fatigue, and inattention can significantly reduce your ability to make good judgments and driver safely. Don t Drink and drive Alcohol and driving don t mix. Even one drink can reduce your ability to respond to changing conditions, and your reaction time gets worse with every additional drink. So don t drink and drive, and don t let your friends drink and drive either. Never run your Go- Vehical indoors. Y the exhaust from the engine contains a tasteless, odorless and poisonous gas

20 called carbon monoxide. Important safety information Keep away from moving parts of the Off Highway Recreational Vehicles The operator of the Off Highway Recreational Vehicles should never place their hands or other parts of their body near any moving part of the Off Highway Recreational Vehicles. Failure to adhere to this warning will cause physical harm to your body. Skidding or Sliding The terrain surface can be a major factor affecting turns, Skidding a turn is more likely to occur on slippery surfaces such as snow, ice, mud and loose gravel. If you skid on ice, you may lose all directional control. To avoid skidding on slippery terrain, keep you speed low and drive carefully. Safety lables A this section presents some of the most important information and recommendations to help you drive your Off Highway Recreational Vehicles safely, please take a few moments to read these pages. The labels are considered permanent parts of the Off Highway Recreational Vehicles. If a label comes off or becomes hard to read, contact your dealer for warning labels

21 replacements. Are you ready to drive? Before each drive, you need to make sure you and your Off Highway Recreational Vehicles 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 Off Highway Recreational Vehicles, and adjustments to make for your comfort, convenience, or safety. Before you drive your Off Highway Recreational Vehicles for the first time, we urge you to do following:

22 Read this owner s manual and the labels on your Off Highway Recreational Vehicles carefully. Make sure you understand all the safety messages. Know how to operate all the controls. Never drive this Off Highway Recreational Vehicles if under 6 years old. Before each drive, be sure: You feel well and are in good physical and mental condition. 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 in your system. 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 Eyes 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, date Operating this Off Highway Recreational Vehicles without wearing an approved motorcycle helmet, eye protection, and protective clothing could increase your chances of head and/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. 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. Driving pants with knee and hip pads, a driving jersey with padded elbows, and a chest/shoulder protector. Drive Training Developing your driving skills is an on-going process. Even if you have driven other Off Highway Recreational Vehicless, take time to become familiar with how this Off Highway Recreational Vehicles works and handles. Practice driving the Off Highway Recreational

23 Vehicles in a safe area to build your skills. Do not drive in rough terrain until you get accustomed to the Off Highway Recreational Vehicles s controls, and feel comfortable with its size and weight. Operating Off Highway Recreational Vehicles 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 Vehical turning over could lead to serious injury or death. Never support with your hands to ground when the Vehicles will turn over. Age Recommendation It is strongly recommended that no one under the age of 6 be permitted this Off Highway Recreational Vehicles without adult supervision. A child driving a Off Highway Recreational Vehicles that is not recommended for his/her age could lose Off Highway Recreational Vehicles control and result in severe injury or death. A child under 6 should have adult supervision when operate on the Off Highway Recreational Vehicles. No Alcohol or Drugs Alcohol, drugs and Off Highway Recreational Vehicles don t mix. Even a small amount of alcohol can impair your ability to operate a Off Highway Recreational Vehicles safely. Likewise, drugs, even if prescribed by a physician, can be dangerous while operating a Off Highway Recreational Vehicles. Consult your doctor to be sure it is safe to operate a vehicle after taking medication. Operating this Off Highway Recreational Vehicles 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 this Off Highway Recreational Vehicles.

24 Is your vehicle ready to drive? Before each drive, it is important to inspect your Off Highway Recreational Vehicles 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 Off Highway Recreational Vehicles has overturned or has been involved in a collision, do not drive it until your Off Highway Recreational Vehicles has been inspected by your dealer, There may be damages or other problems you cannot see. Improperly maintaining this Off Highway Recreational Vehicles or failing to correct a problem before driving can cause a crash in which you can be seriously hurt or die. Always perform a pre-drive inspection before every drive and correct any problems. Pre-drive Inspection Check the following items before you get on the Off Highway Recreational Vehicles: Engine Oil Check the level and add oil if needed. Check for leaks. Coolant Check the coolant and add coolant if need. Check for the leaks. Fuel Check the level and add fuel if needed. Also make sure the fuel fill cap is securely fastened. Check for leaks. Tires Use a gauge to check the air pressure. Adjust if needed. Also look for signs of damages or excessive wear. 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. Pre-drive Inspection Underbody & Exhaust System Check for, and remove any dirt, vegetation or other debris that could be fire hazard or interfere with the proper operation of the Off Highway Recreational Vehicles. Air Cleaner Check the air filter. Replace it if needed.

25 Leaks, Loose Parts Walk around you Off Highway Recreational Vehicles 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. Safe driving precautions Off-road use only You r Off Highway Recreational Vehicles and its tires are designed and manufactured for off-road use only, not for pavement. Driving on pavement can affect handling and control. You should not drive your Off Highway Recreational Vehicles on pavement. Operating this Off Highway Recreational Vehicles on paved surfaces may seriously affect handling and control of the Off Highway Recreational Vehicles, and may cause the vehicle to go out of control. Never operate the Off Highway Recreational Vehicles on any paved surfaces, including sidewalks, driveways, parking lots and streets.

26 When driving off-road, also remember to always obey local off-road driving laws and regulations. Obtain permission to drive on private property. Avoid posted areas and obey no trespassing signs. You should never drive your Off Highway Recreational Vehicles on public streets, roads or highways, even if they are not paved. Drivers of street vehicles may have difficulty seeing and avoiding you, which could lead to a collision. In many states it is illegal to operate Off Highway Recreational Vehicless on public streets, roads and highways. Operating this Off Highway Recreational Vehicles on public streets, roads or highways can cause collision with other vehicle. Never operate this Off Highway Recreational Vehicles on any public streets, roads or highways, even a dirt or gravel one. Keep Hands and Feet on Controls Always keep both hands on the steering wheel and both feet on the foot controls. When driving your Off Highway Recreational Vehicles. It is important to maintain your balance and control of the Off Highway Recreational Vehicles. Removing hands or feet away from the controls can reduce your ability to react and control the vehical. Removing hand from Steering wheel or feet from foot controls during operation can reduce your ability to control the Off Highway Recreational Vehicles or could cause you to lose your balance and fall off the Off Highway Recreational Vehicles. Always keep both hand on the steering wheel and both feet on the foot controls of your Off Highway Recreational Vehicles during operation. Control Speed Driving at excessive speed increases the chance of an accident. In choosing a proper speed, you need to consider the capability of your Off Highway Recreational Vehicles, the terrain, visibility and other operating conditions, plus your own skills and experience. Operating this Off Highway Recreational Vehicles at excessive speeds increases your changes of losing control of the Off Highway Recreational Vehicles, which can result in an accident. Always drive at a speed that is proper for your Off Highway Recreational Vehicles, the terrain, visibility and other operating conditions, and your experience.

27 Use Care on Unfamiliar or Rough Terrain Before driving in a new area, always check the terrain thoroughly. Don t drive fast on unfamiliar terrain or when visibility is limited. (it s sometimes difficult to see obstructions like hidden rocks, bumps, or holes in time to react). Failure to use extra care when Operating this Off Highway Recreational Vehicles on unfamiliar terrain could result in the Off Highway Recreational Vehicles overturning or going out of control. Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the Off Highway Recreational Vehicles. Never drive past the limit of visibility. Maintain a safe distance between your Off Highway Recreational Vehicles and other off-road vehicles. Always exercise caution and use extra care on rough, slippery and loose terrain. Failure to use extra care when operating on excessively rough, slippery or loose terrain could cause loss of traction or vehicle control, which could result in an accident, including an overturn. Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the Off Highway Recreational Vehicles on such terrain. Always be especially cautious on these kinds of terrain. Do Not Perform Stunts You should always operate your Off Highway Recreational Vehicles in a safe and reasonable manner. When driving, always keep all four wheels on the ground. Attempting wheelies and other stunts increases the chance of an accident, including an overturn. Never attempt stunts, such as wheelies or jumps. Don t try to show off.

28 Specifications DIMENSIONS Overall Length in. (2880mm) Overall Width in. (570mm) Overall Height in. (777mm) Wheelbase in. (2050mm) Front Track in. (300mm) Rear Track in. (300mm) Ground Clearance in. (280mm) ENGINE Type Bore,4-Stroke, Liquid-cooled Bore x Stroke mm 7mm Displacement cc Compression ratio : Carburetor BJH0E or CSH0E Max Power kw/5300rpm Maximum Torque /2700~3300Nm/r/min Starting Electric Ignition C.D.I Lubrication Force & Splash Transmission manual clutch, 4 shift/reverse Spark Plug F6T or F6TC Plug gap ±0.mm Fuel type RQ93 (unleaded) Lubricate oil SAE-5W/30 CAPACITIES Maximum load kg Fuel tank L Engine oil ml Coolant ml Starting <5s Climbing Battery V36Ah Head Light V 50W/Both Tail Light V 80W/Both Fuse A SPECIFICATIONS Brake Track < 20miles/h Top speed miles/h (or limited as customers require) CHASSIS Front, Rear brake Hydraulic disc, right foot control Front tire Rear tire Front Suspension Independent Dual A-Arm Rear Suspension Independent Dual A-Arm Final Drive shaft driven TIRE PRESSURE Front kpa 0.7kg/c m2 0psi Rear kpa 0.7kg/c m2 0psi WEIGHT Net Weight kg WARRANTY Parts and workmanship Days

29 Operation Operation controls WARNING-Do not attempt to start or operate the engine until completely familiar with the location and use of each control necessary to operate this vehicle. The operator must know how to stop this machine before starting and driving it. Throttle The right foot pedal is the throttle that controls the Off Highway Recreational Vehicles speed. To disengage the clutch at any time, allow the throttle to return to the idle position. (See Fig. ) Each time prior to starting the engine, check the throttle assembly to ensure that when pedal is pushed all the way forward the assembly is working smoothly and returns to idle when released. Do not operate if pedal or engine throttle linkage fail to return to idle. If unable to correct the problem through lubrication, adjustment or replacement of worn parts, contact your dealer for assistance. Brake The brake is located on the middle of the three control pedals (See Fig. ). Applying pressure to the pedal applies pressure to the brake caliper around the brake disc at the front and rear wheels and slows or stops the vehical. Clutch The left foot pedal controls the clutch cable (See Fig. ). With the pedal down, you can shift the shift lever. Improper operation of the clutch will lead to excessive wear of the clutch friction surface.

