JNSZ800UV-R4 - JMC Motors · Thank you for choosing JOYNER JNSZ800UV-R4. It ... 4 Q33008 HEXAGON...

Parts manual

JNSZ800UV-R4

1

INTRODUCTION

Thank you for choosing JOYNER JNSZ800UV-R4. 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.

14

PARTS MANUAL ................................................................................................................................................... 143

1.ENGINE .................................................................................................................................................................. 1.COOLING SYSTEM..................................................................................................................... 143 2.CYLINDER BLOCK..................................................................................................................... 144

3.CRANKSHAFT ................................................................................................................................... 4.EXHAUST MANIFOLD ............................................................................................................... 146 5.INTAKE SYSTEM ........................................................................................................................ 147 6.LUBRICATING DEVICE ............................................................................................................. 149 7.CYLINDER HEAD ....................................................................................................................... 150 8.COVER-VALVE CHAMBER ....................................................................................................... 152 9.OIL PAN ........................................................................................................................................ 153 10.VALVE MECHANISM ............................................................................................................... 154 11.IGNITION DEVICE .................................................................................................................... 156 12.PISTON AND CONNECTING ROD DEVICE .......................................................................... 157 13. OTHER ACCESSORY 1 ............................................................................................................ 158 14. OTHER ACCESSORY 2 ............................................................................................................ 159

15

2. 5T07D1 TRANSMISSION .................................................................................................................................. 160

1 CASE&ACCESSORY ....................................................................................................................................... 160 2 COUNTERSHAFT ............................................................................................................................................ 162 3 INPUT SHAFT ASSY ........................................................................................................................................ 164 4 SHIFT FORK&SHIFT－FORK SHAFT ........................................................................................................... 167 5 SHIFT CONTROL MACHINSM ....................................................................................................................... 169 6.DRIVEN GEAR ASSY ...................................................................................................................................... 160

3 PARTS MANUAL ................................................................................................................................................ 161

1.FRAME ................................................................................................................................................................ 161 2 ROLL BAR AND REARVIEW MIRROR ..................................................................................................................... 162 3 FRONT PROTECT BAR AND SMALL SPOT LIGHT .................................................................................................... 163 4 CARGO BED ......................................................................................................................................................... 164 5 ELECTRICAL WINCH ............................................................................................................................................ 165 6 ENGINE AND MUFFLER MOUNT ASSY ................................................................................................................... 166 7 DRIVEN SYSTEM .................................................................................................................................................. 168 8 FRONT/REAR DIFFERENTIAL LOCKING ................................................................................................................ 171 9 GEAR SHIFT ......................................................................................................................................................... 172 10 THROTTLE AND PARK BRAKING .......................................................................................................................... 174 11 FRONT SUSPENSION SYSTEM ............................................................................................................................ 177 12 REAR SUSPENSION SYSTEM ............................................................................................................................... 179 13 STEERING ASSEMBLY ......................................................................................................................................... 181 14 RADIATOR ASSEMBLY ........................................................................................................................................ 184 15 GASOLINE AND AIR TAKING ............................................................................................................................... 187 16 PLASTIC PARTS .................................................................................................................................................. 190 17 ELECTRICAL APPLIANCE AND OTHER PARTS ...................................................................................................... 192 18 SEATS AND SAFETY BELTS ................................................................................................................................ 195 19 SPOT LIGHT ....................................................................................................................................................... 197 20 HYDRAULIC PUMP ASSEMBLY OF FOOT BRAKE ................................................................................................ 198 21 HYDRAULIC PUMP ASSEMBLY OF PARKING BRAKE .......................................................................................... 199 22 CLUTCH HYDRAULIC ASSEMBLY....................................................................................................................... 200

