Joyner TROOPER-T2, TROOPER-T4 Owner's Manual

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Owner’s Manual Parts manual

READ THIS MANUAL CAREFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION.

MINIMUM RECOMMENDED OPERA TOR 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.

TROOPER-T2，T4

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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.

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CONTENTS

Owner’s manual ............................................................................................................................................ 7

Warranty policy ....................................................................................................................................... 7

Parts order form, warranty claim form ................................................................................................ 11

Service record form .............................................................................................................................. 12

Preventative maintenance and service log ........................................................................................ 13

Location of warning labels and specification labels ......................................................................... 18

Safety information ................................................................................................................................. 22

Are you ready to drive? ........................................................................................................................ 24

Protective apparel ............................................................................................................................ 24

Helmets and ayes protection .......................................................................................................... 24

Drive training ..................................................................................................................................... 25

Age recommendation ...................................................................................................................... 25

No alcohol or drugs .......................................................................................................................... 25

Is your vehicle ready to drive? ............................................................................................................ 26

Pre-drive Inspection .............................................................................................................................. 26

Operation instructionMain switch ....................................................................................................... 28

Battery switch ................................................................................................................................... 28

Gauges .............................................................................................................................................. 29

Switches ............................................................................................................................................ 29

Steering wheel .................................................................................................................................. 31

Pedal .................................................................................................................................................. 32

Parking brake lever .......................................................................................................................... 32

Drive select lever .............................................................................................................................. 33

Differential control handle ............................................................................................................... 33

Fuel tank ............................................................................................................................................ 34

Seats and safety belts ..................................................................................................................... 34

Safari bed .......................................................................................................................................... 36

Start engine ....................................................................................................................................... 36

Stop engine ....................................................................................................................................... 37

Passenger ......................................................................................................................................... 37

Break-in ............................................................................................................................................. 37

Starting and operating instructions ................................................................................................ 38

Specifications ........................................................................................................................................ 39

Maintenance and adjustment ...................................................................................................................... 42

Air Cleaner ............................................................................................................................................. 42

Engine Lubrication ................................................................................................................................ 42

Transmission lubrication ...................................................................................................................... 43

Differential lubrication .......................................................................................................................... 44

Engine Coolant ...................................................................................................................................... 44

Idle Speed .............................................................................................................................................. 46

Spark plug inspection ........................................................................................................................... 46

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Wedge belt figure .................................................................................................................................. 48

Shift cable adjustment .......................................................................................................................... 48

Parking brake cable adjustment .......................................................................................................... 49

Steering lubrication............................................................................................................................... 50

Throttle cable adjustment .................................................................................................................... 51

Differential lock cable adjustment ....................................................................................................... 51

Spot light adjustment............................................................................................................................ 52

Oil filter change ..................................................................................................................................... 53

Fuel pressure adjustment .................................................................................................................... 53

Front Wheel Replacement .................................................................................................................... 54

Rear Wheel Replacement ..................................................................................................................... 54

Clutch replacement ............................................................................................................................... 55

Front Wheel Alignment ......................................................................................................................... 58

Fuse and relay ....................................................................................................................................... 58

Bulb replacement .................................................................................................................................. 60

Shock adjustment ................................................................................................................................. 62

Chassis wiring diagram ........................................................................................................................ 64

Engine wiring diagram .......................................................................................................................... 65

Engine disassembly, installation and repair ...................................................................................... 66

Timing Belt ........................................................................................................................................ 66

Camshaft ........................................................................................................................................... 73

Cylinder head .................................................................................................................................... 82

Water pump ....................................................................................................................................... 89

Oil pump ............................................................................................................................................ 90

Crankshaft connecting rod mechanism ........................................................................................ 98

Electric injection system ................................................................................................................ 109

PARTS MANUAL ...................................................................................................................................... 149

1. ENGINE ............................................................................................................................... .............. 149

1. COOLING SYSTEM .................................................................................................................. 149

2. CYLINDER BLOCK ................................................................................................................... 150

3. CRANKSHAFT ........................................................................................................................... 151

4. EXHAUST MANIFOLD ............................................................................................................. 152

5. INTAKE SYSTEM ...................................................................................................................... 153

5. INTAKE SYSTEM ...................................................................................................................... 154

6. LUBRICATING DEVICE ........................................................................................................... 155

7. CYLINDER HEAD ..................................................................................................................... 156

7. CYLINDER HEAD ..................................................................................................................... 157

8. COVER-VALVE CHAMBER ..................................................................................................... 158

9. OIL PAN ...................................................................................................................................... 159

10. VALVE MECHANISM .............................................................................................................. 160

10. VALVE MECHANISM .............................................................................................................. 161

10. VALVE MECHANISM .............................................................................................................. 162

11. IGNITION DEVICE .................................................................................................................. 163

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12. PISTON AND CONNECTING ROD DEVICE ...................................................................... 164

13. OTHER ACCESSORY 1......................................................................................................... 165

14. OTHER ACCESSORY 2......................................................................................................... 166

2.5T07D1 TRANSMISSION .................................................................................................................. 167

1 CASE&ACCESSORY ................................................................................................................ 167

1 CASE&ACCESSORY ................................................................................................................ 168

2 COUNTERSHAFT ...................................................................................................................... 169

2 COUNTERSHAFT ...................................................................................................................... 170

3 INPUT SHAFT ASSY ................................................................................................................. 171

3 INPUT SHAFT ASSY ................................................................................................................. 172

3 INPUT SHAFT ASSY ................................................................................................................. 173

4 SHIFT FORK&SHIFT-FORK SHAFT ....................................................................................... 174

4 SHIFT FORK&SHIFT－FORK SHAFT .................................................................................... 175

5 SHIFT CONTROL MACHINSM ................................................................................................ 176

6 DRIVEN GEAR ASSY ................................................................................................................ 178