30 Speedome Tachomete Horn Coolant temperature Voltmete Steering wheel Fuel level gauge Battery charge everse gear light Accelerator Brake pedal Clutch pedal Figure Shift lever Speedome Tachomet Horn Fuel level gauge Start engine. Engage the park brake 2. Press the clutch pedal down, put the shift lever in neutral 3. Insert the key into the Ignition-switch Coolant temperature Voltmete Figure 2 Combination switch If the engine is cold. Pull the choke out fully 2. Press down the clutch pedal 3. Turn the key clockwise to the on position. Release the key and the clutch pedal when the engine starts. 4. Push the choke back slowly to allow the engine to run smoothly. Keep engine running for -2 minutes. 5. Push the choke back fully. If the idle of engine is not smooth, pull out the choke to find the best running position and keep running for a while long until the engine runs smooth without choke. If the engine is warm Press the throttle slightly and turn the key clockwise to the on position, release the key and the throttle when the engine starts.

31 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 0 seconds, a second attempt to start the engine can be allowed. Improper operation will damage the engine. Engine stop key Stop key test. Before driving this vehicle, test the Engine Stop key to assure that it is operating properly. With the engine running, turn the key counterclockwise to the off position for the engine to shut down. Pre-Drive Inspection Perform this pre-drive inspection every day before driving vehicle. If not performed, serious damage to the vehicle or personal injury may result.. Check for Engine Oil Level. Check for transmission Oil Level. Check for leaks, add oil if required. (See page 35, Engine oil replacement, and page 36Transmission lubrication) 2. Check the coolant. Check for leaks, add the coolant if required. (See page36 Engine Coolant) 3. Check for Fuel Level. Add fuel as necessary and do not overfill. Check for leaks.(see Figure 3)

32 Brake light Fuel tank Figure 3 4. Check for Brakes. Depress the brake pedal several times, and then check for proper brake pedal free play. Make sure there is no brake fluid leakage. Adjust if necessary. Brake driving cylinder Brake oil pipe Clutch cable Brake pedal Figure 4 5. Check the clutch cable, Assure the cable snaps back and has a smooth operation. Ensure the clutch can operate smoothly. Adjust if necessary, or replace the clutch if necessary. (See Figure 4) 6. Check Tires. Check tires condition and pressure. The pressure on both Front and Rear tire is 2psi.(see Figure 5) 4 rim nuts around axle nuts 4 rim nuts around axle nuts Axile nuts Rear tire Front tire Figure 5 Axile nuts

33 7. Check Throttle. Check for smooth operation. Ensure the throttle snaps back to idle. (See Figure 4) 8. Check Engine Stop key. Perform engine stop key test. Repair as necessary. (See page30 Engine stop key) 9. Check all Nuts, Bolts, and fasteners. Check wheels to see that all axle nuts and rim nuts are tightened properly. Check and tighten as necessary all other fasteners to specified torque. 0. Check Roll Bars. Ensure all protective roll cage bars are in place before operating the Off Highway Recreational Vehicles. (See page Error! Bookmark not defined. 错误! 未找到引用源 ) 2. Check Brake Light. Check for proper operation. (Figure 4) 3. Check Wheels. Check for tightness of wheel nuts and axle nuts; check that axle nuts are secured by cotter pins. (See Figure 4) 4. Check Steering. Check for free operation and for any unusual looseness in any area.(see Figure 6) Steering wheel Figure 6 Always follow rules for safe operation and wear a helmet. Passengers The vehicle allows for two riders only. Combined maximum weight of driver and the passenger should not exceed 80kg or 400Ibs. Seat The seat must always be securely fastened in the position which best allows the operator control of the foot pedals, steering wheel, and the remote stop key. Figure 7 A. Pull seat adjustment handle upward to disengage seat slide. B. Move seat to desired position. C. Be sure seat adjustment handle snaps back into place and that seat is locked into

34 position. (See Figure 7) Before attempting to adjust the seat ensure that engine of the Off Highway Recreational Vehicles is stopped. Never operate this Off Highway Recreational Vehicles when the provided seat is not securely fastened, to do so could result in a strong possibility of severe personal injury or loss of life. Before attempting to adjust the seat ensure that engine of Off Highway Recreational Vehicles is stopped. Parking Park brake OFF Park brake On Figure 9 Figure 8 Cable adjustment nuts Cable lock nut Figure 0 a. Pull the park brake lever up so that the unit can engage park brake. b. To release the unit, press button on front end of parking lever then push the parking lever to the bottom. c. Adjust the parking cable if necessary. As the figure shown, adjust the adjustment nuts to make sure the cable tight, and then tighten lock nuts. Gear Shift

35 Adjustment nuts Connect to shift lever Lock nuts Figure Figure 2. Operate the gear shift as the picture shown. and the max speed in every gear position is shown as the following form(see Figure ) Gear position Max speed st 26 km/h 2nd 37km/h 3rd 50 km/h 4th 80km/h R 32 km/h Figure 3 2. Adjust the adjustment nuts shown in the above picture, if necessary. To make sure the shift lever right position. (see Figure 2) 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.. 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 000 km st Gear 5 km/h 2nd Gear 25km/h 3rd Gear 40 km/h 4th Gear 70km/h Figure 4 Starting and Operating Instructions a. Before starting the engine, be sure that the driver is seated properly in the Off Highway Recreational Vehicles and tighten the seatbelt. b. Testing the Off Highway Recreational Vehicles in a open place at the beginning to learn how to start, turn and stop. c. Operate the Off Highway Recreational Vehicles slowly until you are familiar with it. d. The turning radius of this Off Highway Recreational Vehicles 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 the Off Highway Recreational Vehicles from

36 rolling over. e. To prevent vehicle from rolling over, be sure to only turn the vehicle at a slow more controllable speed. Service instructions Air filter Service air cleaner every 80 hours NOTE: Service more often under dusty conditions. Remove filter cover, Check the filter cover and the air filter for dusty, If necessary, clear the filter cover and the filter with special liquid or replace them with a new one. (See Figure 5) Filter cover Figure 5 Filter 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. Figure 7 Figure 6 Figure 8 Figure 9 With the engine warm, put the vehicle on the level ground. a. Shut down the engine; put a collecting oil plate under the engine oil outlet. Loosen the oil outlet plug in the warm engine. Let the engine oil out fully (see Figure 7).

37 b. Tighten the engine oil outlet plug. c. Remove the oil filler cap (see Figure 6), fill oil (SAE 0W/0~50) about 2.8 liters to the engine. d. Pull out the engine oil dip stick (see Figure 6), confirm the corrective oil level in the crankcase (see Figure 9). Check engine oil and recharge a. If the color of engine oil changes, you need to replace the engine oil. Replace the engine oil as above. b. Check the engine oil level, change if necessary from d as above. Transmission lubrication You must change the oil in the transmission after the first 5 hours of operating of your new engine and after 0 hours of use thereafter. That will insure proper lubrication of internal parts and prevent costly repairs due to excessive wear. Figure 2 Figure 20 a. Put the vehicle on the level ground. b. Shut down the engine, put a collecting oil plate under the transmission oil outlet. Loosen the oil outlet plug in the warm engine. Let the transmission oil out fully (see Figure 20). c. Remove the iron dust plug, this plug has a magnet on it. Iron dust caused by moving parts will stick to the plug. Clean the iron dust from this dust plug. d. Tighten the transmission oil outlet plug and the iron dust plug. e. Remove dipstick of transmission (see Fig. 4), fill oil (GL5 80W/90) about.9 liters. f. Insert the transmission dipstick, check the oil level in the transmission. Confirm the corrective oil level in the transmission (see Figure 2). Check transmission oil If the color of transmission oil changes, you need to replace oil. Replace transmission oil as above. Engine Coolant You must check the coolant for level and leaks. If it is low, you need to refill coolant into the radiator (approximately 4L). The lack of coolant will cause the engine to overheat. This can cause engine damage. The coolant should always be topped up, since the coolant can evaporate.

38 Figure 22 Figure 23 Put the vehicle on level ground.. Turn the coolant cap counterclockwise and open the cap (see Figure 22 Figure 23). 2. Pour fresh coolant to filler neck. 3. Start the engine at idle. 4. Increase the engine rev s a few times 5. Repeat 2,3,4 till the coolant is at neck and no bubbles come up. 6. Refit the coolant cap, turn it clockwise and tighten it 7. Turn the reserve coolant case cap counterclockwise and open the cap (see Figure 22 Figure 23). 8. Pour fresh coolant of the specified type into the reserve coolant tank till the coolant reaches 2/5 to 3/5 of the reserve coolant tank volume. 9. Close the reserve coolant case cap, turn it clockwise and tighten it Top up the reserve coolant If the coolant in the reserve tank is less than 2/5, it needs to be topped up. 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. New and used coolant can be hazardous. Children and pets may be harmed by new or used coolant. Continuous or brief contact with coolant may be dangerous for your health. Keep new and used coolant away from the children and pets. To minimize your exposure to new and used coolant, 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.