143

PARTS MANUAL

1. ENGINE

1. COOLING SYSTEM

No Part number Name Quantity 1 Q1400612 HEXAGON HEAD BOLT 4

2 372-1307014 WATER PUMP PULLEY 1

3 Q1840840 HEXAGON FLANGE BOLT 1

4 Q1840855 BOLT（M8X55） 1


6 372-1307010 WATER PUMP SET 1

7 372-1307015 ‘O’ RING 1

8 372-1307041 WATER PUMP WASHER 1

9 372-1307018 SEAL STRIP 2 1 10 Q1840825 BOLT 3

11 372-1307019 SEAL STRIP 3 1

12 372-1307012 SEAL STRIP 1 1

13 50-'O' 'O' RUBBER RING 1

14 372-1306016 SEAT - THERMOSTAT OUTER 1

15 372-1306020 THERMOSTAT ASSY 1

16 372-1306001 SEAT - THERMOSTAT 1


18 372-1306012 SEAT - THERMOSTAT INNER 1

19 372-1306018 SEAT - THERMOSTAT 1

1

11 10

9

8 7

6

5

4

3

2

17

16-

15

14

19

18

13 12

144

2. CYLINDER BLOCK

No Part number Name Quantity 1 372-1002010 CYLINDER BLOCK ASSY 1

2 372-1002037 POSITION PIN 6

3 372-1002046 CRANKCASE VENTILATION PIPE 1

4 372-1002044 CYLINDER HEAD SEAL PLUG 2


6 372-1002060 KNOCK SENSOR 1

7 372-1002036 POSITION PIN 2

8 372-1002070 OIL PRESSURE SWITCH 1

9 372-1000410 ENGINE ASSY 1

10 11G10GB308 BALL - STEEL 1

11 372-1002023 BOLT - MAIN BEARING CAP 8

12 372-1002045 CAP - OIL CONTROL 1

13 372-1012021 CONNECTOR - OIL FLITER 1

14 372-1014110BA PIPE - CRANKCASE VENTILATION 1

15 372-1014130BA PIPE(3) - CRANKCASE VENTILATION 1

1

2

3

4

5 6

7

15

8

11

12

9

14

13

10

145

3. CRANKSHAFT

No Part number Name Quantity 1 372-1005031 PULLEY BOLT 1

2 372-1005040 TORSION SHOCK ABSORBER ASSY 1

3 372-1005018 CRANKSHAFT TIMING GEAR 1

4 372-1005017 TOOTHED BELT BAFFLE 1

5 372-1005015 CRANKSHAFT FRONT OIL SEAL 1

6 372-1005033 NEEDLE BEARING 1

7 372-1005032 WOODRUFF KEY 1

8 372-1005010 CRANKSHAFT ASSY 1

9 372-1005016 STOPPER PLATE 2

10 S11-1601101 COVER SET BOLT 4

11 372-1DF1005010 BEARING - CRANKSHAFT 4

12 372-1005036 PIN - DOWEL 1

13 372-1005030 REAR OIL SEAL 1

14 372-1005021 REAR OIL SEAL BRACKET 1


16 372-1005050 FLYWHEEL ASSY 1

17 372-1005054 LOCK-FLY WHEEL BOLT 6

18 S11QZ-QZWZCGQ CRANKSHAFT POSITION SENSOR 1

19 S11-1601020 COVER SET 1

20 S11-1601030 DRIVEN DISK ASSY 1

1

2 3 4 5

7 8

9

13 14 15

16

17

18

12 6

20

10

19 11

146

4. EXHAUST MANIFOLD

No Part number Name Quantity 1 372-1008033 EXHAUST MANIFOLD WASHER 1

2 SQR7080PQQG-PQQG EXHAUST MANIFOLD 1

3 Q1200825F3 STUD 4

4 Q33008 HEXAGON NUT 6

5 372-1008044 HEAT INSULATOR 1

6 Q1460612 HEXAGON HEAD BOLT 4

7 S11-1205110 OXYGEN SENSOR 1

8 Q1200835F3 STUD 1

9 S11-3724863 OXYGEN SENSOR BRACKET 1

1

2

3

4

5

6

7

9 8

147

5. INTAKE SYSTEM

No Part number Name Quantity 1 Q1420625 HEXAGON HEAD BOLT 4

2 372-1107011CA BODY - THROTTLE 1

3 372-1107012 THROTTLE BODY WASHER 1


5 372-1008043 ACCELERATOR PULLING WIRE BRACKET 1

6 S11-1109411 INTAKE TEMPERATUREAND PRESSURE SENSOR 1


8 372-1008013 MANIFOLD - AIR INTAKE 1


10 S11-1112030 OIL RAIL 1

11 S11-1112010 INJECTOR ASSY 3

12 Q1200835F3 STUD 2

13 Q1200828F3 STUD 4

14 372-1008021 INTAKE MANIFOLD WASHER 1

15 Q1200840F3 STUD 1

7

9

29

6

10

11

12

13

14

31

16 17 19

18

21 23

25

15

28

8

5

4 26

3 2

1

20

22

27

30

148

5. INTAKE SYSTEM

No Part number Name Quantity 16 372-1008041 INTAKE MANIFOLD FRONT BRACKET 1

17 372-1008042 INTAKE MANIFOLD REAR BRACKET 1

18 372-1014150 FIXING CLAMP 1


10 372-1014120 CRANKCASE VENTILATION PIPE (2) 1

21 372-1014140 OIL-GAS SEPARATOR ASSY 1





27 372-1008082EA BRACKET - INLET MANIFOLD 1

28 372-1014140AB SEPARATOR - TEMPERATURE SELFCONTROL 1

29 372-1107051 SENSOR - THROTTLE POSITION 1

30 S11-1008020FA BRAKET - THROTTLE 1

31 S11-1109416BA HOSE- PVC VALVE TO AIR INTAKE PIPE 1

7

9

29

6

10

11

12

13

14

31 16 17 19

18

21 23

25

15

28

8

5

4

3 2

1

20

22

27

30

149

6. LUBRICATING DEVICE

No Part number Name Quantity 1 372-1012010 OIL FILTER ASSY 1

2 372-1009130 OIL DIP STICK ASSY 1

3 372-1009120 OIL DIP STICK PIPE ASSY 1

4 372-1011055 SEAL STRIP 1

5 372-1011021 OIL PUMP WASHER 1

6 372-1011030 OIL PUMP ASSY 1

7 Q1840825 BOLT 1

8 Q1840855 BOLT（M8X55） 2


10 372-1010017 OIL STRAINER WASHER 0

11 Q1200616 STUD 2

12 Q33006 HEXAGON NUT 2

13 372-1010010 OIL STRAINER ASSY 1



1

2

3 4

5

6

7

8

9

10

11

12

13

14

15

150

7. CYLINDER HEAD

No Part number Name Quantity 1 372-1003074 SPARK PLUG SLEEVE 3


3 372-1003051 CYLINDER HEAD BOLT 8

4 372-1003052 CYLINDER HEAD BOLT WASHER 8

5 S11-3808013 WATER TEMP SENSOR 1

6 S11-1003069 CAMSHAFT POSITION SENSOR 1


8 372-1003023 GUIDE - VALVE 12

9 372-1003022 EXHAUST VALVE SEAT INSERT 6

10 372-1003021 INTAKE VALVE SEAT INSERT 6

11 372-1003040 GASKET - CYLINDER HEAD 1

12 372-1003202 FRONT TRUNNION 1


14 372-1003067 BLOCK COVER 1

15 372-1003066 CAMSHAFT OIL SEAL 1

16 372-1003010 HEAD ASSY - CYLINDER 1

1

19 2

3

4

5

6 7

20 22

24

10 9

11

12 13

14

15

16

21

23

17

18

8

151

7. CYLINDER HEAD

No Part number Name Quantity 17 372-1003063 CAMSHAFT BEARING CAP POSITION COVER 8