3. CHASSIS .......................................................................................................................................... 179

1.Frame assembly ......................................................................................................................... 179

2.Engine mount assy ..................................................................................................................... 181

3.Muffler ........................................................................................................................................... 182

4.Gear-shift mechanism ................................................................................................................ 183

4.Gear-shift mechanism ................................................................................................................ 184

5.Steering assembly ...................................................................................................................... 185

5.Steering assembly ...................................................................................................................... 186

5. Steering assembly ..................................................................................................................... 187

6. Throttle, parking brake, brake .................................................................................................. 188

6. Throttle, parking brake, brake .................................................................................................. 190

6. Brake (TR1100.07.01.01.00B, TR1100.07.01.01.

00B-T4).................................................. 192

6. Parking ........................................................................................................................................ 193

6. Clutch (TR1100.07.04.01.00, TR11

00.07.04.01.00-T4) ...................................................... 194

7. Front and rear suspension assembly ..................................................................................... 195

7.Front and rear suspension assembly ...................................................................................... 196

8.Driven system .............................................................................................................................. 197

8. Driven system ............................................................................................................................ 199

9. Front/Rear differential locking .................................................................................................. 201

10.Fuel tank and gasoline pump ................................................................................................. 202

10.Fuel tank and gasoline pump ................................................................................................. 204

11.Radiator assembly .................................................................................................................... 206

11.Radiator assembly .................................................................................................................... 207

12.Roll bar and Rearview mirror .................................................................................................. 208

12.Roll bar and Rearview mirror .................................................................................................. 209

13. Cargo bed ................................................................................................................................. 212

14. Electrical winch ........................................................................................................................ 213

15. Plastic parts .............................................................................................................................. 214

15. Plastic parts .............................................................................................................................. 215

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16. Seats and safety belts ............................................................................................................ 218

17.Other parts ................................................................................................................................. 220

17.Other parts ................................................................................................................................. 221

DEALER PRE-DELIVERY INSPECTION ............................................................................................. 222

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Owner’s manual

Warranty policy

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Page 9

Page 10

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Parts order form, warranty claim form

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Service record form

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Preventative maintenance and service log

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Page 15

Page 16

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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.

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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 .

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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.

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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.

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.

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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 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.

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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.

■ 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.

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■ 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.

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Operation instructionMain switch

Functions of the respective switch positions are as follows:

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.

OFF

ON 1

ON 2

START

MAIN SWITCH

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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

1. 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 “ ” to turn on the low beam and the taillights. Set the switch to “ ” to turn on the high beam and the taillights. Set the switch to “ ” to turn on the spotlights.

2 3

Key

Bul

Channel

Key

Off

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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 “ ” when turn left

Set the switch to “

” when turn right

Four-wheel drive switch “2WD/4WD”

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

z (“2WD”) Power is routed to the back wheels only z (“4WD”) Power is delivered to both the front and the back wheels. z Front free: the vehicle working with front differential. z Front lock: the vehicle working with front differential locked. z Rear free: the vehicle working with rear differential. z Rear lock: the vehicle working with rear differential locked.

z 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.

z Injury or death may occur if change differential to differential locked at a high speed. z Injury or death may occur if drive the vehicle at a high speed with both front

differential locked and rear differential locked

Rear diff lock handle

Front diff lock handle

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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 1020C/2150F, 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

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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.

z Before start the engine, you should check the three pedal to be they are operating

smoothly.

z Before start the engine, you must make sure that the spring pressure can returns the

three pedals to the rest position fully when released.

z 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.

z Improper operation of the clutch will lead to excessive wear of the clutch friction

surface.

z 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

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.

Clutch Pedal

Brake Pedal

Park brake not engaged Park brake engaged

throttle Pedal

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z Adjust the parking cable if necessary. z Be sure to fully release the parking brake lever before driving the vehicle. z 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.

z Never start the vehicle at 3, 4 or 5 gear z Stop the vehicle fully before shifting to reverse. z 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: z 2DW(2 driven wheels):

1. Rear differential.

2. Rear differential locked

z 4DW(4 driven wheels):

1. Rear differential and front differential.

2. Rear differential locked and front differential.

Rear differential locked and front differential locked Shift the handles right side and pull down, then stop the handle in the differential locked position.

Rear diff lock handle

Front diff lock handle

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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 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.

z Never overfill the gas tank. z Keep the fuel tank cap clean. z Make sure to cover the key hole back

after use

z to prevent dirt from entering the lock mechanism

Seats and safety belts Seats

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.

Fuel tank

Fuel tank cap

Seat lock

Left seat

Right seat

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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:

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 above right shoulder

Cross above left shoulder

Cross above right leg

Cross above left leg

Cross between 2 legs

Cross above left leg

Back Hook

Limiting rock

Take off back hooks Take off side hooks

Turn around seat

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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.

z Before attempting to adjust the seat ensure that engine of TROOPER is stopped. z 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.

z 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. z The max load is 150Kg/330Ib.never exceed the stated maximum load limit for this safari bed. or injury or z Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo. Allow greater distance for braking.

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

Cross above right leg

Cross above right shoulder

hook

Cross above left shoulder

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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.

z 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.

z 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.

z 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.

z 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.

z 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.

z Before driving this vehicle, test the Engine Stop key to assure that it is operating

properly.

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.

Page 38

The speed of vehicle The first 1000 km

Max speed in each gear

1st Gear 12.4MPH

2nd Gear 24.8MPH

3rd Gear 37.2MPH 4th Gear 52.7MPH 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.