39 Harm or damage may occur if use coolant that does not meet the specification 50% standard green coolant and 50%distill water. Spark Plug a. Remove the spark plug and inspect it each time you change the oil. (Use a spark plug wrench) The electrodes should be kept clean and free of carbon. The presence of carbon or excess oil will greatly reduce proper engine performance. If possible, check the spark plug gap (area between electrodes) using a wire feeler gauge. This specification is ~ Figure 24 b. Before installing spark plug coat threads lightly with graphite grease if possible, to ensure easy removal next time the spark plug needs inspection (see Figure 24). c. It is advisable to replace the spark plug at least once a year to insure easy starting and good engine performance. Carburetor Adjustment Never make unnecessary adjustments. The factory recommended settings are correct for most applications. It s not necessary to disassemble the screw unless the carburetor needs to be replaced. Prepare a 50r/w tachometer before adjustment. a. Warm up the engine (5~0min) b. Tighten the air screw gently. Back out 2-3/8 turns counter clockwise (see Figure 25). c. Connect the tachometer, adjust the throttle to limit the idle speed. The standard value is (400RPM). d. Turn the air screw counter slowly and observe the RPM of the engine, stop adjusting as the RPM reaches the top speed. e. Adjust the screw and adjust the idle speed to an ideal value. f. Repeat step d and e until the rotate speed of engine stables.

40 Cleaning Instructions Figure 25 Keep your vehical clean. With a clean rag, wipe off and dirt and oil from around controls. Wipe off any spilled fuel and oil. Keep the engine clean of foreign object and be sure to check that air intake fan is free of debris for proper cooling. Vehicles Lubrication Lubricate vehicle every 90 days of use, Apply several drops of oil in specific points shown as following picture

41 Storage Instruction In the event your vehical is not to be operated for periods in excess of 30 days or at the end of each driving season prepare for storage as follows: a. Drain fuel tank and carburetor by allowing engine to run out of fuel, or use a fuel stabilizer. b. Lubricate engine cylinder by removing the spark plug and pour one ounce of clean lubricating oil through the spark plug hole into the cylinder. Crank the engine slowly to spread oil and replace spark plug. c. Do not save or store gasoline over winter. Using old gasoline, which has deteriorated from storage, will cause hard starting and affect engine performance. Do not drain fuel while engine is hot. Be sure to move Off Highway Recreational Vehicles outside before draining fuel.

42 Repair Front Wheel Replacement Do not disassemble the center castle nuts when you replace the front wheels. (See Figure 26) Tighten the nuts after replacing the wheels. Castle nuts Torque:80±5 N.M Wheel nuts Torque:70±5 N.M Figure 26 Rear Wheel Replacement Do not disassemble the center castle nuts when you replace the rear wheels. (See Figure 27) Tighten the nuts after replacing the wheels. Castle nuts Torque:80±5 N.M Wheel nuts Torque:70±5 N.M Figure 27

43 Clutch replacement Do not remove the whole engine from vehicle when you replace the clutch, but you ll need to remove rear suspension, driven shaft, clutch cable, muffler, wires and rubber cushion that is in the middle of transmission and frame.. Remove bolt M4 (See Figure 28) Bolt M4 Figure Remove two bolts (M2) on the starter (See Figure 30), Remove the starter (See Figure 29) Bolt M2 Starter Figure 30 Figure Remove two nuts (M4) on two side of transmission (See Figure 3,Figure 32) Bolt M4 Bolt M4 Figure 32 Figure 3

44 . Remove two bolts(m8) on the lower mud plate of transmission (See Figure 33,Figure 34) Bolt M8 Oil pan Bolt M8 Oil pan Figure 34 Figure Remove the lower mud plate (See Figure 35). Oil pan Mud plate Figure Remove the transmission (See Figure 36,Figure 37) Transmission Engine Figure 37 Figure Remove upper mud plate (See Figure 38)

45 Upper mud plate Figure Insert the aligning shaft into hole (See Figure 40). Remove six bolts on the pressing plate of clutch (See Figure 39) Bolt Bolt Aligning shaft Bolt Aligning shaft Figure 40 Figure Remove the pressure plate (See Figure 42). Remove the friction disc of clutch (See Figure 4,Figure 43) Pressure plate Figure 42 Friction disc Figure 4

46 Engine without clutch Figure Insert the aligning shaft into the hole; align new friction plate to the flywheel of engine (See Figure 44,Figure 45). Centering shaft Centering Friction disc Figure 45 Friction disc Figure Fix pressure plate of clutch. Two bolts with Y.G mark must be inserted into two anchor holes. Tighten six bolts with torque 30 N.m (See Figure 46,Figure 47). Bolts with GY Torque 30 N*M Figure 47 Figure Fix upper mud plate (See Figure 48,Figure 49Figure 49)

47 Upper mud plate Upper mud plate Figure 49 Figure Fix parts according to reverse operation to the disassembly Timing setup and balancing shaft setup. When the first piston locates top dead center, make sure the mark on camshaft timing sprocket wheel in the position shown as the following figure. 2. Make a mark between two holes as the Figure 5, and turn the left balancing shaft sprocket, make sure the mark on the balancing shaft sprocket aligned to the mark made at the beginning of this step. 3. Make a mark about 30mm above the bolt as the Figure 52, and turn the right balancing shaft sprocket; make sure the mark on the balancing shaft sprocket aligned to the mark made at the beginning of this step. 3. Fix guide plate, and tension plate 4. Fix the sprocket. Mark on the sprocket must be in straight line to the single white link on the timing chain. (See Figure 53)

48 Camshaft timing sprocket wheel Mark Left balancing shaft sprocket Right balancing shaft sprocket Figure 50 Crank shaft Mark here Mark Left balancing shaft sprocket Figure 5

49 Make a Mark 30mm above the bolt 30mm Mark Figure 52 Left balancing shaft sprocket Water pump disassembly. Take off fan belt and loosen 4 bolt tightening water pump pulley. Fan belt Bolt Water pump pulley Figure 53

50 2. Loosen the 6 bolts shown as the Figure 54. Bolts Bolts Figure Loosen the clamp bolts shown as Figure 55, and disconnect two peace of water pipe, and take off the water pump. The engine without water pump is shown as Figure 55. Clamp Bolts Water pipes Figure 55

51 Figure 56 Distributor replacement ) Turn around the crank shaft, align the line on the pulley of crankshaft straight to the 0 degree line on the cover of engine (See Figure 57,Figure 58,Figure 59) Figure 58 Figure 57 Figure 59

52 2) Remove the rocker cover of head by removing two bolts (See Figure 60) Figure 60 3) Check the anchor hole, if it is not on the direction shown by Fig. Repeat above as to obtain the hole position shown by Figure 53. 4) Insert the screwdriver into the hole, turn the drive of oil pump shaft until parallel to the crankshaft (See Figure 62,Figure 63) Figure 62 Figure 6 5) Align the mark 2 on the shaft of distributor to the mark on the aluminum housing (See Figure 63)

53 Figure 63 6) Insert the distributor slowly to the hole (See Figure 64). Confirm the direction of distributor is as per the figure (See Figure 65,Figure 66). Tighten the nut of distributor housing. Figure 64 Figure 66 Figure 65 7) Fix the cover of the distributor (See Figure 67).

54 Figure 67 8) Check the spark timing. Adjust if need as followings a) Loosen the nut of the distributor housing b) Turn the distributor slowly. Increase the spark timing by counterclockwise turn. Decrease the spark timing by clockwise turn. A. Gear shift ) Install thick pivot plate and short crank to shifter shaft (See Figure 68 Figure 69Figure 70 Figure 7)

55 Short crank Thick pivot plate Shifter shaft Shifter shaft Figure 68 Figure 69 Spring washer Nut Washer Short crank Shifter shaft Step finished Figure 70 Figure 7 2) Install thin pivot plate and long crank. (see Figure 72 Figure 73 Thin pivot plate Thin pivot plate Figure 72 Figure 73

56 Step 2 finished 3) Install the shifter shaft ASSY finished above to transmission. (See Figure 74) Bolt M0x.5x20 Shifter shaft ASSY Figure 74 B. Front Wheel Alignment a) Put the vehicle on level ground. b) The toe-in of the front wheels should be.8 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.8 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.

57 Figure 75

58 B DJ B B R R R 面板组合开关 ( 翘板开关 ) R B B R B R B B B B B 电压表 O RS RS RS R B DJ R 水温表 O B DJ B O B B N B B R U 转速表 O B B DJ 里程表 DJ O B L B K B B Wiring diagram 206 空 0 RY BR RY L RY W K 空空空空空空空 09 N Y GY WB 空 B UR UR B GW B 空 UR UR 空空空 Y 08 空空空 2 O O BR GW L W NR GR B 8 0 GY 油量表 DJ 点火开关 DJ B 50 2 SB RS S 50 WG 30 WB ?9 波纹管 BR DJ BR 250 BR DJ BR 中号保险丝 5A BR 电源继电器 R 04 R R 配一个 DL650 熔断丝盒 DJ 调节器 32 Y 3 G 33 B 28 GR SR 00 φ6 蓄电池 大号保险丝 40A 蓄电池 - φ φ front turn R/sidelights 50 DJ NR L B RY DJ NB 喇叭 308 RS B 右大灯 DJ RS RS U RS RS RS RS 250 R DJ DJ DJ RS 刹车传感器 小 φ4 小 φ4 406 RS 304 UR UW DJ 闪烁器 headlight R RS Y UW RY RS R DJ DJ NR DJ DJ 右组合尾灯 φ4 NB 204 horn button DJ 保险丝盒 油量传感器 DJ UW 307 RY 左大灯 DJ K 左位置灯 D650-B 主线束 D B WR WG RY φ RB 风扇 DJ702Y RG 温控开关 90 C DJ 起动电机 05 S DJ φ8?9 波纹管 技术要求. 采用国标导线符合, 普通插件材料采用尼龙 ; 2. 端子压接 电线接头应符合 QCn QCn 2900; 3. 所有带有防水塞 密封垫插件应安装到位, 不得有脱落 漏装现象, 带有密封件的插件与对接端插件插接后, 加上 2.5KPa 个大气压进行密封性检查时不得有漏气 漏水现象 ; 4. 图中所有线号与护套内端子号一一对应, 线色 线径严格按图示规定 ; 5. 线束中导线导通率达到 00 %, 最终出线处用 PVC 黑胶带封口, 所有导线 ( 除黑色外 ) 不得露出, 波纹管连接处用 PVC 胶带缠绕牢固 规则 美观 ;?9 波纹管 350 φ6 300 发电机 Y G B 水温传感器 30 GB DJ22-4 DJ 温控开关 82 C 分电器 DJ RB RS SB 燃油泵 小号烟斗胶套 30 B R φ4 φ ?9 波纹管?9 波纹管 φ5 RS φ5 2 SB 点火线圈 机油 27 DJ YG GY 倒档传感器 DJ 附件. 中号片式保险丝 :5A 0A 7.5A 5A 各一只 ; 2. 大号片式保险丝 :40A 一只. D650 主线束