18 S11-3808010 WATER TEMP. SENSOR SET 0

19-1 372-1003201 HANGER - REAR ENGINE 0

19-2 372-1003201BA HANGER - REAR ENGINE 1

20 372-1003001 HEAD ASSY - CYLINDE 1

21 372-1003024 PLUG - BOWL SHAPE 1

22 372-1003028 PLUG 1

23 372-1003038 STUD 1

24 372-1003076 BUSH - WATER PROOF 1

1

19-1

19-2 2

3

4

5

6 7

20 22

24

10 9

11

12 13

14

15

16

21

23

17

18

8

152

8. COVER-VALVE CHAMBER

No Part number Name Quantity 1 372-1003090 OILING PORT COVER ASSY 1

2 Q2540616 SCREW 6

3 372-1003075 ENGINE TRIMING COVER ASSY 1

4 372-1003030 COVER ASSY - ROCKER 1

5 372-1003036 CYLINDER HEAD COVER GASKET 1


1

3

2

4

5

6

153

9. OIL PAN

No Part number Name Quantity 1 372-1009010 OIL PAN ASSY 1


3 372-1009017 SEAL WASHER-OIL DRAIN THREADED PLUG 1

4 372-1009014 MAGNET PLUG 1

1 1

2 1

3 1

4 1

154

10. VALVE MECHANISM

No Part number Name Quantity 1 372-1007030 TENSIONING PULLEY ASSY 1



4 372-1007040 TIMING GEAR COVER ASSY 1



7 Q43140 SHIELD-SHAFT SPRING RING 1

8 372-1006032 SADDLE FLIP WASHER 1

9 372-1006031 DRIVE RING 1

10 372-1006041 GEAR ( SUB ) - INTAKE CAMSHAFT 1

11 372-1006030 GEAR (MAIN ) - INTAKE CAMSHAFT 1

1 2

3 4

5

6

35 36

29 33

28

27

26

25

24

21

23

22

20

32

19 18 17

16 15 14

13

12

7 8 9 10 11

31

30

155

10. VALVE MECHANISM

No Part number Name Quantity 12 372-1006020 CAMSHAFT ASSY - INTAKE 1

13 372-1006071 HEXAGON FLANGE BOLT 1

14 372-1006066 TIMING BELT SPROCKET 1

15 372-1006064 LOCK-CLUTCH HUB NUT 1

16 Q2180620 INNER HEXGON HEAD BOLT 4

12 372-1006020 CAMSHAFT ASSY - INTAKE 1

13 372-1006071 HEXAGON FLANGE BOLT 1

14 372-1006066 TIMING BELT SPROCKET 1

15 372-1006064 LOCK-CLUTCH HUB NUT 1

16 Q2180620 INNER HEXGON HEAD BOLT 4

17 372-1006063 COUPLING FLANGE 1

18 372-1006062 EXHAUST CAMSHAFT GEAR 1

19 372-1006060 CAMSHAFT ASSY - EXHAUST 1

20 372-1007017 ADJUSTMENT WASHER 12

21 372-1007018 VALVE LIFTER 12

22 372-1007019 VALVE LOCK BLOCK 24

23 372-1007021 EDDY SLEEVE 12

24 372-1007014BA UPPER VALVE SPRING SEAT 12

25 372-1007013 VALVE SPRING 12

26 372-1007020 VALVE SEAL 12

27 372-1007016 LOWER VALVE SPRING SEAT 12

28 372-1007012 EXHAUST VALVE 6

29 372-1007081 TOOTHED TIMING BELT 1

30 372-1007011 INLET VALVE 1

31 372-1006042 PIN - GEAR 1

32 372-1006067 PIN - STOPPER 1

33 372-1007014 SEAT - VALVE SPRING UPPER 1

34 Q673B155 CLAMP 1 35 472-1007042 LOWER TIMING GEAR COVER 1 36 480-1011062 BOLT 1

156

11. IGNITION DEVICE

No Part number Name Quantity 1 S11-3705100 IGNITION COIL 3

2 Q2320525 SCREW AND WASHER UNIT 6

3 S11-3705001 IGNITION COIL BRACKET 1

4 S11-3707100 SPARK PLUG ASSY 3


6 S11-3707040 HI.TENSION CORD NO.3 1

7 S11-3707030 HI.TENSION CORD NO.2 1

8 S800.04.01.05.00-R2 HI.TENSION CORD NO.1 1

9 S11-3724183 CLIP 0

1

2

3

4

6

8

5

7

9

3

157

12. PISTON AND CONNECTING ROD DEVICE

No Part number Name Quantity 1 372-1DE1004030 RING ASSY - PISTON 1

2 372-1004031 PISTON PIN 3

3 372-1004021 PISTON 3

4 372-1004110 CONNECTING ROD ASSY 3

5 372-1DF1004110 BEARING - CONNECTING ROD 6

1 1

3 1

4 1

5 1

2 1

158

13. OTHER ACCESSORY 1

No Part number Name Quantity 1 S11-3724180CA Engine Harness 1 2 S11-3605010BA-1 372 ECU 1 3 SV1100.05.02.01.00 Shift Bracket 1 4 S11-1206211 carbon can PCV 1 5 S11-3708110BA Starter assembly 1 6 S11-1700103 lower Steel cushion 1 7 S11-1200011CA Single Exhaust Gasket 1 8 Q1841245 Hex socket head bolt M12*45 1 9 Q218B1245 Bolt 12*45 1 10 Q1841240 Bolt 12*50 2 11 372-1002030 Upper steel cushion 1 12 S11-3708111 locating dowel 2 13 Q1840845 Bolt 8*45 2 14 Q1840850 Bolt 8*50 1 15 S11-3802020 Electric odometer sensor assy 1

1

3

4

5 7 6

4

2

3

12 8

9

10

11

13

14

15

159

14. OTHER ACCESSORY 2

No Part number Name Quantity

1 S11-3701110BB Alternator 1 2 S11-3701211BA Alternator bracket 1 3 S11-1001415BA Rear bracket 1 4 S11-3701315 V-ribbed belt 1

1

4

2

3

160

2. 5T07D1 TRANSMISSION

1 CASE&ACCESSORY

Ref Part No. Part Description Qty Comments 1 QR512－1701101 Clutch case 1 2 4T08A1－1701111 Transmission case 1 3 5T07－1701020 Side cover 1 4 5T07－1702010 Declutch bearing 1 5 5T07－1702020A Declutch fork 1 6 5T07－1702004 Clutch fork 2 sleeve 1 7 5T07－1702030 Clutch fork seal 2 8 5T07－1702001 Clutch fork 1 sleeve 1 9 QR512－1701103 Double－screw rod 2 10 5787－M8x40 Flange bolt M8x40 12

161

1 CASE&ACCESSORY

Ref Part No. Part Description Qty Comments 11 5T07－1701001 Locating pin 2 12 5T07－1701002 Oil plug screw 1 13 5T07－1701003 Screw plug washer 2 14 5T07－3729010 Back－up light switch 1 15 5T07－1701058A Double－screw rod 1 16 5T07－1701009 Bearing stop plate 1 17 5T07－1701004 Oil－stop plate 1 18 5787－AM6X12 Flange bolt M6x12 2 19 7246－W6 Flat washer 6 4 20 5T07－1701400 Oil groove 1 21 S800.04.01.02.01－R2 Clutch rocker 1 22 5787－AM8X35 Flange bolt M8x35 1 23 6177.1－8 Flange nut M8 1 24 5T07－1701603 Side cover bolt 8 25 QR512－1602113 Declutch release spring 1 26 S800.04.01.02.00－R2 5T07D1 Transmission assy 1

162

2 COUNTERSHAFT

Ref Part No. Part Description Qty Comments

1 QR512－1701401 Output shaft 1 2 QR512－1701410 First gear assy 1 3 QR512－1701420 Second gear assy 1 4 QR512－1701441 Third gear 1 5 QR512－1701461 Fourth gear 1 6 5T07－1701610 Front bearing of output shaft 1 7 5T07－1701240 Needle bearing of 1ST&2ND gear 2 8 QR512－1701439 Synchronizer out ring of 1ST&2ND gear 2 9 QR512－1701406 Synchronizer middle ring of 1ST&2ND gear 2 10 QR512－1701435 Synchronizer inner ring of 1ST&2ND gear 2 11 QR512－1701430 Synchronizer of 1ST&2ND gear 1

163

2 COUNTERSHAFT

Ref Part No. Part Description Qty Comments 12 QR512－1701433 Synchronizer spring of 1ST&2ND gear 2 13 QR512－1701434 Synchronizer gear－hub of 1ST&2ND gear 1 14 QR512－1701431 Synchronizer gear-sleeve of 1ST&2ND gear 1 15 QR512－1701432 Synchronizer gear block of 1ST&2ND gear 3 16 5T07－1701205 Synchronizer retainer of 1ST&2ND gear 1 17 5T07－1701202 Spacer of 3RD&4TH gear 1 18 5T07－1701250 Rear bearing of output shaft 1 19 QR512－1701187 Adjusting washer of rear bearing Demand 20 4T08A－1701402 Countershaft sleeve 1 21 MQC4－1701219 Countershaft nut 1 22 4T08A1－1701400 Countershaft assy 1

164

3 INPUT SHAFT ASSY


1 QR512－1701201 Input shaft 1 2 5T07－1701080 Input shaft seal 1 3 4T08－1701130 Bearing 6204/YA/P63 1 4 QR512－1701240 3TH gear assy 1 5 5T07－1701150 Needle bearing of 3RD&4TH gear 2 6 QR512－1701257 Synchronizer ring of 3TH&4TH＆5TH gear 1 7 QR512－1701250 Synchronizer assy of 3TH&4TH 1 8 QR512－1701252 Synchronizer gear－hub of 3TH&4TH gear 1 9 QR512－1701251 Synchronizer gear-sleeve of 3TH&4TH gear 1 10 QR512－1701254 Synchronizer spring of 3TH&4TH＆5TH gear 1 11 QR512－1701253 Synchronizer gear block of 3TH&4TH gear 3

165

3 INPUT SHAFT ASSY


12 5T07－1701103 Synchronizer retainer of 3TH&4TH gear 1 13 QR512－1701258 Synchronizer waveform washer ring 1 14 QR512－1701260 4TH gear assy 1 15 5T07－1701110 Back bearing of input shaft 1 16 QR512－1701285 Spacer of 5TH gear 1 17 QR512－1701200 Input shaft assy 1 18 QR512－1701287 Adjusting washer of rear bearing Demand 19 QR512－1701280 5TH gear assy 1 20 QR512－1701257 Synchronizer ring of 3TH&4TH＆5TH gear 1 21 QR512－1701258 Synchronizer waveform washer ring 1 22 QR512－1701290 Synchronizer assy of 5TH gear 1

166

3 INPUT SHAFT ASSY


23 QR512－1701254 Synchronizer spring of 5TH gear 2 24 QR512－1701293 Synchronizer gear block of 5TH gear 1 25 QR512－1701292 Synchronizer gear－hub of 5TH gear 1 26 QR512－1701291 Synchronizer gear－sleeve of 5TH gear 1 27 QR512－1701294 Synchronizer ring of 5TH gear 1 28 QR512－1701298 Nut of 5TH gear synchronizer 1 29 QR512－1701710 Reverse gear 1 30 5T07－1701053 Ring of reverse gear 1 31 5T07－1701061A Shaft of reverse gear 1 32 5T07－1701052 Washer of reverse gear shaft 1 33 5T07－1701057A Bolt of reverse gear shaft 1