Page 39

Specifications

Model

TROOPER

Dimensions:

Overall length

Overall width

Overall height

Seat height

Wheelbase

Ground clearance

Minimum turning radius

3300mm/130 inch 1600mm/63 inch 1990mm/78 inch 800mm/34.6 inch 2470mm/97.2 inch 300mm/11.8 inch

6000mm/236 inch Basic weight: With oil and full fuel tank

780kg/1719 Ib Engine: Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system

Liquid cooled—4stroke

Upstanding double cylinder

1080cc

72mm×66.5mm/2.83 inch x2.62 inch

9.5:1

Electric starter

Wet sumb Engine oil Type

Recommended engine ail classification

Quantity: With oil filter cartridge replacement

＞ 0 ℃ / ℉ SE15W/40, ＜ 0 ℃ / ℉

SE15W/30

3.0L/3.17qt Final gear case oil: Type Quantity

SAE85 API GL-5 gear oil

1.8L/1.9 qt

Radiator capacity(including all routes): 5.0L/5.28 qt

Air filter: Engine Intake duct

Wet element

Dry element Fuel: Type Fuel tank capacity

Unleaded gasoline only

30L Fuel system: Type

EFI Spark plug: Type/manufacturer

S11-3707100/ Chery

Clutch type: Dry, diaphragm spring

Page 40

Transmission: Transmission type Operation

Manual

Right hand operation (five shifts,one

reverse) Chassis Frame type Caster angle

Steel tube frame

3º Tire

Type Size front rear

Tubeless

27 inch

27 inch Brakes: System Type front

rear

Operation

Front and rear unified

Dual disc brake

Foot operation Suspension: Front suspension Rear suspension

Independent Dual A-Arm

Longitudinal Control Arm Shock absorber: Front shock absorber Rear shock absorber

Coil spring/oil damper

Coil spring/oil damper Wheel travel: Front wheel travel Rear wheel travel

120mm/4.72inch

150mm/5.9inch Electrical: Ignition system Generator system Battery type Battery capacity

Distributor block

AC magneto

Lead acid storage battery

12V 45Ah 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

7.5A

20A

15A

25A Bulb voltage, wattage quantity: Headlight Tail/brake light

12V 35W/35W×2

12V 5W/21W×2

Page 41

Spotlight 12V 35W/35W×4 Indicator lights: Reverse indicator light Coolant temperature warning light Charge indicator light Four-wheel-drive indicator light

LED

Page 42

Maintenance and adjustment

Air Cleaner

Clean air filter refer to Preventative maintenance and service log. Under dusty conditions Service more often

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 plug

Cover

Filte

Rubber bushing

Oil inlet

Oil measurer

Page 43

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.

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 .

Oil inlet

Oil outlet

Oil measure

Oil outlet

Page 44

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.

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.

Oil inlet

Oil outlet plug

Page 45

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.

z 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.

z Children and pets may be harmed by coolant.

Keep coolant away from the children and pets.

z 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.

z Recycle or properly dispose of used coolant.

Release lever Release lever

Cap

Page 46

z 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

z 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/0.035～0.043inch.

z Spark plugs replacement The spark plugs should be replaced every 30000km/18641miles, or 18 months.

Screws

Plastic cove

Spark plug seat

Plastic cover

djustment screw and nut

Page 47

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

retardarce 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/18.4Ft-Lb )

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.

0.9～1.1mm

0.035～0.043inch

Special spanner

Spark plug seat

Page 48

5. Make sure spark plugs hole lip is clear.

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/22.48lbf) on the belt, if the movement is more than

10mm/0.4inch, it is necessary to replace the belt.

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.

10mm/0.4inch

Page 49

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.

Adjustment nuts

Shift lever

Transmission

Page 50

Steering lubrication

Proper lubrication will ensure steering box work well and longer time. Please lubricate

the steering box refer to Preventative maintenance and service log.

To lubricate the steering box

1. Take the steering box off from TR1100 firstly, unbolt these nuts and bolts showed in the following picture, pull off the steering joint, and take off the steering box slowly.

2. Inject lithium base grease about 20g through grease cup with a grease gun.

3. Clean the steering box, and install it with reverse step 1.

Adjustment nut

Parking brake lever

Unbolt the nut

Unbolt the bolt

Pull off the joint

Page 51

Throttle cable adjustment

After a long time used, the throttle cable may be too loose to work well, so adjustment is needed. It is recommended to adjust the throttle cable refer to Preventative maintenance and service log. To tense the cable

1. Unbolt the engine-end adjustment nuts shown in the following picture, and move the cable end forwards to make the cable in a proper tension, and tighten 2 adjustment nuts, if the movement is not enough, following step 2 is necessary, or not necessary.

2. Unbolt the pedal-end adjustment nuts shown in the following picture, and move the cable end backwards to make the cable in a proper tension, and then tighten 2 adjustment nuts.

Differential lock cable adjustment

After a long time used, the throttle cable may be too loose to work well, so adjustment is needed. It is recommended to adjust the differential lock cable refer to Preventative maintenance and service log. To tense the cable

1. Loose these 2 thin nuts, and then turn the screw sleeve counterclockwise a few

Grease cup

Adjustment nut

Forwards Backwards

Backwards

Forwards

Page 52

round until the cable get a proper tension.

Spot light adjustment

To get the desired spot-light position, adjust as following steps: Solution 1

1. Loosen the spot light adjustment nut, and turn the spot light forwards and backwards until find the desired position.

Solution 2

2. Loosen the adjustment nuts on at the both ends of spot light lever, and then rotate the lever clockwise to pull the spot light support up, or counter clockwise to push the spot light support down.

Screw sleeve

Thin nut

Adjustment nut

Spot light adjustment nut

Adjustment nut

Spot light

Page 53

Oil filter change

It is recommended strongly to change the oil filter refer to maintenance and service log. To change the oil filter, just take off the oil filter with a special oil filter spanner showing in the following picture, and replace it with a new one.