59 C h a r g e i n d i c a t o r Electrical schematic diagram B O BR L L L R U SR S SB WG W W W WB Spot switch Dipping switch 2 NR K G 3 ~ RB Alternator 4V 35A R Charge indicator Charge indicator GR Distributor block coil,ign NB U UW P Wire's colour symbol RS---red/grey B---black R---red U---blue RU---red/blue P---purple S---grey W---white YG---yellow/green L---Cambridge blue N---brown K---pink NB---brown/black NR---brown/red UW---blue/white RB---red/black GY---green/yellow SB---grey/black BR---black/red Y---yellow WG---white/green GB---green/black WR---white/red BW---black/white Figure 76

60 Parts manual CYLINDER BLOCK PART

61 Q' No. ERP Code Code name Description ty 02.DLJ.270Q Q oil feed plug 02.DLJ.LJ462Q - - LJ462Q Cylinder head locating dowel D D 3 02.DLJ.QTB55-φ0.5 7 QTB55-φ0.5 7 Plug φ DLJ.QTB54-φ40 QTB54-φ40 freeze plug φ DLJ.9-φ6x8 9-φ6x8 Pinφ DLJ.QTB542-φ30 QTB542-φ30 freeze plug φ DLJ.270Q Q-0203 Tie-in pipe of drive valve 8 02.DLJ.QTB28-NPT/4 QTB28-NPT/4 Hexagon-headed taper bolt NPT/ DLJ.QTB42-φ 2 QTB42-φ 2 Hollow-swage locating pin φ DLJ.270Q Q Jetting pipe 02.DLJ.270Q Q Front bearing of balancing shaft DLJ.270Q Q-020 Rear bearing of balancing shaft DLJ.QTB QTB Calathiform plug DLJ.270Q Q-0202 Main bearing cap bolt DLJ.QTB53A- FB QTB53A- FB Crankshaft rear oil seal with unidirectional flow around FB DLJ.270Q Q Rear oil seal housing gasket 7 02.DLJ.270Q-02007A 270Q-02007A Rear oil seal housing 8 02.DLJ.LJ462Q - - LJ462Q D D Flywheel bolt DLJ.270Q Q Crankshaft bearing bushing DLJ.270Q Q Crankshaft thrust bearing bushing DLJ.270Q-02006C 270Q-02006C Oil pressure switch DLJ.276Q-020D 276Q-020D Cylinder block and bearing cap assembly DLJ.QTB42-φ3 5.5 QTB42-φ3 5.5 Hollow-swage locating pin φ

62 SPROCKET COVER AND OIL PAN PART No. ERP Code Code name Description Q'ty 02.DLJ.276Q Q-0220 Sprocket cover 2 02.DLJ.270Q Q Oil filter threaded sleeve 3 02.DLJ.900-M8X M8X22 Taper bolt AGM8-M DLJ.QTB23- NTP/4 QTB23- NTP/4 Hexagon-headed taper bolt NTP/ DLJ.QTB23- NTP3/8 QTB23- NTP3/8 Hexagon-headed taper bolt NTP3/8

63 No. ERP Code Code name Description 6 02.DLJ.270Q Q Jetting pipe 7 02.DLJ.LJ276MT LJ276MT Dipstick 8 02.DLJ Left gasket of sprocket cover 9 02.DLJ Right gasket of sprocket cover 0 02.DLJ.QTB0- M8 88 QTB0- M8 88 Hexagon-headed bolt with edge M DLJ.QTB0-M8 68 QTB0-M8 68 Hexagon-headed bolt with edge M DLJ.QTB53A- Crankshaft front oil seal with QTB53A- FB FB unidirectional flow around FB DLJ.QTB0-M8 78 QTB0-M8 78 Hexagon-headed bolt with edge M DLJ A A Oil Pan gasket 5 02.DLJ.LJ276MT LJ276MT Oil Pan assembly 6 02.DLJ M6X M6X2 Bolt assembly M DLJ.QTB24-M4.5 QTB24-M4.5 Drain Plug M DLJ.270Q-02303B 270Q-02303B Drain Plug gasket 9 02.DLJ.276MT MT backing plate DLJ.LY LY Tird and forth gear assy Q't y 2 02.DLJ.QTB0-M6 0 QTB0-M6 0 Hexagon-headed bolt with edge M6 0 2

64 CYLINDER HEAD PART No. ERP Code Code name Description Q' ty 02.DLJ.5782-M8X M8X40 Bolt M DLJ.270Q Q-0009 washer of cylinder head cover bolt DLJ.270Q Q-00 Rubber pad of cylinder head cover bolt DLJ.276Q Q-0300 Cylinder head cover assembly 5 02.DLJ.270Q-0400B 270Q-0400B Filler cap assembly

65 6 02.DLJ.270Q Q-0403 Filler cap ruuber washer 7 02.DLJ.270Q-002B 270Q-002B Seal ring of cylinder head cover 8 02.DLJ M8X M8X30 Unit bolt M DLJ.QTB5-M8 QTB5-M8 Nut M DLJ.93-φ8 93-φ8 Spring washer φ DLJ.270Q Q-007 Thermostat housing 3 02.DLJ.270Q Q-006 Thermostat gasket 4 02.DLJ.270Q Q-005 Thermostat 5 02.DLJ.270Q Q-000 Cylinder head and camshaft bearing part 6 02.DLJ.270Q Q-009 Camshaft bearing bushing cap bolt DLJ.270Q Q-0007 Valve rocker arm shaft DLJ.898-M8X M8X25 Stud AGM DLJ.899-M8X M8X28 Stud AGM DLJ.270Q Q-004 Inlet valve guide DLJ.QTB40-φ 6 4 QTB40-φ 6 4 Locating pin φ DLJ.270Q Q-005 Exhaust valve guide DLJ.899-B 899-B bolt DLJ.270Q-0023A 270Q-0023A Hexagon -headed taper plug DLJ.898-M8X M8X20 Stud AGM8-M DLJ.270Q Q-008 Minor water pipe DLJ.270Q Q-002 Intake valve seat DLJ.270Q-003B 270Q-003B Exhaust valve seat DLJ.270Q-009B 270Q-009B Water Temperature sender unit DLJ.270Q Q-003 Front Semi-Circle Oil Seal 3 02.DLJ.270Q Q-004 Rear Semi-Circle Oil Seal DLJ.270Q Q-0022 Cylinder head bolt DLJ.GTB30-φ2 φ 3 GTB30-φ2 φ 3 head bolt washer φ2 φ DLJ M8X M8X28 Bolt assembly M DLJ.276Q Q-002 Cylinder head gasket DLJ.270Q Q-0025 Rubber blanking plug DLJ.ZB/TT ZB/TT hose clamp DLJ.270Q Q-0024 Exhaust pipe gasket DLJ.93-W8 93-W8 Washer DLJ.QTB5-M8 QTB5-M8 Nut M8-8 4

66 PISTON,CONNETING ROD AND CRANKSHAFT PART No. ERP Code Code name Description Q' ty 02.DLJ.276Q Q Piston ring () 2 02.DLJ.276Q Q Piston ring (2) 2 02.DLJ.276Q Q Piston ring (3) DLJ.270Q Q Connecting rod bearing DLJ.276Q Q-0300 Piston 2 02.DLJ.276Q-03004B 276Q-03004B Piston Pin DLJ.270Q Q-0300 Connecting rod assembly() 2 Connecting rod assembly(2) DLJ.270Q Q-0303 Connecting rod bolt DLJ.270Q Q-0304 Connecting rod nut DLJ.270Q Q-0400 front pulley bolt 8 02.DLJ.859-SW2 859-SW2 Spring washer 2

67 9 02.DLJ.270Q Q Washer 0 02.DLJ.270Q Q Crankshaft belt pulley 02.DLJ.270Q-04004A 270Q-04004A Driven bevel gear 2 02.DLJ.QTB44-4X9 QTB44-4X9 Woodruff key DLJ.276Q-04006B 276Q-04006B Crankshaft 4 02.DLJ.LJ462Q-00035D LJ462Q-00035D Locating pin of fly wheel 5 02.DLJ.LJ LJ Ring gear assembly of fly wheel 6 02.DLJ.LJ462Q D LJ462Q D flywheel bolt 6

68 BALANCING SHAFT PART No. ERP Code Code name Description Q' ty 02.DLJ.QTB30-φ24 φ8.5 3 QTB30-φ24 φ8.5 3 Thick washer φ24 φ DLJ.270Q Q Balancing chain assembly 3 02.DLJ.270Q-0430A 270Q-0430A Balancing shaft sprocket assembly DLJ.QTB0-M6 0 QTB0-M6 0 Hexagon-headed bolt with edge M DLJ.270Q Q-0430 Baffle plate of Balancing shaft DLJ.270Q-04302A 270Q-04302A Balancing shaft DLJ.270Q Q Front balancing weight DLJ.270Q Q Balancing weight bolt DLJ.270Q Q Rear balancing weight DLJ.QTB0-M6 45 QTB0-M6 45 Hexagon-headed bolt with edge M DLJ.270Q-04200B 270Q-04200B Guide pad assembly of balancing chain 2 02.DLJ.270Q-0402A 270Q-0402A Cam chain drive sprocket