167

4 SHIFT FORK&SHIFT－FORK SHAFT


1 QR512－1702311 Shift fork of 1ST&2ND gear 1 2 5T07－1702041A Shift fork of 3RD&4TH gear 1 3 308－7.9375 Steel ball 7.9375 6 4 5T07－1702042A Shift fork of 5TH gear 1 5 5T07－1702061A Shift fork of 3RD&4TH gear 1 6 4T08A－1702042A Stop block 1 7 QR512－1702231 PIN 4.5x20 1 8 QR512－1702411 Shift－fork shaft of 1ST&2ND gear 1 9 5T07－1702067 Shift－fork shaft spring 3 10 QR512－1701421 Shift－fork shaft of 3RD&4TH gear 1

168

4 SHIFT FORK&SHIFT－FORK SHAFT


11 QR512－1702431 Shift－fork shaft of 5TH gear 1 12 QR512－1702441 Shift－fork shaft of reverse gear 1 13 5T07－1702234 Shift－fork shaft screw plug 3 14 5T07－1702233 Washer of screw plug 3 15 QR512－1702341 Shift fork pin of reverse gear 1 16 5T07－1702068 Shift block spring 1 17 5T07－1702050A Shift arm 1 18 93－W8 Flat washer 8 2 19 5T07－1702232A Bolt of shift arm 2

169

5 SHIFT CONTROL MACHINSM


1 5T07－1702100A Shift－select shaft assy 1 2 5T07－1702101A Shift－selecting shift 1 3 QR512－1702214 Snap ring of shift interlock 3 4 5T07－1702102 Release－sprig seat of 1ST&2ND gear 1

170


5 5T07－1702103 Release sprig of 1ST&2ND gear 1 6 5T07－1702104 Spring－stop plate 2 7 5T07－1702107A Stop plate of shift interlock 1 8 5T07－1702105A Shift－select arm. 1 9 QR512－1702113 Spring pin 3.5x28 1 10 5T07－1702106 Pin of shift－select arm 1 11 5T07－1702114A Release spring of 5TH & reverse gear 1

12 5T07－1702112

Release － spring seat of 5TH & reverse gear 1

13 879.1－P3x22 Pin 3x22 1 14 5T07－1702108A Seat of reverse gear spring 1 15 5T07－1702109A Limiting spring reverse gear 1 16 QR512－1702111A Limiting cam of reverse gear 1 17 879.1－5x22 Pin 5x22 1 18 QR512－1702070 Guide case assy of shift－select shaft 1 19 QR512－1702071 Guide case of shift－select shaft 1 20 5T07－1702072 Stop plate of release spring 1 21 5787－Mx12 Flange bolt M6x12 2

22 QR512－1702227

SHIFT － SELECT SHAFT OIL SEAL 1

23 5T07－1702062

Anti－ dust cover of shift－ select shaft 1

24 5T07－1702073 Limiting bolt of reverse gear 1 25 QR512－1702229 Washer of limiting bolt 1 26 119－P6x12 Pin B 6x12 2 27 5787－M8x20 BOLT AM 8x20 4 28 5T07－1702065A Limiting bolt of shift 1 29 QR512－1702229 Washer of limiting bolt 1 30 5787－M8x75 Flange bolt M8x75 1 31 5T07－1702063 Shift pushing block 1 32 5T07－1702062 Anti－dust cover 1 33 6170－M8 Nut M8 1 34 93－SW8 Spring washer 8 1 35 5T07－1702046 Big washer of shift arm 1 36 5T07－1702045 Small washer of shift arm 1 37 S800.05.02.04.00－R2 Gear changing arm 1 38 SV1100.05.02.02.03 Cuprum bush 1 39 5T07－1702047 Anti－dust washer of shift arm 1 40 S800.05.02.05.00－R2 Choosing gear arm mount 1 41 S800.05.02.04.00－R2 Gear changing arm 1 42 879.1－P5x28 PIN 5x28 1 43 S800.05.02.06.00－R2 Gear cable mount 1

171

6 DRIVEN GEAR ASSY


1 5T07D1--1701600 Driven gear assy 1 2 5T07-1701310 Front bearing of differential 1 3 QR512-1701604 Driving gear of odometer 1 4 4T08A-1701602 Front bearing of output shaft 1 5 4T08A-1701601 Output shaft 1 6 4T08A-1701603 Connecting disc 1 7 QR512-1701611 Driven gear of speed reducer 1 8 4T08A-1701605 Rear bearing of output shaft 1 9 5T07-1701320 Rearing bearing of differential 1 10 5T07-1701309 Flange bolt 8 11 MQC4-2303016 Retaining ring 2 12 5T07-1701090 Right seal of differential 1 13 5T07-1701010 Left seal of differential 1 14 QR512-1701605 Right seal adjusting washer of differential Demand

172

PARTS MANUAL

1 Frame

Ref Part No. Part Description Qty Comment

s

1 S800.01.01.00.00－R4 Main frame 1 2 6177.1- M10*1.25 Flange nut M10*1.25 15 3 S800.01.05.00.00-R2 Right seat mount 1 4 5787- M10*1.25*20 Flange bolt M10*1.25*20 3 5 70.1-M10*1.25*25 Hex bolt M10*1.25*25 4 6 D1600.08.01.00.06 Cable buckle 12 7 S800.01.02.06.00-R2 Upper engine roll bar 1 8 S800.01.06.00.01-R2 Lower engine board 1 9 6187.1- M6 Self locking nut M6 8 10 JD0900008-W 6 Rubber flange washer 6 8 11 5787-M6*12 Flange bolt M6*12 8

173

2 Roll bar and Rearview mirror


1 70.1- M10*1.25*25 Hex bolt M10*1.25*25 40 2 6177.1- M5 Flange nut M5 8 3 S800.09.01.00.02-R2 Ø40 U clamp 4 4 923- M8 Nut M8 2 5 95-FW8 Flat washer 8 2 6 93-SW8 Spring washer 8 2 7 5787-M5*12 Flange bolt M5*12 8 8 S800.09.01.06.00-R2 Right bracket 1 9 S800.09.01.04.00-R2 Rearview mirror 2 10 S800.01.02.02.00-R4 Right roll bar 1 11 S800.01.02.03.00-R2 Front upper roll bar 1 12 S800.01.02.11.00-R4 Lower seat roll bar 1 13 S800.01.02.01.00-R4 Left roll bar 1 14 S800.09.01.05.00-R2 Left bracket 1 15 S800.01.02.09.00-R4 Middle roll bar 1 16 S800.01.02.08.00-R4 Right upright roll bar 1 17 S800.01.02.07.00-R4 Left upright roll bar 1 18 S800.01.02.04.00-R2 Upper seat roll bar 1 19 S800.01.02.04.00-R2 Rear upper roll bar 1 20 S800.01.02.05.00-R2 Lower roll bar 1