Fuel pressure adjustment

Never make unnecessary adjustments. The factory recommended settings are correct for most applications. The recommend fuel pressure is 3.5kgf/m2 (49.8 psi). It’s not necessary to adjust fuel pressure unless the fuel pressure really needs to be adjusted. To adjust the fuel pressure:

1. Loose the lock-nut with a 14mm spanner as the following picture.

2. Turn the adjustment-bolt clockwise with a inner hexagon spanner to increase the fuel pressure, and counterclockwise to decrease the fuel pressure.

3. Keeping one eye on the fuel pressure indicator while turn the adjustment-bolt, when the indicator shows about 3.5kgf/m2 (49.8 psi), stop turning, and tighten the lock-nut.

Oil filter spanner

14mm spanner

Lock nut

Inner hexagon spanner

Adjustment bolt

Page 54

Front Wheel Replacement

It is not needed to disassemble the center castle nuts when you replace the front wheels or the rear wheels. Just take off these 5 cap-nuts, and replace the wheels with a new one. Tighten these 5 nuts after replacing the wheels, the wheel need to be assembled by a JOYNER authorized dealer. Castle nuts Torque:180±5 N*M/182±3.5FT_LB Wheel nuts Torque:70±5 N*M/51±3.5FT_LB

Rear Wheel Replacement

Page 55

Clutch replacement

1. Remove two bolts, and demount Starter-assembly carefully.

2. Remove four bolts on the transmission case, lay down these carefully. Caution: When

fix the four bolts in the transmission case; you must tighten them according to the prescribed torque 45-55 N*M/33-40.5 Ft-Lb.

Q1840845

Q1841245

S11-37081

Q218B1245

Q1841240

Q1841245

Page 56

3. Remove upper steel cushions and lower steel cushion.

4. Insert a spine-shaft into the hole of the Clutch assy , remove the six bolts on the Clutch

pressure plate, now It’s clear. Caution: When fix the six bolts in the Clutch pressure plate; You must tighten them according to the prescribed torque 20.5 Ft_Lb

S11-170010372-100203

Spline-shaft

Page 57

5. Insert a spline-shaft into the hole of the Clutch assy, fix the six bolts on the Clutch

pressure plate, and tighten them according to the prescribed torque 20.5 Ft_Lb.

S11-1601020 S11-1601030

FIGURE 1

Page 58

6. Fix parts according to reverse operation to the disassembly.

Front Wheel Alignment

Correct front wheel alignment can ensure the vehicle run in a good track. After a long time use, doing some alignment work is needed.

a. Put the vehicle on level ground. b. The “toe-in” of the front wheels should be 0.98 inch. It means the dimension A should

be 0.98 inch more than dimension B.

c. Turn the steering wheel to align the center of the steering-rack with the center of the

frame.

d. Loose the lock nuts on both ends of Front Tie Rods. Turn the 2 tie-rods forwards to

increase A and decrease B, backwards to decrease A and increase B. repeat it until the dimension A and B meet the requirement described as item a. and then tighten all the lock nuts on the both end of tie-rod.

Fuse and relay

To check or replace fuses:

1. Take off the cover of the fuse box. Press the hook down and pull off the cover.

2. Check and replace the fuse according the fuses and relays diagram.

Lock nut

Front tie rod

Page 59

Front fuse and relays box

Spot light relay

High beam light relay Dipped beam light relay

Flash relay

Night light fuse

R gear indicator fuse

Brake indicator fuse

Turning single fuse

Head light fuse

Dipped beam fuse

High beam fuse

Horn fuse

Spot light fuse

Press the hook down

Page 60

Rear fuses and relays box

Bulb replacement

To replace the bulb of the head light:

1. Loose the 2 crews at the bottom of the head light, and take off the 2 hoops around the head light.

2. Separate the head light as the picture.

3. Unscrew the screw that fixes the bulb, and take off the bulb carefully.

4. Disconnect the bulb from the wiring.

5. Connect a new bulb with the same specification to the wiring.

6. Put all the parts disassembled above with reversing step 1～4.

Engine relay

Fuel pump relay

Fan relay

ECU normal open circuits fuse

Gauge and indicator fuse

EFI fuse

ECU normal close circuits fuse

Fuel pump fuse

Engine fuse

Fan fuse

Page 61

Hoop

Screw

Screw driver

Separate the head light carefully

Unscrew the bulb

scre

Take off the bulb carefully

Separate the head li

ht like this.

Page 62

To replace the bulb of the taillight:

1. Unscrew the 6 screws from the taillight.

2. Separate the taillight cover from the taillight body.

3. Take off the bulb you need to replace through turning the bulb counter clockwise about a half round, and replace a new one.

4. Put all the parts back with reversing step 1～2.

Shock adjustment

After a long time use, the shock need to be adjusted for more tension refer to maintenance and service log, adjust the shock with a special spanner. In other case, the chock nitrogen needs to be added to get more nitrogen pressure; the recommended nitrogen pressure is 1.0MPa/145psi. Adjust the shock refer to the following drawing.

Screw

Taillight cove

Taillight body

Page 63

set up

S(mm)

P(N)

40 0

6793

Front shock spring specification

115

1563

3518

S(mm)

P(N)

35 0

11299

155

2551

Rear shock spring specification

1. Loose the lock nut on the top of the shock spring, and then turn the pushing-nut clockwise to increase tension, and counter clockwise to decrease tension.