69 CAMSHAFT AND CHAIN TRAIN PART No. ERP Code Code name Description Q'ty 02.DLJ.270Q Q Bolt assembly 2 02.DLJ 270Q Q Washer 3 02.DLJ 270Q-05005A 270Q-05005A Tensioning spring 4 02.DLJ 270Q Q Tensioning spring plate 5 02.DLJ QTB3-M QTB3-M Small hexagon-headed bolt with 0 edge M DLJ 270Q-05002A 270Q-05002A Camshaft timing sprocket wheel 7 02.DLJ 270Q Q-0500 Timing chain assembly 8 02.DLJ 270Q Q-0502 Valve clearance adjusting nut DLJ 270Q Q-050 Valve clearance adjusting bolt DLJ 270Q Q-0004 Valve locker 8 02.DLJ 270Q Q-0003 Retainer DLJ 270Q Q-0200 Stem seal DLJ 276Q Q-0500 Camshaft 4 02.DLJ QTB40- φ6 4 QTB40- φ6 4 Dowel pin φ DLJ 276Q-0002A 276Q-0002A Valve spring 4

70 6 02.DLJ.270Q-0005A 270Q-0005A Intake Valve DLJ.270Q Q-000 Lower seat of valve spring DLJ.270Q Q-0008 Wave form washer DLJ.270Q Q-050 Valve rocker arm of first cylinder DLJ.270Q Q-060 Valve rocker arm of second cylinder DLJ.270Q Q-0006 Exhaust Valve DLJ.QTB3- M8 32 QTB3- M8 32 Small hexagon-headed bolt with edge M DLJ.270Q Q Dowel DLJ.270Q Q Chain tightner DLJ.QTB0-M6 0 QTB0-M6 0 Hexagon-headed bolt with edge M DLJ.270Q Q Chain guide plate DLJ.270Q-04005A 270Q-04005A Crankshaft timing chain sprocket

71 INTAKE MANIFOLD PART No. ERP Code Code name Description Q'ty 02.DLJ.270Q Q Intake manifold paper gasket 2 02.DLJ.LJ276MT LJ276MT Intake mainfold 3 02.DLJ.898-M8X M8X25 Stud AC-M DLJ.848-M8X M8X28 Stud AC-M DLJ.QTB77 QTB77 Flat washer DLJ.93-SWφ8 93-SWφ8 Spring washer φ DLJ.QTB5-M8 QTB5-M8 Nut M DLJ.QTB26 QTB26 Clip DLJ.899-Z 3/8 899-Z 3/8 Square head taper plug Z 3/8

72 OIL FILTER AND OIL PUMP PART No. ERP Code Code name Description Q'ty 02.DLJ.270Q Q-7000 Oil Filter 2 02.DLJ M6X M6X48 Bolt assembly M DLJ.LJ276MT LJ276MT Oil pump 4 02.DLJ M6X M6X53 Bolt assembly M6 53

73 WATER PUMP AND FAN PART No. ERP Code Code name Description 02.DLJ.ZB/TT ZB/TT Hose clamp DLJ.270Q Q-90 Rubber pipe (2) 3 02.DLJ.270Q Q-903 water pump pulley 4 02.DLJ.QTB0-M8 88 QTB0-M8 88 Hexagon-headed bolt with edge M DLJ M6X M6X20 Hexagon head bolt M DLJ.QTB QTB Washer DLJ.276Q Q-9200 Fan assembly 8 02.DLJ.QTB93A-AV0X845 QTB93A-AV0X845 Fan belt AV DLJ.QTB0-M8 23 QTB0-M8 23 Hexagon-headed bolt with edge M DLJ.270Q-9002B 270Q-9002B bolt 02.DLJ.QTB0-M8 78 QTB0-M8 78 Hexagon-headed bolt with edge M DLJ.ZB/TT ZB/TT Hose clamp DLJ.LJ276MT LJ276MT Rubber pipe () 4 02.DLJ.276Q Q-900 Water pump gasket 5 02.DLJ.276Q Q-900 Water pump 6 02.DLJ.276-E E600 Roller bearing E DLJ.270Q-F Q-F2-00 Water seal 8 02.DLJ.276Q Q-9003 Impeller Q't y

74 DISTRIBUTOR AND ITS LINE UNIT No. ERP Code Code name Description Q't y 02.DLJ.270Q-2350W 270Q-2350W Distributor assembly(non contact) 2 02.DLJ.FDQ FDQ Rotor 3 02.DLJ.7825-SP 7825-SP Spark plug DLJ.FDQ FDQ Distributor cap assembly 5 02.DLJ.270Q Q-2390 Distributor protective cover 6 02.DLJ.LJ276MT LJ276MT Vacuum rubber tube 7 02.DLJ.LJ276M-2390F LJ276M-2390F High tension leads 8 02.DLJ.LJ462Q DW LJ462Q DW Ignition coil

75 CARBURETOR PART No. ERP Code Code name Description Q'ty 02.DLJ.270Q Q Carburetor gasket DLJ.270Q Q Carburetor insulator 3 02.DLJ.276Q Q-3000 Carburetor 4 02.DLJ.JB2D-H JB2D-H Electric petrol pump

76 AIR FILTER AND PIPE LINE PART No. ERP Code Code name Description Q'ty 02.DLJ.LJ276MT F LJ276MT F Air filter housing 2 02.DLJ.QK QK Flexible hose clamp DLJ.LJ276MT F LJ276MT F Flexible intake hose 4 02.DLJ.LJ276MT F LJ276MT F Rubber breathing pipe 5 02.DLJ.270Q Q Storing dust pipes 6 02.DLJ.QK QK air filter

77 STARTER, ALTERNATOR AND THEIR FASTENING PIECE No. ERP Code Code name Description Q'ty 02.DLJ.LJ368Q LJ368Q Starter 2 02.DLJ.LJ368Q LJ368Q Starter clamp bolt DLJ.QTB5-M8 QTB5-M8 Hexagon nut M DLJ.93-SW8 93-SW8 Spring washer DLJ.270Q-02203A 270Q-02203A Adjusting bolt 6 02.DLJ M8X M8X25 Bolt M DLJ.QTB30-φ24 φ8.5 3 QTB30-φ24 φ8.5 3 Thick washerφ24 φ DLJ.270Q-2500A 270Q-2500A Alternator bracket 9 02.DLJ.270Q Q-2500 Second fixed swift 0 02.DLJ.270Q Q First fixed swift (insert) 02.DLJ M8X M8X20 Bolt M DLJ.LJ462Q D LJ462Q D Alternator

78 TRANSMISSION TANK No. ERP Code Code name Description Q't y 02.DLJ.4T06C-702 4T06C-70 Upper housing of transmission 2 02.DLJ.4T06C-702 4T06C-702 Lower housing of transmission 3 02.DLJ.MQC4-703 MQC4-703 Locating pin DLJ.GB AM6X40 GB AM6X40 Bolt AM DLJ.GB AM8X50 GB AM8X50 Bolt AM DLJ.GB AM8X70 GB AM8X7 Bolt AM DLJ.GB AM8X90 GB AM8X90 Bolt AM DLJ.GB AM8X35 GB AM8X35 Bolt AM DLJ.MQC MQC Baffle plate of seal ring of the first shaft 0 02.DLJ.GB3452,-82 40X2,65 GB O type seal ring DLJ.GB89-85 M GB89-85 M6X6-6.8 Bolt M

79 2 02.DLJ.MQC MQC Dip stick 3 02.DLJ.GB3452,-82 5X2,65 GB O type seal ring DLJ.ZBT3200,3-87 ZBT3200,3-87 Bolt Z / DLJ.ZBT3200,9-87 ZBT3200,9-87 Bolt Z /2 4( magnetism ) 6 02.DLJ.MQC MQC Sight hole cover 7 02.DLJ.MQC MQC Sealing cover assembly of shift 3 lever 8 02.DLJ.MQC MQC Breathing pipe tie-in 9 02.DLJ.MQC MQC Breathing pipe DLJ.MQC MQC Perkins joint 2 02.DLJ.MQC MQC Breathing pipe plug DLJ.MQC MQC Line fastener DLJ.4T T Reverse switch DLJ.GB3452, GB O type seal ring DLJ Supporting piece DLJ.MQC MQC Line fastener DLJ.LJ368Q LJ368Q Shouldered tap bolt DLJ.LJ368Q LJ368Q Shouldered tap bolt DLJ.LJ368Q LJ368Q Stud DLJ.67 M0X M0X.25 Nut M DLJ.4T06CA T06CA T06CA4Transmission assembly DLJ.848 W0 848 W0 Washer0

80 CLUTCH, SHIFTER SHAFT AND ROCKER ARM No. ERP Code Code name Description Q'ty 02.DLJ.QST60HH4 QST60HH4 Clutch pressure plate 2 02.DLJ.LJ462Q D LJ462Q D Clutch cover bolt DLJ M8X M8X6 Bolt tab M DLJ.859 W8 859 W8 Light gage spring washer DLJ.DST60A7 DST60A7 Clutch plate 6 02.DLJ.MQC MQC Clutch release bearing 7 02.DLJ.MQC MQC Release bearing carrier 8 02.DLJ.MQC MQC Circlip DLJ.MQC MQC Clutch fork 0 02.DLJ.MQC MQC Bushing ring 2 02.DLJ.MQC MQC Tension spring 2 02.DLJ.4T06C T06C-7006 Clutch action arm 3 02.DLJ.GB AM8X35 GB AM8X35 Bolt AM DLJ.GB HV GB HV Washer8-200HV 5 02.DLJ.GB M8 GB M8 Nut M8

81 DIFFERENTIAL No. ERP Code Code name Description Q'ty 02.DLJ.MQC MQC Differential Planet gear DLJ.MQC MQC Half axle of Differential DLJ.MQC MQC Planet gear shaft 4 02.DLJ.GB P5x5.8 GB/T Needle bearing P DLJ.MQC MQC Planet gear washer DLJ.MQC MQC Half axle adjusting washer 0~ DLJ.MQC MQC Half axle adjusting washer 0~ DLJ.MQC MQC Half axle adjusting washer 0~ DLJ.MQC MQC Differential case 8 02.DLJ.4T T Main reduction gear 9 02.DLJ.GB M0x.25x0-0.9 GB/T Bolt M DLJ.GB/T Z/P63 GB/T Endocentric ball bearing 6207Z/P DLJ.MQC MQC Differential seal ring assembly DLJ.MQC MQC Thrust ring of Differential DLJ.MQC MQC Steel cable baffle ring 2