174

3 Front protect bar and small spot light


1 6170- M12 Flange nut M12 3

2 96-SW12 Spring washer 12 3

3 95-FW12 Flat washer 12 3

4 S650.01.03.00.01 Decorative cover 2

5 S800.01.03.00.00-R2 Front bumper 1

6 D650.06.00.12.00B Small spot light 3

7 95 -FW14 Flat washer 14 2


9 6170- M14*1.5*35 Bolt M14*1.5*35 2

175

4 Cargo bed


1 S800.01.04.00.00-R4 Cargo bed 1

2 6177.1-M10*1.25 Flange nut M10*1.25 8

3 S650.02.03.02.00 Rubber 2

4 882-PP 8*30 Pivot pin 8*30 4

5 S800.02.03.01.00-R2 Air shock 2


7 91-CP3.2*30 Cotter pin Ø3.2*30 6

8 882-PP10*70 Pivot pin 10*70 2


10 S650.09.01.07.00 Release lever 2

11 6177.1- M6 Flange nut M6 8

12 5787-M6*20 Flange bolt M6*20 8

13 D1600.08.01.00.06 Cable buckle 6 Each side

176

5 Electrical winch


1 S800.01.01.00.00-R2 Main frame 1

2 882 -PP10*70 Pivot pin 10*70 2


4 91-CPØ3.2*30 Cotter pin Ø3.2*30 6

5 6187.1- M6 Self-lock nut M6 8

6 S650.06.12.00.03 Wire cable guide 1

7 S650.01.05.00.00 Electrical winch mount 1

8 5787-M8*25 Flange bolt M8*25 4

9 S650.06.12.00.01 Electric winch 1

177

6 Engine and muffler mount assy

178

6 Engine and muffler mount assy


1 6177.1- M10*1.25 Flange nut M10*1.25 18 2 D650.04.01.00.01 Engine rubber bumper 8 3 5787- M10*25 Flange bolt M10*25 10 4 93-SW10 Spring washer 10 14 5 95-W10（11*20*2） Washer 10（11*20*2） 13 6 S800.04.01.04.00-R2 Engine mount, right 1 7 MV800.06.04.00.01 Oil pressure sensor 1 8 SV800.04.07.00.02 Connecting pipe 1 9 S800.04.01.01.00-R2 SQR372 Engine 1 10 6177.1- M5 Flange bolt M5 2

11 S800.04.01.00.01-R2 Ignition coil mount 1

12 5787-M5*30 Flange bolt M5*30 4

13 5787-M8*30 Flange bolt M8*30 1


15 95-W8 Washer 8 1

16 SV1100.04.01.04.00 Engine mount , rear 1

17 S800.04.01.03.00-R2 Engine mount , front 1

18 5787- M10*1.25*25 Flange bolt M10*1.25*25 3

19 6177.1-M10 Flange bolt M10 1

20 5787-M8*45 Flange bolt M8*45 2

21 S800.07.04.04.00-R2 Hydraulic clutch mount 1

22 5787- M8*35 Flange bolt M8*35 1

23 S800.04.01.02.01-R2 Hydraulic clutch arm 1

24 6177.1- M8 Flange nut M8 3

25 D650.04.04.00.08-2 U clamp screw rod 1

26 D650.04.04.00.08-1 U clamp mount 1

27 S800.04.04.01.00-R2 Sport muffler 1

28 6187.1-M8 Self-locking nut M8 6

29 DS250.11.01.00.02 Rubber 2

30 5787- M8*40 Flange bolt M8*40 4

31 5787- M8*20 Flange bolt M8*20 2

32 S800.04.04.03.00-R2 Exhaust muffler mount 2

33 5787- M10*25 Flange bolt M10*25 2

34 S11-1200011CA Seal washer 2

35 S800.04.04.02.00-R2 Exhaust pipe 1

36 5787- M10*1.25*30 Flange bolt M10*1.25*30 2

37 SV1100.04.04.04.00 Seal washer 1

38 S800.04.04.04.00-R2 Catalyst package 1

179

7 Driven system


1 5787- M10*35 Flange bolt M10*35 4 2 S650.03.01.00.04A Stub axle , left 1 3 D650.03.01.00.06 40*58*7*5 Seal 40*58*7*5 2 4 S800.03.01.02.00-R2 Front propellers shaft 2 5 91－CP4*40 Cotter pin 4*40 1

180

7 Driven system


6 JGC1801-K Nut M18*1.5 2 7 PT SZW1002 Bell type housing 1 8 KHC1802 Circlip 1 9 SH07680 Bigger seal retainer 2 10 BT1045 Boot 1 11 SH07350 Smaller seal retainer 2 12 PT SZ－9056 Core shaft 1 13 BT－2075 Boot 2 14 KHZ0011 Circlip 1 15 KHC1854 Bigger circlip 1 16 PT SZW5024 Bell type housing 1 17 5787- M12*1.25*120 Flange bolt M12*1.25*120 4 18 S800.03.01.00.03-R2 Small circlip 2 19 S800.03.01.01.00-R2 Front differential 1 20 6177.1-M12*1.25 Flange nut M12*1.25 8 21 S650.03.01.00.05A Stub axle , right 1 22 S650.06.10.00.00 Electric locker for 2WD to 4WD 1 23 93-FW6 Flat washer 6 2 24 818- M6*16 Cross head screw M6*16 2 25 91-CP Ø3.2*30 Cotter pin Ø3.2*30 2 26 882 -PP8*60 Pivot pin 8*60 2 27 S800.03.03.01.00-R4 Front inboard slip driveshaft 1 28 2303016 Steel cable baffle ring 2 29 S800.04.01.02.00-R2 5T07D1 Transmission 1 5T07D1 30 D650.03.01.00.05 Bear TV0402-275 2 31 893.2-C Ø 55 Internal circlip Ø 55 2 32 D650.03.01.00.04 Seal 40*55*6 2 33 5787- M8*20 Flange bolt M8*20 16 34 D650.03.02.00.05 Brake disc 4 35 S650.03.01.00.01 Hub bolt M12*1.5 16 36 S650.03.01.00.03A Front hub 2 37 S650.03.01.01.00A Front left wheel 27*8-12 1 38、39 38 S650.03.01.01.02A Front tire 27*8-12 2 39 S650.03.01.01.01 Front rim 12-6 2 40 S650.03.01.00.02 Hub nut M12*1.5 16 41 S650.03.01.04.00A Front right wheel 27*8-12 1

181

7 Driven system


42 S650.03.02.04.00A Rear right wheel 27*10-12 1 43 S650.03.02.01.02A Rear tire 27*10-12 2 44 S650.03.02.01.01 Rear rim 12-8 2 45 TR1100.03.01.00.03 Rear hub 2 46 13871-FB45*65*8 Seal FB 45*65*8 2 47 893.2-C Ø 65 Internal circlip Ø 65 2 48 Peer 35*65*35 Bear 35*65*35 2 49 S800.03.03.02.00-R2 Rear inboard slip driveshaft 1 50 S650.03.02.01.00A Rear left wheel 27*10-12 1 51 13871- FB42*62*8 Seal FB 42*62*8 2 52 S650.02.01.00.03 Seal 8 53 S650.03.02.00.01 Bush 8 54 S650.03.02.00.02 Spacer 4 55 5787-M12*1.25*105 Flange bolt M12*1.25*105 4 56 S800.03.01.02.00-R2 Rear propellers shaft 2 57 JGC2024－K Nut M24*1.5 1 58 PT SZW1008 Bell type housing 1 59 KHC2026 Smaller circlip 1 60 SH07780 Bigger seal retainer 2 61 BT－1055 Boot 1 62 SH07350 Smaller seal retainer 2 63 PT SZ－9055 Core shaft 2 64 BT-1063 Inner boot 1 65 KHZ0017 Circlip 1 66 KHC1836 Circlip 1 67 PT SZW5023 Bell type housing 1 68 S800.03.02.01.00-R2 Rear differential 1 69 S800.03.02.00.02-R2 Big circlip 2