Lock nut Pushing nut

Special spanner

Clock wise

Special spanner

Page 64

Chassis wiring diagram

High beam switch 1

High beam R

High beam L

Far beam relay

Dipping switch 1

dipped beam R

Dipped beam relay

Fuse 7.5A

dipped beam L

Clearance lamp

side light *4

Dipping switch 2

High beam switch 2

Turning signa

R *

Turning signa

L *

Turn signal switch

Fuse 5A

Spot relay

Spot switch 1

spot light*4

Fuse 15A

Fuse 20A

Body wiring conn 67

Body wiring conn 82

Body wiring conn 69

Body wiring conn 82

Ignition switc

Battery

IGN 1

IGN 2

I/p wiring conn 21

Fuelsensor

oil pressure switch

oil pressure sensor

Body wiring conn 30

oil pressure warning

water temperatuer warning

Charge indicator

Body wiring conn 28

water temperture Swich

Reverserwarning

High beam switch

Spot light switch 1

Dipping beam switch

Spot light switch

Brakes light R

Brakes light L

Fuse 5A

Brakes light switch

Fuse 5A

Horn button

Horn

button

Master switch

Spot light signal

IGN 1

Battery

IGN 1

Start motor

4WD Convertor

switch

Convertor

Capstan switch

Capstan relay

Reverse light R

Reverse light L

Fuse 5A

Reverse light switch

Body wiring conn

I/p wiring conn

I/p wiring conn 23

I/p wiring conn 27

Spot light switch 2

High beam

switch

Dipping switch 2

High beam switch 1

High beam switch 2

Dipping switch 1

High beam indication

Dipping beam signal

High beam switch 3

ING 2

IGN 2

Wire's colour symbol

B---black R---red BL---blue W---white Y---yellow V---Violet G---Green Br---brown K---pink OR---Orange Gr---Grey CB---Cambridge blue RB---red/black BrB---brown/ Black GY---green/yellow BR---black/red WG---white/green GB---green/black WR---white/red BW---black/white YG---yellow/green

GND

Reverse light switch 1

Fuse 20A

Body wiring conn 99

Page 65

Engine wiring diagram

Page 66

Engine disassembly, installation and repair

Timing Belt

1. Configuration diagram

1 Water pump pulley 2 Timing belt cover. upper 3 Timing belt cover. Lower 4 Torsion shock absorber 5 Timing pulley damper 6 Tensioner 7 Crankshaft timing pulley .8 Timing belt

Page 67

2. Disassembly

2.1. According the right picture, remove

water pump pulley

Torque: 25±1.5 N*m/18.5±1Ft_Lb

2.2. Removing timing belt cover

Torque: 6±1N.m/18.5±0.7Ft_Lb

2.3. Remove tensional vibration damper

2.3.1. Fix the flywheel and prevent the

gear ring from rotating,

2.3.2. Remove bolt of tensional vibration

damper.

2.3.3. Ensure the mark on the timing belt

match the mark on the oil pump

2.4. Remove timing belt covers

Page 68

2.5. Remove the tensioner

2.5.1. Carry out the operation at the upper

thrust point of compression of the first cylinder piston

2.5.2. After removing the timing cover cap,

turn the bolt and rotate the timing gear clockwise with wrench, align timing mark of camshaft timing gear with the cam mark of camshaft

cover cap; 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.

2.5.3. Make sure that the crankshaft timing

pulley wheel mark is aligned with

the mark of the oil pump.

2.5.4. 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

2.7. Remove the crankshaft timing gear

Timing mark

Page 69

2.8. Make careful and detailed checks on the timing belt. Replace with new parts if any

of the conditions shown in the figure occurs.

2.8.1. Cracks on the backside rubber;

2.8.2. Cracks of teeth roots, cracks clearing off the fabric lining layer;

2.8.3. Tears and wears of fabric lining layer, missing rear teeth, broken teeth, etc.

2.8.4. Abnormal tears and wears on belt sides

2.8.5. Even if the damages on the outer appearance can not be confirmed, the belt

should be replaced under any of the following circumstances:

2.8.5.1. If the water in the water pump is leaked, which makes it necessary to refill the

water continuously;

2.8.5.2. 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 P 372-1007081BV Belt wide 27.0 mm/1.06inch

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 372-1007081BV Wide 27.0 mm/1.06inch Outside diameter φ50mm/1.968 inch

Check to see if there are any damages on the outer appearance

Specifications and model of clockwise pulley

Chap

Tears and wears

Abnormal Tears and wears

MIS

Drop-off of belt core

Page 70

Model

ＥＦ

Item ＧＬ、ＺＬ、ＧＳ、ＺＳ Diameter of camshaft timing gear （mm/ inch）

φ110.7

+0.1

-0.2

/φ4.3582

+0.039

-0.078

Diameter of crankshaft timing gear（mm/ inch）

φ54.65

+0.7

-0.13

/φ2.1516

+0.0275

-0.0051

Baffle of crankshaft timing gear

Check to see if there is any deformation Standard size of crankshaft timing gear：

3. Installation

3.1. Installation of crankshaft timing gear

3.2. Installation of timing belt

3.2.1. 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/73.7*3.68Ft-Lb.

3.2.2. Make sure that the punched mark

on the crankshaft clockwise pulley is

aligned with the mark of the oil

pump.

3.3. Install the tensioner

3.3.1. 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/0.3149 inch;

Tighten the bolt of the stretching

wheel with a torque of 25 ±

3N.m/18.4±2.2Ft_Lb. Use a

screwdriver to swing the stretcher

toward the right.

Wide 28.6mm/1.125inch

Page 71

3.3.2. Turn the crankshaft for two circles

towards the engine rotating

direction, so that the camshaft

pulley and the crankshaft pulley

match the clockwise marks

respectively.

3.3.3. Use hands to press down for about

5 mm /0.1968 inch. The force for

pressing the clockwise belt is about:

［Reference］ 20～30 N/4.5～6.7lbf

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/5.62±0.67FT-Lb.

3.4. Install the baffle of the crankshaft-timing pulley [Attention] Install the baffle towards the direction

shown in the right figure.