82 ONE SHAFT OUTPUT (option) No. ERP Code Code name Description Q'ty 02.DLJ.MQC MQC Steel cable baffle ring DLJ.MQC MQC Differential seal ring assembly DLJ.MQC MQC Thrust ring of Differential DLJ.GB/T Endocentric ball bearing GB/T Z/P Z/P DLJ.4T06C T06C Bushing ring 6 02.DLJ.4T06C T06C Output shaft 7 02.DLJ.4T06C T06C Bushing ring DLJ.4T06C T06C Connection plate 9 02.DLJ.4T T Main reduction gear 0 02.DLJ.GB M0x.25x0-0.9 GB/T Bolt M

83 FIRST SHAFT AND COUNTERSHAFT No. ERP Code Code name Description Q'ty 02.DLJ. 4T06CA T06CA-7030 Input shaft assembly 2 02.DLJ.GB/T Rearing RS/P53 GB/T RS/P DLJ. MQC MQC The first shaft seal ring assembly 4 02.DLJ.GB/T Rearing RS/P53 GB/T RS/P DLJ. MQC4-700 MQC4-700 Thrust ring of the first shaft bearing 6 02.DLJ. MQC MQC The first shaft seal cap assembly 7 02.DLJ.4T T Countershaft 8 02.DLJ.MQC MQC Cylindrical roller bearing with locking notch and without inner circle 9 02.DLJ.MQC MQC Thrust ring of countershaft bearing(right) 0 02.DLJ.MQC MQC Sealing cap assembly of countershaft(right) 02.DLJ.GB/T N/P53 GB/T Endocentric ball rearing 6304N/P DLJ.MQC MQC Thrust ring of countershaft bearing(left) 3 02.DLJ.MQC MQC Tight nut of countershaft 4 02.DLJ.MQC MQC Sealing cap assembly of countershaft(right) 5 02.DLJ.4T T The first gear of countershaft

84 6 02.DLJ.GB P2 7.8 GB Needle P DLJ.MQC MQC The first gear gasket of countershaft 8 02.DLJ.GB ,7625G60b GB Steel ball DLJ.MQC MQC First gear bushing ring of countershaft DLJ.GB K GB Needle bearing K DLJ.4T T The second gear of countershaft DLJ.4T06CA T06CA-7023 The third gear of countershaft DLJ.MQC MQC The second and the third gear bushing DLJ.5846 K GB Needle bearing K DLJ.MQC MQC The second and the third gears gasket DLJ.MQC MQC The third gear spacer DLJ.MQC MQC The second and the third gears pressure DLJ.4T06CA T06CA-7024 The fourth gear of countershaft DLJ.GB K GB Needle bearing K DLJ.MQC MQC The fourth gear gasket 3 02.DLJ.MQC MQC Low synchronizer shell DLJ.MQC MQC Low synchronizer sleeve DLJ.MQC MQC Low synchronizer ring(left) DLJ.MQC MQC Low synchronizer ring spring(left) DLJ.MQC MQC Low synchronizer ring(right) DLJ.MQC MQC Low synchronizer spring DLJ.MQC MQC Synchronizer guide spring DLJ.MQC MQC High synchronizer ring(left) DLJ.MQC MQC High synchronizer sleeve (left) DLJ.MQC MQC High synchronizer ring(right) DLJ.MQC MQC High synchronizer spring DLJ.MQC MQC Synchronizer guide spring DLJ.MQC MQC Racing gear of reverse gear DLJ.MQC MQC Reverse gear shaft DLJ.GB9-86 D5x3 GB9-86 Pin D DLJ.MQC MQC Sealing cap assembly of reverse gear DLJ.MQC MQC Speed gage worm DLJ.MQC MQC Speed gage worm wheel DLJ.MQC MQC Speed gage worm wheel bushing ring DLJ.GB3452,-82 9X.8 GB O Type seal ring DLJ.MQC MQC Seal ring assembly of speed gage worm DLJ.MQC MQC Speed gage thrust bolt

85 GEAR SHIFTED GEAR FORK No. ERP Code Code name Description Q'ty 02.DLJ.MQC MQC Shift fork for the first gear 2 02.DLJ.MQC MQC Shift fork for the first and second gear 3 02.DLJ.MQC MQC Shift fork for the third and fourth gear 4 02.DLJ.MQC MQC Reverse gear shift fork 5 02.DLJ.MQC MQC Reverse gear shift cantilever 6 02.DLJ.MQC MQC Shift fork assembly of reverse gear 7 02.DLJ.GB M h GB Bolt M DLJ.MQC MQC Shift fork washer of reverse gear 9 02.DLJ.MQC MQC Shift lever for the first and second gear 0 02.DLJ.MQC MQC Shift lever for the third and fourth gear 02.DLJ.MQC MQC Reverse gear shift lever 2 02.DLJ.GB ,5X8 GB Pin DLJ.GB ,5X20 GB Pin DLJ.GB X9,8 GB Needle DLJ.GB G606 GB Steel ball

86 6 02.DLJ.MQC MQC Hole plug 7 02.DLJ.GB GB Steel ball DLJ.MQC MQC Locating spring of high and low speed shit lever DLJ.MQC MQC Locating spring DLJ.MQC MQC Transposition Rocker shaft 2 02.DLJ.MQC MQC Transposition shaft DLJ.GB9-86 D4X8 GB9-86 Pin D4X DLJ.GB G606 GB Steel ball G DLJ.MQC MQC Spring of transposition shaft DLJ.MQC MQC Transposition shaft washer DLJ.MQC MQC Long spring of transposition shaft DLJ.MQC MQC Short spring of transposition shaft DLJ.4T06C T06C Shift shaft assembly DLJ.MQC MQC Transposition shaft rocker DLJ.GB X22 GB pin 5x DLJ.MQC MQC Seal ring assembly of shift shaft DLJ.MQC MQC Dirt guard of shift shaft DLJ.GB G60b GB Steel ball G60b DLJ.MQC MQC Locating spring DLJ.MQC MQC Shift fork washer of reverse gear DLJ.ZBT M ZBT Bolt M DLJ.MQC MQC Transposition shaft cap DLJ.GB3452,-82 9,5 2,65 GB type seal ring DLJ.GB AM6X20 GB Bolt AM6X20

87 air filter for usa N N Air cleaner 2 02.N N hoop(65-82) M6x30/ M6x30 Flange Bolt M6x N N Air filter joint 5 02.N N Air filter coat SJ2842- M6/ M6 Flange nut m6

88 Frame

89 No. ERP CODE Code name Description Q'ty 02.DB DB Frame component 2 02.DB DB engine board 3 02.DB DB seat motherboard 4 02.DB DB front motherboard 5 02.DB DB left side board 6 02.DB DB right side board 7 02.DB DB seat rear board D88-M6X6 D88-M6X6 Cross head screw M6* JD JD Washer ,-M6 / M6 Self-locking nut M D88-M6X6 D88-M6X6 Cross head screw M6* JD JD Washer ,-M6 / M6 Self-locking nut M D88-M6X6 D88-M6X6 Cross head screw M6*6 7 5 JD W6 JD Washer ,-M6/ M6 Self-locking nut M D88-M6X6 D88-M6X6 Cross head screw M6* JD W6 JD Washer ,-M M6 Self-locking nut M D88-M6X6 D88-M6X6 Cross head screw M6* JD JD W6 Washer ,-M6 / M6 Self-locking nut M D88-M6X6 D88-M6X6 Cross head screw M6* JD JD Washer ,-M6 / M6 Self-locking nut M6 0

90 Engine mount No. Erp code Code name Description Qty 02.D D choke cable 2 02.N N engine mount,front φ0x20x2/05 95-φ0X20X2 washer φ0(*20*2) φ20/05 93-φ20 spring washer φ M0X,25X25/ M0X,25X25 bolt-washer M0*.25* D D engine rubber bumper M0X,25/ M0X,25 bolt-washer M0* D D engine(lj276m) 9 02.D D engine mount,left 0 02.D A D A engine mount,rear M8X25/ M8X25 bolt-washer M8* φ8/05 93-φ8 spring washer φ ,2-φ8X24X2/05 96,2-φ8X24X2 washer φ8(8.4*24*2) D D engine mount,middle 5 02.DS DS small engine rubber bumper 6 02.D D adjust washer 0 8 7

91 Gear shift inlet rod of engine gear-shift No. ERP CODE Code name Description Q'ty ,-M8/ M8 self-locking nut M ,-M6/ M6 self-locking nut M D D shifter mount M6X20/ M6X20 bolt-washer M6* D D shifter assy M6X2/ M6X2 bolt-washer M6* D shift gear handgrip bush D D shift gear handgrip screw axle Φ6/05 93-Φ6 spring washer%%c M6/ M6 nut M6(m=5.2) 02.N N shift lever fork M4X.5/ M4X.5 Nut M4* D D shift lever 4 02.D D shift lever bolt M D D guide M0X.25X20/ M0X.25X20 bolt-washer M0*.25* JD JD nylon bush

92 8 02.D D shifter shaft 9 02.D D copper sleeve D D thick pivot plate 2 02.D D short crank Φ0X8X,5/05 95-Φ0X8X.5 washer %%c0(%%c0.5*%%c8*%%c.6) Φ0/05 93-Φ0 spring washer %%c SJ2842-M0X,25/05 SJ2842-M0X.25 nut-washer M0* D D long crank D D thin pivot plate D D thin rod copper flange cover D D threaded shaft 2

93 Steering assy No. ERP CODE Code name Description Q'ty ,3-M6x20/ M6X20 M6*20 screw TR TR plastic cover 3 02.TR TR steering wheel ,-M6/ M6 M6 self-locking nut TR TR steering wheel subassembly ,-M6X0/ M6X0 bolt M6* Φ6/05 93-Φ6 spring washer %%c N N integrated switch assy 9 02.D D steering wheel shaft 0 02.E E steering column housing ,-Φ5/ Φ5 circlip %%c5, external 2 02.D D steering column assy 3 02.D D steering universal rod Φ8X24X2/05 96-Φ8X24X2 washer %%c8(8.4*24*2) 2