182

8 Front/Rear differential locking


1 6187.1- M8 Self locking nut M8 4 2 6177.1- M8 Flange nut M8 2 3 S800.03.01.07.00-R2 Release lever mount 2 4 5787- M8*20 Flange bolt M8*20 4 5 JD1082101 Rubber cover 2 6 S800.03.01.06.00-R2 Release lever 2 7 REV－35 Spring 2 8 REV－36 Spacer 2 9 70.1- M8*45 Hex bolt M8*45 2 10 REV-33 Spring 2 11 S800.03.02.05.00-R4 Rear cable 1 12 5787-M6*12 Flange bolt M6*12 4 13 S800.03.01.00.02-R2 Cable bracket 2 14 S800.03.01.05.00-R2 Front cable 1

183

9 Gear shift

184

9 Gear shift


1 S800.05.02.07.00-R2 Gear shift assembly 1 2、3、4

2 S800.05.02.07.01-R2 5 speed gear shift indicator 1

3 S650.05.02.01.02 Ripple rubber 1

4 S650.05.02.01.03 Gear shift lever 1


6 818- M6*25 Cross head screw M6*25 4

7 91-CP2.5*25 Cotter pin 2.5*25 1

8 6187.1-M6 Self locking nut M6 4

9 6177.1-M6 Flange nut M6 2

10 S800.05.02.02.00-R4 Changing gear cable 1

11 S800.05.02.01.00-R4 Choosing gear cable 1

12 S800.05.02.06.00-R2 Gear cable mount 1

13 5787-M8*75 Flange bolt M8*75 2

14 5787-M8*20 Flange bolt M8*20 1

15 S800.05.02.04.00-R2 Gear changing arm 1

16 879.5- SP5*28 Spring pin 5*28 1

17 5T07-1702047 Rubber seal 1

18 S800.05.02.05.00-R2 Choosing gear arm mount 1

19 5787- M8*30 Flange bolt M8*30 2

20 5787- M8*30 Flange bolt M8*30 1

21 SV1100.05.02.02.03 Cuprum bearing 1

22 S800.04.01.02.00-R2 5T07D1 Transmission 1

23 5T07-1702063 Nylon 1

24 S800.05.02.04.00-R2 Gear changing arm 1

25 5T07-1702045 Small washer 1

26 5T07-1702046 Big washer 1


28 6170-M8 Nut M8 1

29 5T07-1702064 Rubber 1

185

10 Throttle and park braking

186



1 5787- M8*35 Flange bolt M8*35 6

2 S800.07.04.01.00-R4 Hydraulic clutch assembly 1

3 5787- M8*20 Flange bolt M8*20 14

4 6177.1- M6 Flange nut M6 8

5 5787- M6*35 Flange bolt M6*35 3

6 S800.07.01.01.00-R4 Hydraulic braking assembly 1

7 D650.07.01.00.04 Master cylinder rod 2

8 6172.1- M8 Thin nut M8 2

9 S800.07.01.00.02-R2 Foot braking bump mount 3

10 70.1- M6*50 Hex bolt M6*50 4


12 91-CP3.2*25 Cotter pin 3.2*25 4

13 6177.1- M10*1.25 Flange nut M10*1.25 4

14 S800.01.07.00.00-R2 Steering mounting 1

15 5787- M10*1.25*50 Flange bolt M10*1.25*50 4

16 S800.07.01.00.01-R2 Pedal spring 3

17 S800.07.03.02.00-R2 Upper throttle pedal 1

18 S800.07.03.03.00-R2 Lower throttle pedal 1

19 D650.07.01.00.05 Pedal rubber cover 1

20 5787-M6*12 Flange bolt M6*12 2

21 882-PP10*80 Pivot pin 10*80 1

22 S800.07.03.01.00-R4 Throttle cable 1


24 91-CP2.5*25 Cotter pin 2.5*25 5

25 S800.07.01.02.00-R2 Upper braking pedal 1

187



26 S800.07.01.02.00-R2 Lower braking pedal 1

27 5787-M8*16 Flange bolt M8*16 2

28 882-PP10*105 Pivot pin 10*105 2

29 5787-M8*50 Flange bolt M8*50 2

30 S800.07.04.03.00-R2 Lower clutch pedal 1

31 S800.07.04.02.00-R2 Upper clutch pedal 1

32 70.1- M6*80*28 Hex bolt M6*80*28 1

33 882-PP 6*40 Pivot pin 6*40 3

34 D1600.07.01.00.01 Short push rod holder 3

35 D650.07.02.01.00 Parking lever 1

36 6187.1-M8 Self lock nut M8 9

37 882-PP 8*25 Pivot pin 8*25 1

38 S800.07.02.00.02-R2 Parking brake connection 1

39 S800.07.02.00.02-R2 Steel bush 1

40 S650.07.02.01.00A-4S Parking cable 1

41 882 -PP10*105 Pivot pin 10*105 1

42 S800.07.02.03.00-R2 Parking arm 1


44 S800.07.02.04.00-R2 Hand hydraulic park brake assembly 1

45 5787- M8*55 Flange bolt M8*55 1

46 S800.07.04.04.00-R2 Hand hydraulic mounting 1

188

11 Front suspension system


1 5787-M12*1.5*85 Flange bolt M12*1.5*85 8

2 S650.02.01.00.03 Seal Ø54*12 16

3 S650.02.01.00.01 Bear 16

4 S650.02.01.00.02 Spacer 8

5 1152- M8*1 Blowhole M8*1 8

6 6177.1- M12*1.5 Flange nut M12*1.5 12

7 S800.02.01.03.00-R2 Upper suspension arm , FL 1

8 5787- M12*1.5*60 Flange bolt M12*1.5*60 4

9 894.2-C34 External circlip Ø34 4

10 S650.02.01.01.00 Ball joint 4


12 S800.02.01.01.00A-R2 Lower suspension arm , FL 1

189

11 Front suspension system


13 S650.09.01.09.03-COC Ø32 U clamp 10

14 S800.02.01.00.01-R2 Half shaft protect board ,FL 1

15 5787- M5*16 Flange bolt M5*16 20

16 S800.02.01.04.00-R2 Upper suspension arm, FR 1

17 S800.02.01.02.00A-R2 Lower Suspension arm, FR 1

18 S800.02.01.00.02-R2 Half shaft protect board ,FR 1

19 S800.02.01.05.00-R2 Front shock 2

190

12 Rear suspension system


1 6177.1-M12*1.5 Flange nut M12*1.5 12

2 S650.02.01.00.03 Seal Ø54*12 24

3 S650.02.01.00.01 Bear 16

4 5787-M12*1.5*85 Flange bolt M12*1.5*85 8

5 S650.02.01.00.02 Spacer 8

6 1152- M8*1 Blowhole M8*1 8

7 S800.02.02.02.00-R2 Upper suspension arm , RL 1

8 S800.02.02.03.00-R2 Lower suspension arm , RL 1

9 S800.02.02.04.00-R2 Lower suspension arm , RR 1

10 S800.02.02.05.00-R2 Upper suspension arm , RR 1

11 6177.1- M12*1.25 Flange nut M12*1.25 4

12 5787-M12*1.25*105 Flange bolt M12*1.25*105 4

191

12 Rear suspension system


13 S650.03.02.00.01 Rear shaft carrier bear 8

14 S650.03.02.00.04 Rear shaft carrier 2

15 S650.03.02.00.02 Spacer 4

16 5787- M12*1.5*60 Flange bolt M12*1.5*60 4

17 S800.02.02.01.00-R2 Rear shock 2


19 S650.09.01.09.03-COC Ø32 U clamp 10

20 S800.02.02.00.01-R2 Half shaft protect board ,RL 1

21 5787-M5*16 Flange bolt M5*16 20

22 S800.02.02.00.02-R2 Half shaft protect board ,RR 1

192

13 Steering assembly