3.5. Install the tensional vibration damper

(use SST)

3.5.1. When there is not a flying wheel,

3.5.1.1. Fix a part of the crankshaft pulley.

3.5.1.2. Pay attention not to make the gear

belt moving, tighten the bolt according to the specified torque :98.0±10N.m/72±7.37Ft_Lb

Page 72

3.5.2. When there is a flying wheel,

3.5.2.1. Fix the flywheel to prevent the

tooth ring from turning

3.5.2.2. Then tighten bolt of tensional

vibration damper.

3.6. Install timing belt cover

Install seal strip in the position shown as right figure. 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/4.42±0.73Ft-Lb.

3.7 Install water pump pulley Torque: 6±1N.m/4.42±0.73Ft-Lb.

Page 73

Camshaft

1. Configuration diagram

(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

※:Non-reusable part

Unit: N*m/kg*cm/Ft_Lb

Page 74

2. Removal

2.1. 1) Cover-valve chamber

2) Disassembly order of Cover-valve

chamber

2.2. Dismount the timing belt sprocket

with a special tool.

Attention: Manufacture a special tool according the right figure A special tool is needed to prevent the camshaft from rotate, See figure below.

2.3. Removal of camshaft bearing cover

2.3.1. Align the marks on the camshaft

gears as shown in the right figure.

Timing mark

Air outlet camshaft gear

Air inlet camshaft gear

Page 75

2.3.2. 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)

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.

2.6.1. 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.

2.6.2. 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.

Screw

Bolt

Fixer

Page 76

2.7. Camshaft

2.7.1. Use the caliper to measure the

height of the camshaft. If it is below

the specified limits, make proper

replacement. Camshaft Unit：mm /inch

Model

Item ZL、RL

GL、GS、

Stan dard

φ23.0

-0.02

-0.033

/φ0.9055

-0.0008

-0.0013

φ23.0

-0.02

-0.033

/φ0.9055

-0.0008

-0.0013

Limit

φ22.9/φ0.9016

2.7.2. Checks on camshaft axial clearance (1)、When the axial spacing is measured with a clipper to be larger than the benchmark value, the camshaft is to be replaced. The air inlet camshaft axial clearance is 0.1～0.170mm/0.0039～

0.0067inch。The air exhaust camshaft axial spacing is 0.1 ～0.173mm/0.0039～

0.0068 inch。Limits for operation：

0.18mm/0.007 inch.

2.7.3. 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

3.1.1. Fix the two φ6 holes of the camshaft gear S/A.

3.1.2. Turn the slave gear to the right, match the mark

Page 77

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)

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.

3.3. Installation of the camshaft Attention: Size of the axial clearance of

the camshaft

3.3.1. Smear lubricating oil at the

camshaft gear section and the

cylinder cover axial diameter

section.

3.3.2. Fix the camshaft slave gear by

roughly adjusting on the cylinder

cover.

3.3.3. Install camshaft, the timing mark

must be aligned shown as the right

figure.

3.3.4. Smear lubricating oil on the

camshaft assembly, the gears and

the cylinder head axial diameter

section.

3.4. Tighten the camshaft-bearing cap

shown as right figure.

3.5. Remove the bolt for fixing the slave

gear of the camshaft assembly.

Fixer

Bolt

Timing mark

Air outlet camshaft gear Air inlet camshaft gear

Fixer

Page 78

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.

3.6.1. Tighten the bolts according to the

sequences shown as the right figure

with the specified torques.

3.6.2. 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/0.0394±0.0394inch。

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 50-60 mm/ 1.9685-2.3622inch) and SST press the cylinder, lower 1mm/0.0394 inch 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.

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/73.7±3.6Ft_Lb.

Sealing line

Outside

Page 79

Attention: process the special tool according the right figure.

3.9. Installation of cylinder head gasket

3.9.1. Clean the the used cylinder head

gasket

3.9.2. Put new one into the groove on the

timing-belt cover accurately

3.9.3. Cover the cylinder head with

cylinder head cover; tighten the

bolts according the right figure. Torque: 6±1N.m /6±0.7Ft_Lb.

4. Routine check

4.1. Standard of valve clearance:

4.2. Align the timing marks on the

drive-gear and driven-gear.

4.3. Use a plug gauge to measure the

clearance according the right figure

First cylinder

Second cylinder

Third cylinder

Fourth cylinder

I N

IN E

O O O — — O — —

valve

clearance

0.18±0.05mm/0.007±0.002

0.25±0.05mm/0.0098±

Timing mark

Air outlet camshaft gear Air inlet camshaft gear

Page 80

4.4. Rotate camshaft a round, keep the

position as the right figure, measure the clearance again.

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

4.4.1. Rotate camshaft to make the

cam-top (valve clearance exceed

the standard) upwards, and gap of

valve lifter towards inside.

4.4.2. Rotate camshaft and the cam press

valve lifter down.

4.4.3. 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.

4.4.3.1. Move the adjusting washer out

with a screwdriver, and then remove the washer with a magnet iron wire from inside.

First cylinder

Second cylinder

Third cylinder

Fourth cylinder

IN EX IN EX IN EX IN EX

— — — O O — O O

Page 81

4.4.3.2. Use a caliper to measure and

adjust the thickness of the separation cushion.

4.4.3.3. Select proper separation cushion

on the basis of the throttle

thrusting rod benchmark values. (1). IN Selected cushion thickness = removed cushion thickness + (measured throttle spacing – 0.18mm/0.007inch) (2). EX Selected cushion thickness = removed cushion thickness +(measured throttle spacing –0.25mm/0.0098inch)

[Reference] there are 32 kinds of shim’s thickness Shown as the illustration (mm/inch)

4.4.3.4. Use the selected adjusting gasket

to adjust the throttle clearance. Attention Install the feeler with the identification mark facing downwards.

4.4.3.5. Rotate camshaft to make cam-top

downwards, and the throttle to be

pressed down, and then take

special tool out

4.4.3.6. Rotate camshaft 2-3 round, and

then recheck the valve clearance,

if valve clearance can’t get to the

standard, repeat 4.1-4.4 to adjust

the valve clearance.