94 Φ8/05 93-Φ8 spring washer %%c M8X25/ M8X25 bolt M8* D D tie rod end Φ0X28X2/05 95-Φ0X28X2 washer %%c Φ0/05 93-Φ0 spring washer %%c ,2-M0X.25/ M0X.25 nut lock M0*.25(nylon) M2X,5/ M2X.5 nut M2* D D steering gear box D D big iron cushion D D small iron cushion D D thin rubber cover D D thick rubber cover D D mounting rack(hole) D D mounting rack(no hole) M0X.25X25/ M0X.25X25 bolt washer M0*.25*25 4

95 Pedal control and park brake No. ERP CODE Code name Description Q'ty 02.D D disc brake with floating caliper,front D D disc brake with floating caliper,rear DN DN Master cylinder assy 4 02.DLJ.JK63B JK63B hydraulic power brake valve 5 02.D D hydraulic brake pads 4 set 6 02.DLJ.ZJ609.F02-0 ZJ609.F02-0 hydraulic threeway valve 7 02.TR TR clip DLJ.ZJGS.0-02 ZJGS.0-02 Hose bolt M0x DLJ.ZJGS.0-0 ZJGS.0-0 Seal washer D D hydraulic brake hose,front,left 02.D D hydraulic brake hose,front,right 2 02.D D hydraulic brake hose,middle 3 02.D D hydraulic brake hose,rear,left 4 02.D D hydraulic brake hose,rear,right 5 02.D A D A Master cylinder rod D D four caliper hydraulic brake assy

96 parking brake assy No. ERP CODE Code name Description 02.SV SV disc brake with floating caliper,front 2 02.D D single hydraulic oil cup 3 02.D D single hydraulic pump 4 02.D D pipe 5 02.D D hydraulic brake pads set 6 02.DLJ.ZJGS.0-02 ZJGS.0-02 Hose bolt M0x DLJ.ZJGS.0-0 ZJGS.0-0 Seal washer D D parking brake assy Q't y

97 Throttle and park assy No. ERP code Code name Description Q't y M8X20/ M8X20 Flange bolt M8* D D four caliper hydraulic brake assy

98 M6X20 / M6X20 Bolt-washer M6* D D support ,-M6/ M6 self-locking nut M M6X20 / M6X20 Bolt-washer M6* ,-M6/ M6 self-locking nut M D A D A pushing bar M M8 M8 nut 2 0 D D push rod holder X30/ X30 cotter pin 3.2* Φ φ0 washer(φ0.5*φ8* 95-Φ0X8X.5 0X8X,5/05 φ.6) D D clutch pedal 4 02.D D pedal rubber cover D D clutch cable ,-M6X55/ M6X55 M6*55 socket head bolt M6/ M6 M6 nut(m=5.2) D D spring φ0X60/ φ0X60 φ0*60 pin roll Φ2X25/05 9-Φ2X25 cotter pin φ2* Φ 6X3X,5/05 95-Φ6X3X.5 φ6 washer D D brake pedal X40/ X40 φ6*40 pin roll X05/ X05 φ0*05 pin roll D D throttle pedal D D throttle cable M8X20/ M8X20 M8*20 bolt D D park assy Φ 8X6X,5/05 95-Φ8X6X.5 φ8 washer X30/ X30 cotter pin 3.2* D D axle 8* D D parking brake connection X30/ X30 cotter pin 3.2* D D M8 self-locking nut D D bolt-washer M8* D D parking brake assy D D park brake cable D D steel bush 40

99 Front housing No. ERP code Code name ENGLISH Q'ty 02.S S M2*.5 wheel nut S A S A left wheel(27*8-2) X40/05 9-4X40 cotter pin 4* M8X,5/ M8X.5 nut-castle M8*.5,front axle D D front axle washer D A D A front hub D A D A bolt M2*.5,hub D D brake disc D D bolt M6,brake disc 8

100 02.D D seal (40X55X6) ,2-Φ55/ Φ55 circlipφ55,internal D D front hub bearing(30x55x30x25) D D stub axle,l M0X.5X30X20/ M0X.5X30X20 bolt-washer M0*.5*30* D D internal seal(40x58x7x5) D D front axle D D ball joint Φ CΦ29 φ29,external circlip M2X.5X45X8/ M2X.5X45X8 bolt-washer M2*.5*45* D D front shock absorber Φ6X30X,2/05 95-Φ6X30X.2 washer φ6(φ6.5*φ 30*2) SJ2842-M2X.5/05 SJ2842-M2X.5 flange nut,m2* D D FL upper suspension arm SJ2842-M0X,25/05 SJ2842-M0X.25 flange nut,m0* D D suspension arm bush D D suspension arm spacer M0X,25X75/ M0X.25X75 bolt-washer M0*.25*75* D D FL lower suspension arm 3 02.D D FR upper suspension arm D D FR lower suspension arm D D stub axle R S A S A right wheel(27*8-2) D D washer JD JD rubber dirt-proof boot D D valve cock S S front rim 2* S A S A front tire 27*8-2 2

101 Muffler No. ERP code Code name Description Qty 02.DLJ.270Q Q exhaust manifold gasket 2 02.D D front exhaust pipe 3 02.D D front pipe shield Φ8/05 93-Φ8 spring washer φ ,-M8/ M8 nut M8(m=6.8) D D sheet of heat insulation (65*65) ,-M8/ M8 nut self-lock M D D cushion flange 9 02.D A D A catalac convertor M8X30/ M8X30 bolt washer M8* ,-M8/ M8 self-locking nut M D D U clamp mount 3 02.D D U clamp screw rod

102 4 02.D B D B long muffler M8X30/ M8X30 bolt-washer M8* JD.90003A JD90003A muffler rubber cover JD JD90002 spacer Φ8X24X2/05 96-Φ8X24X2 washer φ8(φ8.4*φ 24*2) D D muffer bracket M8/ M8 self-lock M M0X,25X25/ M0X.25X25 bolt washer M0*.25* SJ2842-M0X,25/05 SJ2842-M0X.25 nut washer M0*.25 2

103 Fuel tank and gasoline pump No. ERP code Code name Description Q'ty fuel tank assy 2 02.D B D B fuel tank 3 02.SR SR A A fuel tank cap 4 02.SR SR fuel level sensor 5 02.SR SR rubber washer 6 02.D D hoop (0-6) FTCARB-086 FTCARB-086 fuel hose( φ 8x φ 6 0.2mete CARB) r 8 02.D D fuel filter 9 02.FTCARB-086 FTCARB-086 fuel hose( φ 8x φ 6 0.2mete

104 CARB) r 0 02.FTCARB-086 FTCARB-086 fuel hose( φ 8x φ 6 0.4mete CARB) r 02.D D fuel filter clip M8X25/ M8X25 bolt-washer M8* Φ 6X2X/05 95-Φ6X2X washer Ф SJ2842-M8/05 SJ2842-M8 nut-washer M D D fuel pump 7 02.FTCARB-086 FTCARB-086 fuel hose( φ 8x φ 6 0.4mete CARB) r 8 02.FTCARB-0409 FTCARB-0409 fuel hose( φ 4.5x φ 9 0.5mete CARB) r 9 02.TR TR carbon canister FTCARB-0409 FTCARB-0409 fuel hose( φ 4.5x φ 9 0.5mete CARB) r 2 02.D D carbon can bracket D D carbon can plate M6X6/ M6X6 bolt-washer M6* SJ2842-M6/05 SJ2842-M6 washer nut M ,-M2X30/0 M2*30 socket head 70.-M2X30 5 screw ,2- Φ washer φ 2 ( φ 3* φ 96.2-Φ2X24X2 2X24X2/05 24*2.5) D D rear bumper bar M0X20/ M0X20 bolt-washer M0* SJ2842-M0/05 SJ2842-M0 washer nut M M4X0/ M4X0 bolt M4X0 5

105 rear cargo rack and roll bar No. ERP code Code name Description Q'ty 02.D D nylon bush M2X,5X30/ M2X.5X30 bolt washer M2*.5* D B D B right roll bar M0X.25X45/ M0X.25X45 bolt washer M0*.25* D D rear cross bar SJ2842-M0X,25/ M0*.25 nut washer M0* M2X.5X30/ M2X.5X30 bolt hexagon M2*.5* D D front cross bar D B D B left roll bar

106 SJ2842-M2X,5/ M2X.5 nut washer M2* D D reserve tank 5 02.D D cap of reserve tank 6 02.D D airproof washer of reserve tank 7 02.D D takeoff reserve tank 8 02.D D hoop(0-6) D D radiator connecting tube meter M6X6/ M6X6 bolt-washer M6* D D oil separator cover D D oil separator air filter SV SV hoop(2-38) D D oil separator tank D D recycle exhaust gas tube M8X20/ M8*20 bolt-washer M8* ,-M8/ M8 self-locking nut M8 4

107 Rear housing No. ERP code Code name Description Q'ty

108 02.S S wheel nut M2* D H D H (F938)wheel(25*-2),BL X40/05 9-4X40 cotter pin 4* DLJ.JGC2202-K JGC2202-K nut-castle M22*.5,rear shaft D A D A disk base D A D A M2*.5 bolt D D brake disc D D bolt M6,butterfly disc Φ55/ CΦ55 φ55,internal circlip D D (Φ30XΦ55X32),rear hub bearing 2 02.D D valve cock S S rear rim 2* S A S A F938 rear off-road tire 27x D D parking brake assy M0X,25X00/ M0X.25X00 bolt-washer M0*.25*00* D D shaft carrier spacer D D shaft carrier bush D D shaft carrier SJ2842-M0X,25/05 SJ2842-M0X.25 Nut-washer M0* M8X20/ M8X20 bolt-washer M8* D D RL upper suspension arm SJ2842-M0X,25/05 SJ2842-M0X.25 nut-washer M0* M0X.25X75/ M0X.25X75 bolt-washer M0*.25*75* D D left proppeller shaft D D right propeller shaft SJ2842-M2X,5/05 SJ2842-M2X.5 nut-washer M2* M2X.5X60/ M2*.5*60*8 bolt-washer M2*.5*60* D D rear shock absorber D D RL lower suspension arm SJ2842-M0X,25/ M0*.25 nut-washerm0* D D suspension arm spacer D D suspension arm bush M0X,25X75/ M0*.25*75*8 bolt-washer M0*.25*75* D D RR lower suspension D D RR upper suspension D H D H (F938)wheel(25*-2),BR DLJ.BT-045 BT-045 outer boot seal 2