193



1 2673- M4*5 Hex screw M4*5 2

2 DI250.03.01.00.01 Plastic cover 1

3 DI250.03.01.00.02 Rubber cover 1

4 D250.03.00.00.02 Rubber washer 1

5 815- M6*25 Cross sunk screw M6*25 6

6 D250.03.01.00.00 Steering wheel 1

7 6787.1- M6 Self locking M6 6

8 S800.05.01.01.00-R2 Steering column assembly 1 9-15

9 S800.05.01.01.01-R2 Steering wheel shaft 1

10 S650.05.01.00.01 Rubber cover 1

11 893.1-CØ28 Internal circlip Ø28 1

12 276-B61902 Ball bearing 61902 1

13 S800.05.01.01.02-R2 Steering column housing 1

14 276-B61803 Ball bearing 61803 1

15 893.1-CØ15 External circlip Ø15 1

16 6177.1-M10*1.25 Flange bolt M10*1.25 6

17 5787-M10*1.25*50 Flange bolt M10*1.25*50 4

18 S800.01.08.00.00-R2 Steering mount 1

19 5782- M8*25 Bolt M8*25 2


21 S800.05.01.02.00-R2 Steering universal rod 1

22 5787- M10*1.25*25 Flange bolt M10*1.25*25 2

23 5787- M10*1.25*20 Flange bolt M10*1.25*20 4

24 D650.05.01.00.03 Thick rubber boot 1

25 D650.05.01.00.05 Smaller washer 1

194



26 D650.05.01.00.03 Mounting rack 2

27 D650.05.01.00.04 Thin rubber boot 1

28 D650.05.01.00.06 Bigger washer 1

29 S650.05.01.03.05A Steering assembly 1 30-36

30 6176-M14*1.25 Nut M14*1.25 2


32 S650.05.01.03.05.01 Connection 2

33 S650.05.01.03.05.02 Ripple boot 2

34 S650.05.01.03.05.03 Spacer 2

35 S650.05.01.03.05.04 Steering box 1

36 S650.05.01.03.05.05A Steering shaft 1

37 6771.1-M14*1.25 Flange bolt M14*1.25 2

38 6170- M14*1.5 Nut M14*1.5 2

39 S650.05.01.03.01 Joint ball 2

40 9457- M14*1.5 Slotted nut M14*1.5 2

41 91-CP3.2*25 Cotter pin 3.2*25 2

42 S800.05.01.03.01-R2 Steering roll 2

43 6170-M14*1.5-L Nut M14*1.5-L 2

44 POA14-L Joint bear POA M14*1.5-L 2

45 S650.05.01.03.04 Joint bear spacer 4

195

14 Radiator assembly

196



1 D250.09.902 Overflow bottle cover 1

2 D250.09.903 Overflow bottle 1

3 6187.1- M8 Self locking nut M8 4

4 5787-M8*20 Flange bolt M8*20 4

5 D650.04.03.00.04 Hose clip(10~16) 7

6 S800.04.02.00.09-R2 No.1“T” pipe 1

7 DS150.05.02.00.02 “T” connection 1

8 S800.04.02.00.10-R2 No.2 “T”pipe 1

9 S800.04.02.00.11-R2 No.3 “T”pipe 1

10 5787-M10*1.25*20 Flange bolt M10*1.25*20 8

11 D650.04.02.00.03 Hose clip(25-38) 13

12 S800.04.02.00.07-R2 Inlet cup hose 1

13 S800.04.02.04.00-R2 Aluminum radiator assay 1

14 SV1100.04.07.00.01 Hose clip(19-25) 4

15 S650.04.02.00.08 Inlet cup cover 1

16 93-W8 Washer 8 1

17 5787- M8*25 Flange bolt M8*25 2

18 CF250T-420001 Plastic inlet cup 1

19 S650.04.02.02.06 Plug 1

20 818-M6*20 Cross head screw M6*20 12

21 JD0900008 -W6 Rubber flange wash 6 12

22 S800.04.02.02.00-R2 Radiator right mount 1


24 S650.04.02.00.08 Inlet cup cover 1

25 S650.04.02.10.00 Cuprum inlet cup 1

197



26 S800.04.02.00.04-R2 No.1 engine water outlet hose 1

27 D650.04.02.03.00 Temperature detect switch(TDS) 1

28 S800.04.02.00.08-R2 Water hose connection 2

29 S800.04.02.00.12-R2 Cuprum inlet cup hose 1

30 S650.04.02.02.00 “T”connection 2



33 6177.1-M8 Flange nut M8 6

34 S800.04.02.05.00-R2 Water hose bracket 3

35 S800.04.02.03.00-R2 Lower radiator mount 1

36 S800.04.02.01.00-R2 Left radiator mount 1

37 S800.04.02.00.01-R2 No.1 engine water inlet hose 1



40 D1600.04.02.00.06 Hose clip (16-25) 2

41 S800.04.02.00.14-R2 Small cycle water hose 1

42 D1600.04.02.02.00 Radiator fan 1

43 5787-M6*20 Flange bolt M6*20 4

198

15 Gasoline and air taking

51

199



1 6177.1-M10 Flange nut M10 4

2 S800.04.03.01.00-R2 Fuel tank strap 2

3 S650.04.03.01.02 Fuel tank rubber strap 2

4 S800.04.03.00.03-R2 No.1 connector pipe 1

5 S650.04.03.01.00 Fuel tank assy 1 3、6、7

6 S650.04.03.01.03 Fuel tank cap 1

7 S650.04.03.01.02 Fuel level sensor unit 1

8 D650.04.03.00.04 Hose clip (10-16) 16

9 S800.04.03.00.01-R2 Fuel tank outlet hose 1

10 5787-M8*20 Flange bolt M8*20 4


12 5787-M6*50 Flange bolt M6*50 2

13 D650.04.03.00.10 Fuel filter clip 2


15 D650.04.03.00.05 Fuel filter 1

16 S800.04.03.00.04-R2 Fuel filter outlet hose 1

17 D1600.04.02.00.06 Hose clip (16-25) 1

18 D1600.04.03.02.00 Fuel bump 1

19 S800.04.03.00.05-R2 Fuel bump outlet hose 1

20 D1600.04.03.03.00 Fuel press adjuster 1

21 5782-M4X12 Bolt M4X12 2


23 95-W4 washer 4 2

24 S800.04.03.00.02-R2 Gasoline returning hose 1

25 S800.04.03.00.07-R2 Fuel press adjuster out pipe 1

200



26 D1600.04.03.00.03 Express connector (7.95) 1

27 S800.04.01.01.00-R2 Chery 372 engine 1

28 SV800.04.05.00.02 Rubber sleeve 1

29 S800.04.05.00.05-R2 Hose clip (46-70) 2

30 S650.04.05.00.01 Flexible intake hose 1

31 S800.04.05.00.04-R2 Gas-recycle hose 1

32 S800.04.05.00.06-R2 No.1 PCV pipe 1

33 S11-1109110 change Air filter box 1

34 5787-M8*35 Flange bolt M8*35 2

35 95-W8(Ф24*Ф8.5*2) washer 8(Ф24*Ф8.5*2) 2

36 S800.04.05.02.00-R2 Air filter bracket 1

37 JD1910002 Metal spacer 2

38 JD1910003 Rubber spacer 2

39 5787-M8*70 Flange bolt M8*70 4

40 S800.04.05.00.03-R2 Board 1

41 6170- M8 Bolt M8 4

42 S800.04.05.02.00-R2 Air filter bracket 1

43 S11-1206211 Pressure Control Valve (PCV) 1

44 S800.04.05.00.07-R2 No.2 PCV pipe 1

45 S800.04.03.00.06-R2 No.2 connector pipe 1

46 D800.04.03.00.01 Connector 1

47 5787- M6*20 Flange bolt M6*20 3