2.18/0.0858 2.4/0.0944 2.62/0.1031

2.2/0.0866 2.42/0.0952 2.64/0.1039

2.22/0.0874 2.44/0.0960 2.66/0.1047

2.24/0.0881 2.46/0.0968 2.68/0.1055

2.26/0.0889 2.48/0.0976 2.7/0.1062

2.28/0.0897 2.5/0.0984 2.72/0.1070

2.3/0.0905 2.52/0.0992 2.74/0.1078

2.36/0.0929 2.58/0.1015 2.8/0.1102

2.32/0.0913 2.54/0.1 2.76/0.1086

2.38/0.0937 2.6/0.1023

Underside

Page 82

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

Page 83

2. Dismounting

2.1. Removal of spark plug

2.2. There are 8 cylinder cover bolts. In

the process of removing the cylinder, please follow the sequences shown as the right illustration, loosen the bolts one by one evenly and gently.。

2.3. Removal of the cylinder dustproof

sealing and cylinder cover base.

Attention The cylinder cushion cannot be used repeatedly.

2.4. 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/0.0039inch Air inlet branching pipe surface 0.10 mm/0.0039inch

Page 84

3.2. Valve spring

3.2.1. Use a square ruler to measure the right

angle of the valve spring. Replace the spring if it fails to meet the specifications.

[Limit] 1.2mm/0.0472inch

3.2.2. Measure the free state of spring [Benchmark value] 37mm/1.4567 inch

3.3. Routine checks on throttles

3.3.1. Check to see if there are some

deformations, obvious tears and wears

Check list on valve Unit: mm/inch

3.3.2. Checks on the clearance between

the throttle guiding pipe and throttle thrusting rod .

3.3.2.1. Use a dial gauge to measure the

inner diameter of the

throttle-guiding pipe, and use a

caliper to measure the outer

diameter.

3.3.2.2. 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

wide

0.85 ～ 1.41/ 0.0335 ～

0.0555

—

EX 1.07～1.36 /0.042～0.0535 —

Width of valve top

IN 1.0±0.2 /0.0394±0.0078

0.75/

0.0295

EX 1.0±0.2 //0.0394±0.0078

0.75/

0.0295

item standard limit

Valve guide Inside

diameter(mm/inch)

φ5.0 /0.1968 —

Valve stem outside

diameter (mm/inch)

φ5.0 /0.1968 —

Spacing

(mm/inch)

0.056～0.020/

0.0022～0.0008

0.07/0.0027

0.066～0.030/

0.0026～0.0012

0.08/0.0031

Page 85

3.3.3. Replacement of valve guide

3.3.3.1. Heat the cylinder cover to 176～

212℉ with hot water.

3.3.3.2. Use special tools to drive in the

valve-guiding pipe to the position

as shown in the right figure from

the side of the combustion

chamber. Attention The removed guiding pipe cannot be used repeatedly. The air intake and exhaust valve guiding pipes should not be mixed up in installation.

3.3.3.3. 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

3.3.3.4. Use reamer to grind the inner

diameter to achieve the standard

value of the clearing.

3.3.4. Valve mating surface

3.3.4.1. 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.

model EF

item GL,ZL,RL,GS,ZS

Height (mm/inch)

IN 13.71±0.25/0.5398±0.0098 EX 12.11±0.25/0.4768±0.0098

For IN

For EX

Page 86

3.3.4.2. 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.

3.3.4.3. Use a 45 degree cone as the

mating benchmark value.

3.3.4.4. Check the mating position of the

throttle. If it is in the center of the

valve, the position is the best one.

If not, proper corrections have to

be made.

3.3.4.5. Make conic cutting at the center of

the mating position with 70

degrees toward inwards and 30

degrees outwards.

3.3.4.6. Use polishing agent to grind and

polish the throttle sealing.

3.4. Assemble of cylinder head

3.4.1. Cylinder head Pay attention to the following instructions in the process of assembling for the other accessories on the cylinder cover.

3.4.2. 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

Page 87

3.4.3. Installation

3.4.3.1. Installation of valve spring

washer and valve oil sealing

3.4.3.1.1. 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.

3.4.3.2. Installation of IN and EX

3.4.3.2.1. Assembling of valve springs Attention It is for you to distinguish the different suppliers by means of paintings on the valve spring, valve spring of same engine should have the same identification paint marking.

3.4.3.3. 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.

3.4.3.4. Installation of the throttle

thrusting rod and throttle spacing by adjusting the separation cushions

3.4.3.5. Install the cylinder cover base,

make identification of the marks for the front and rear directions.

Sub stool

Valve

Oil sealing

Spring bottom plate

Page 88

3.4.4. Assembling of dustproof sealing

strip and cylinder cover

3.4.4.1. Apply lubricating oil at the threads

and grooves of the bolts.

3.4.4.2. 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 /22±

1.5Ft_Lb; the torque for the second tightening operation is 50±3N.m /36±2.2Ft_Lb; And the torque for the third tightening operation is 70±3.5 Nm /51±

2.5Ft_Lb.

3.4.4.3. Installation of the spark plug

[Torque] 20±1Nm /14±0.7Ft_Lb Attention: The tools should be placed

vertically, so as not to make the spark plug insulator become deformed, otherwise it is easy to leak oil.

Page 89

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

2. Dismounting

2.1. Dismounting and removal of O-shaped ring Attention: These rings are not reusable.

2.2. Removing the three bolts and dismount the water pump principal body.

2.3. Removal of the dustproof sealing stripe

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/18±1Ft-lb

5.3. Install the new O-rings

※:Non-reusable part Unit: N*m/kg*cm/Ft_Lb

Page 90

Oil pump

1. Configuration diagram (The dismounting and installation of the lubricating oil pump

should be carried out according to the following procedures).