109 39 02.DLJ.MQC MQC steel cable baffle ring DLJ.SH07680 SH07680 BIG band DLJ.BT-085 BT-085 inner boot seal DLJ.SH07350 SH07350 SMALL band DLJPT SZW5004 PT SZW5004 end motion type inboard joint DLJ.PT SZ-900 PT SZ-900 solid bar,left DLJ.PT SZW003 PT SZW003 fixed enter type outboard joint PT SZ-9002 PT SZ-9002 right solid bar Radiator and air cleaner No. ERP code Code name Description Q'ty 02.D D hoop (0-6) D D overflow bottle hose 3 02.D D engine water outlet hose 4 02.D D hoop(25-38),water tube 5 02.D D hoop(25-38),water tube 6 02.D D engine water inlet hose 7 02.D D hoop(25-38),water tube D D water temperature switch 9 02.D D radiator ,-M6/ M6 self-locking nut M D D radiator bracket M6X5/ M6x5 bolt washer M6* M2X.5X30/ M2x.5x30 bolt hexagon M2*.5*30 4

110 4 02.D D radiator cushion 5 02.E A E A radiator mounting bar 6 02.JD JD90003 radiator rubber washer JD JD90002 radiator spacer Φ6x3x,5 95-Φ6x3x.5 washer %%C M6X25/ M6x25 bolt washer M6* M6X40/ M6x40 bolt washer M6* ,-M6/ M6 self-locking nut M N N air cleaner bracket N N hoop(65-82),air cleaner N N air cleaner N N air cleaner jacket D88-M6X35 D88-M6X35 bolt M6X D D plastic cover of radiator

111 Electric appliance

112 No. ERP code Code name Description Q'ty 02.D D headlight D D headlight bulb(35w/35w) D D FL turning signal 4 02.D D FR turning signal 5 02.D D spot light D D spot light bulb(30w) DS DS horn button 8 02.JD JD washer 9 02.D D RR turning signal 0 02.D D RL turning signal 02.D D Bracket of speedometer D D tail light D A D A flasher apparatus 4 02.D A D A regulator 5 02.D D horn 6 02.D B D B harness 7 02.D D relay box 8 02.N N speed sensor 9 02.D D four switch assy N A N A speedometer 2 02.N N tachometer N N coolant temperature indicator D D voltmeter N N fuel level gauge D D flasher coat D D battery bracket D D battery cover M8/ M8 nut-washer M M8X40/ M8X40 bolt-washer M8* D D battery(36ah) 3 D88-M6X6 88-M6X6 Cross head screw M6* ,-M6/ M6 Self-locking nut M6 2

113 Seat and safety belt 2 3 J O Y N E R J O Y N E R J O Y N E R J O Y N E R No. ERP code Code name Description Q'ty 02.D A D A safty belt D D safty belt tube D D left seat 4 02.D D right seat 5 02.D D Track without release lever D D Track without release lever 7 02.D D Track with release lever

114 Other parts NO ERP Code Part No. Part Description Qty 02.D D spark plug wrench 2 02.DLJ.270Q Q spark plug DLJ.270Q Q Oil Filter wrench

115 Front rack option No. ERP code Code name Description Q'ty 02.D D front rack M8X25/ M8X25 bolt-washer M8X ,-M8/05 683,-M8 nut M D D front rack OPTION set

116 Rear rack option 3 2 No. Code name Code name Description Q'ty 02.D B D B rear rack M8/ M8 nut M D D rear rack OPTION set

117 Paddock roof rack option No. ERP code Code name Description Q'ty 02.D D paddock roof rack 2 02.D D paddock roof rack plate.a D88-M6X35 D88-M6X35 bolt M6x JD JD washer ,-M6/05 683,-M6/05 nut M M0x.5/ M0x.5/05 nut M0x D D Paddock roof rack option

118 Rifle roof rack option No. ERP code Code name Description Q'ty 02.D D rifle roof rack 2 02.D D rifle roof rack plate2.a D88-M6X D88-M6X35 bolt M6x JD JD washer ,-M6/ ,-M6/05 nut M M0x.5/ M0x.5/05 nut M0x D D Rifle roof rack option

119 Nerf roof rack option forward No. ERP code Code name Description Q'ty 02.SV SV left nerf bar 2 02.SV SV right nerf bar M0X35 / M0X35 bolt-washer M0X SJ2842-M0/05 SJ2842-M0 nut M D D Nerf roof rack option

120 3000B winch option No. ERP code Code name Description Q'ty 02.D D wire calbe guide 2 02.D A D A 3000B electrical winch 3 02.D D electrical winch switch 4 02.D D electrical control case M8X25/ M8X25 bolt-washer M8X ,-M8/05 683,-M8 nut M D D B winch option

121 Spotlight option 5 No. ERP Code Code name Description Q'ty 02.D A D A spotlight D D spotlight bulb φ washer-φ 95-φ0X20X,5 0X20X,5/05 0X20X, M0*20/ M0*20 bolt-washer M0* D D Spotlight option

122 Tow ball option No. ERP Code Code name Description Q'ty 02.JD JD TOW BALL φ φ8/05 93-φ8 spring washer φ SJ2842-M8/05 SJ2842-M8 nut M D D Tow ball option

123 safty belt tube option NO ERP Code Part No. Part Description Qty 02.D D safty belt tube 2

124 Shock absorber coat option 2 2 NO ERP Code Part No. Part Description Qty 02. D D Front shock absorber coat D D Rear shock absorber coat 2

125 Tools and bag kit option 2 NO. ERP Code Part No. Part Description Qty 02.D D Open-jawed spanner 8~ D D Open-jawed spanner 2~ D D Open-jawed spanner 3~ D D Open-jawed spanner 7~ JD JD Thread-locking anaerobic adhesive 6 02.D D Screwdriver 7 02.D D Screwdriver D D Long Nose Pliers 0 02.D D Tools bag 02.D D Cable tie D D Tools and bag kit option set

126 Envelopment and foam cover option NO. ERP Code Part No. Part Description Qty 02. D D Protect-jacket front, upper D D Protect-jacket side,upper D D Protect-jacket rear,upper D D Protect-jacket side,front D D Protect-jacket side,rear D D Small Protect-jacket side,rear D D foam cover D D Entire vehicle cover D D canvas roof D D Protect-jacket assy SET

127 Preparation attach instruction Remove packing

128 Install the front suspension arm Install the front suspension arm frame forward D D D D Erp code D D D D code name FR lower suspension arm FR upper suspension arm FL lower suspension arm FL upper suspension arm Description Q'ty. Install the left upper suspension arm,f-, the left lower suspension arm,f-2 on the front of frame as the figure above. 2. Install the right suspension arms as above. Note: Before installing, check the grease in the moving parts, put 3# Lithium-grease into the moving part if necessary. 3. Jesus Tighten the bolts and nuts with thread glue. )

129 front shock absorber, stub axle Attach

130 Attach tie rod and front whees Attach tie rod end and front wheel 2 3 forward tie rod end stub axle,r 3 02.S A S A left wheel(27*8-2) 2 02.S A S A right wheel(27*8-2) 02.D D tie rod end No. Erp code code name Description Q'ty. Install the shaft of outer tie rod end- to stub axle,r from the underside (nut on top). 2. Install flat washer,spring washer then tighen nut. Note: don't adjust outer tie rod end as wheel alignment is done before packing. 3. Attach the wheel(27*8-2),fr-2 on the hub, tighten the nuts. 4. Attach the wheel(27*8-2),fl-3 as described above.

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132 Attach the rear suspension arm Attach the rear suspension arm forward D D D D D D D D BL lower suspension arm BL upper suspension arm BR lower suspension arm BR upper suspension arm Erp code code name Description Q'ty. Attach upper suspension arm,br - on the rear part of frame. Insert the bolt-6. Tighten the bolts and nuts with threads glue. 2. Attach lower suspension arm,br -2 on the rear part of frame. Insert the bolt-5. Tighten the bolts and nuts with thread glue. Note; apply 3# Lithium-grease to the move part of arm if necessary. 3. Attach lower/upper suspension arm,lb as described above.

133 Attach propeller shaft and shaft carrier Attach propeller shaft and shaft carrier transmission right drive shaft attaching 3 rear right suspension arm same as page 4 2 The right proppeller shaft is longer than the left 4 5 forward D D D D D D left proppeller shaft right proppeller shaft shaft carrier Erp code code name Description Q'ty.Check the clip on the output shaft of transmission, confirm the clip is in the groove on the output shaft of transmission. 2. Insert right proppeller shaft-2 onto the output shaft of transmission, confim the clip on the output shaft clip in the groove. 3. Put 3# Lithium-grease on the seal area if necessary. 4. Insert other end of right proppeller shaft-2 into shaft carrier-. 5. Insert bolt into the hole of hub and upper arm. Tighten the bolt and nut with thread glue. 6. Attach lower arm to the hub as above. 7. Tighten the nut-4 with thread glue. 8. Insert pin into the lock-hole on the proppeller shaft, and lock the pin Attach the brake hose to the lower suspension arm with clamp provided. 0. Attach the left side as figure. 2

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135 Attach rear shock absorber and rear wheel Attach rear shock absorber and rear wheel 3 lower suspension,br 2 forward 3 2 No. 02.S A 02.S A 02.D Erp code S A S A D code name wheel (27X-2),BL wheel(27*-2),br rear shock absorber Description 2 Q'ty. Attach rear shock absorber- on the frame and lower suspension,br. 2. Insert bolt into the hole of shock and lower suspension,br. Tighten the bolt and nut with thread glue. 3. Attach wheel (27X-2),BR-2 on the hub. tighten the nuts. 4. Attach the left side as above.

136 Attach rear shock absorber and rear wheel