○

1 Oil pan，tighten bolt：8±2 Nm/5.9±1.47Lb_Ft ② 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.

Non-reusable part

Page 91

2.2. Remove the oil collecting filter and its

flange

Attention The filter flange is not reusable.

2.3. Dismount the oil pump assembly and

oil pump cushion

2.4. Dismounting of oil seal stand

3. Clearing

3.1. For the mating surfaces of the oil

bottom case, oil pump and oil seal stands, for the mating surfaces of the rear oil seal stand and oil pump scraper and chipping chisel or some other tools may be used to clear the used ones.

Attention Do not drop the residues into the cylinder body.

Page 92

4. Disintegration and assembling of oil pump

4.1. Configuration diagram

1 Weather seal 2 Oil pump cover plate3 Driven rotor4 Drive rotor5 Split pin6 Relief valve spring seat7 Relief valve spring8 Relief valve9 Crankshaft front oil sealing10 Oil pump body

4.2. Disintegration

4.2.1. Weather seal Attention The weather seal are not reusable.

4.2.2. Remove the oil pump cover Attention: The bolt is assembled with glue; loosen it with screw driver according to the illustrations

4.2.3. Remove the driven and drive rotor

of the oil pump

※:Non-reusable part

Unit: N*m/kg*cm/Ft-lb

Page 93

4.2.4. 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 suddenly, while taking off the open pins.

4.2.5. Removal of the oil pump pressure

relief valve spring stand, spiral

spring, oil pump pressure relief

valve

4.2.6. Removal of the front oil seal of the

crankshaft Attention The removed oil seals are not reusable.

4.3. Routine checks

4.3.1. Checks on lubricating oil pump

spacing

4.3.1.1. 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.

4.3.1.2. Use a feeler to measure the clearance between the interior gear and the exterior gear

[Benchmark]

0.05-0.18mm/0.002-0.007inch(average of 9 points) [Limit] 0.35 mm/0.0137inch

MARK

Page 94

4.3.1.3. Use a feeler to measure the

clearance between the rotator and the pump body

[Benchmark]

0.10-0.181mm/0.004-0.0071 [Limit] 0.25mm/0.0098inch

4.3.2. Routine checks on the pressure

relief valve

4.3.2.1. Remove the pressure relief valve,

there should be no visible tears, wears and scrapes on the pressure relief valve

4.4. Installation

4.4.1. 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/0.0197inch.

4.4.2. Assembling of the oil pump

pressure relief valve and split pins Attention The split pins are not reusable.

Page 95

4.4.3. 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.

4.4.4. The new weather seal should be put

inside the oil pump cover groove.

5. Disintegrating and assembling of oil seal

5.1. Configuration diagram

Mark

※:Non-reusable part

Unit: N*m/kg*cm/Ft_Lb

Page 96

5.2. Disintegration

5.2.1. Use a flat screwdriver to remove the

rear oil seal.

Attention The oil seals are not reusable.

5.3. Checks

Check to see if the tears and wears of the lip section of the oil seals are within the normal conditions, and if there are any damages in outer appearance.

5.4. Assembling

5.4.1. Smear lubricating oil on the new

oil seal lip section.

5.4.2. 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

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/0.118-0.157inch.

[Torque] 25±1.5N*m/18±1Ft_Lb

6.2. Assembling of new oil pump

washer, oil pump assembly [Torque] 20±1.5N*m/14.5±1Ft_Lb

Oil sealing lip

SST

Seal line

Page 97

6.3. Installation of new lubricating oil collecting and filtering device, oil pump collecting and filtering device

[Torque] 6±1N*m/4.4±0.7Ft_Lb

6.4. Assembling of oil pan

6.4.1. Clear the mating surface with the cylinder body

6.4.2. Apply sealing silica before assembling [Grease] Letai 5699

Attention

·The liquid cushion with silica line diameter of Ф3-4mm/Ф0.1181-0.1574inch, without any broken section

·Make the assembly in 15 minutes after the application of silica

6.4.3. Tighten in the sequence shown in the right figure with the torque of 6±1N*m/4.4±0.7Ft_Lb from the center to the two sides

Front

Rear

Page 98

Crankshaft connecting rod mechanism

1. Configuration diagram (Dismount and assemble the oil pump in the follow

sequence)

(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

※:Non-reusable part

Unit: N*m/kg*cm/Ft_Lb

Page 99

2. Disintegration of crankshaft connecting rod mechanism

2.1. Check the connecting rod axial clearance

2.1.1. Use centimeter or feeler to measure axial spacing

[Benchmark]:0.15-0.24mm/0.0059-0.0094inch [Limit]:0.30mm/0.0118inch

2.2. Check the connecting rod bush vertical

clearance

2.2.1. Remove the bush cover Attention: Parts and components of various cylinders should be placed in good order.

2.2.2. Clean the bush and axle diameter

2.2.3. Place clearance gauge on the

connecting bearing diameter. Tighten bush cover according to regulated torque

torque: 40±2N*m/28±1.5Ft_Lb

Attention Do not turn the crankshaft

2.2.4. Remove the bush cover, measure the

maximum width of the spacing ruler [Benchmark]: 0.020-0.044 mm/0.0008-0.0017inch [Limit]: 0.07 mm/0.0027inch

Page 100

100

2.2.5. 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.

2.2.6. Removal of connecting rod bearing cover

and connecting rod bush

2.2.7. 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.

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]:0.089-0.211mm/0.0035-0.0083inch [Limit]:0.30mm/0.0118inch

item

Benchmark value

Thickness of thrust Face(mm/inch)

1.9

-0.03

-0.11

/0.0748

-0.0012

-0.0043

Connecting rod bush

Connecting rod cover

Lagging cover