48 D650.04.06.00.02 Sheet metal 1

49 D650.04.06.00.01 mount 1

50 D650.04.06.01.00A Fuel vapor canister 1

201

16 Plastic parts

202

16 Plastic parts

Ref Part No Part Description Qty Comments

1 818-M6*35 Screw M6*35 4

2 JD0900008 6 Rubber washer 6 100

3 S800.08.00.00.01-R2 Hood vent 1

4 S800.08.01.00.00-R2 Hood 1

5 818-M6*20 Screw M6*20 100


7 818- M6*25 Screw M6*25 13

8 S800.08.02.00.00-R2 Dash 1

9 5787- M5*16 Flange bolt M5*16 13

10 S800.08.00.00.04-R2 Fire wall 1

11 S800.08.00.00.16-R2 Left foot panel 1

12 S650.08.00.00.04-4S Counsel 1

13 S800.08.00.00.15-R2 Right rear fender 1

14 S800.08.00.00.14-R2 Left rear fender 1

15 S800.08.00.00.12-R2 Left inner fender 1

16 S800.08.00.00.13-R2 Rear inner fender 1

17 S800.08.00.00.09-R2 Left side panel 1

18 S800.08.00.00.07-R2 Vent cover 1

19 S800.08.00.00.11-R2 Right side panel 1

20 S800.08.00.00.08-R2 Left seat panel 1

21 S800.08.00.00.10-R2 Right seat panel 1

22 S800.08.00.00.05-R2 Tunnel 1

23 S800.08.00.00.17-R2 Right foot panel 1

24 S800.08.00.00.03-R2 Front bumper 1

25 S800.08.00.00.02-R2 Fog rill 1

26 S650.08.00.00.21-R4 Cover sheet in the middle of rear seats

27 S800.08.00.00.18-R4 Front seat cover sheet ,left 1

28 S800.08.00.00.19-R4 Front seat cover sheet ,right 1

29 S650.08.00.00.23-4S Rear seat driveshaft cover sheet 1

30 S800.08.00.00.21-R4 Middle cover sheet, left 1

31 S800.08.00.00.20-R4 Middle cover sheet, right 1

203

17 Electrical appliance and other parts

204



1 S800.06.03.01.00-R2 Front turning light 2

2 S650.06.02.00.00 Head light 2 3~6

3 S650.06.02.01.00 Headlight bulb 2

4 S650.06.02.03.00 Spring 2

5 95 -W5 Flat washer 5 2

6 948-M5*50 Bolt M5*50 2

7 S800.06.03.03.00-R2 Side turning light 2


9 S650.04.02.02.04 Inlet cup bracket 2

10 5787- M6*10 Flange bolt M6*10 2

11 5787-M6*16 Flange bolt M6*16 12

12 S800.06.03.02.00-R2 Fog light 2


14 D650.06.00.09.00 Horn 1

15 5787-M8*20 Flange bolt M8*20 1

16 6170-M8 Nut M8 2


18 DN250.10.07.00.00 Total power switch 1

19 6177.1- M5 Flange nut M5 4

20 D1600.01.02.00.06 Speedometer bracket 1

21 S800.06.05.01.00-R2 Speedometer 1

22 D1600.06.05.00.00 Tachometer 1

23 DS250.10.00.00.05 Horn button 1

24 S650.06.08.00.00 Ignition switch 1

25 S800.06.04.03.00-R2 Combination switch 1

26 5787-M8*90 Flange bolt M8*90 2

27 S800.09.01.07.00-R2 Battery bracket 1

28 D1600.06.02.00.03 Battery rubber cover 1

29 D1600.06.02.00.00 Battery 1

30 S800.08.00.00.18-R2 Plastic battery box 1

205



31 S650.06.00.14.00 Taillight 2

32 N650.06.04.00.01 Fuel level gauge bracket 1

33 6177.1- M4 Flange nut M4 8

34 D1600.06.09.00.00 Voltmeter 1

35 MV800.06.03.00.00 Coolant temperature indicator 1

36 D1600.06.07.00.00 Oil pressure gauge 1

37 N650.06.04.00.00 Fuel level gauge 1

38 S800.06.04.01.00-R2 Combination button 1

39 S650.06.07.00.00A Combination button 1

40 5787-M6*35 Flange bolt M6*35 4

41 S650.06.12.00.05 Electric winch relay 1

42 6177.1-M8 Flange nut M8 4

43 S650.06.14.02.00 Express connection-peg(Red) 2

44 S650.06.14.01.00 Express connection-peg(Red) 1

45 S650.06.12.00.01 Electric winch 1

46 S650.06.12.00.03 Wire cable guide 1

47 S650.06.14.01.00 Express connection-peg(Black) 1

48 S650.06.14.02.00 Express connection-peg(Black) 2

49 SV800.01.02.00.04 ECU plastic cover 1

50 SV800.01.02.00.02 ECU bracket 1

51 S800.09.01.00.05-R2 Wire bracket 1

52 S800.06.01.01.00-R4 Harness wiring 1

53 SR2000.06.00.04.01A Wire (battery + to power

switch) 1

54 S800.06.00.04.03-R4 Wire (power switch to starter) 1

55 SR2000.06.00.04.02A Wire (battery - to frame) 1

56 SR2000.06.00.04.04A Wire (frame to transmission) 1

57 S800.06.00.05.02-R4 Rear electric winch wire 1

58 S800.06.00.05.01A-R2 Front electric winch wire 1

59 S800.06.01.02.00-R4 Wire (to CHERY engine wire) 1

60 S800.06.00.01.00-R4 Controlling wire 1

206

18 Seats and Safety belts

207

18 Seats and Safety belts


1 6177.1-M10*1.25 Flange nut M10*1.25 16 2 91-CPØ3.2*25 Cotter pin Ø3.2*25 8 3 882-PP 7*80 Pivot pin 7*80 8 4 S800.09.01.02.00-R2 Left seat mount 2 5 70.1-M8*20 Hex bolt M8*20 16 6 S800.09.01.01.01-R2 Track without release lever 2 7 S800.09.01.01.03-R2 Seat 4 8 S800.09.01.01.02-R2 Track with release lever 2 9 TR1100.08.01.18.00 Safety belt 4 10 S800.09.01.03.00-R2 Right seat mount 2

208

19 Spot light


1 5787-M10*25 Flange bolt M8*25 4 2 6177.1- M8 Flange bolt M8 4 3 S800.10.01.04.00-R2 Rod end bearing M8-L 2 4 6172.1- M8-L Jam nut M8-L 2 5 S800.10.01.02.00-R2 Adjust roll 2 6 6172.1-M8 Jam nut M8 2 7 S800.10.01.05.00-R2 Rod end bearing M8 2 8 S800.10.01.01.00-R2 Spot light mount 1 9 D1600.06.10.00.00A Spot light 4 10~18 10 6170- M12*30 Bolt M12*30 1 11 D1600.06.10.00.01A Spot light bulb 1 12 95 -FW12 Flat washer 12 2 13 96-SW12 Spring washer 12 2 14 6170-M12 Nut M12 1 15 D1600.06.10.00.02A Adjust mount 1 16 6170- M12*25 Bolt M12*25 1

209

20 HYDRAULIC PUMP ASSEMBLY OF FOOT BRAKE


1 ZJ602.04-00/22 Master cylinder assy 1 2 ZJ509.05-00R Right caliper assy 2 3 S800.07.01.01.01-R2 Outlet hose No.1 of “T”connection 2 4 S800.07.01.01.02-R2 Outlet hose No.1 of master cylinder 1 5 ZJ609.F02-01 “T” connection 2 6 S800.07.01.01.03-R2 Outlet hose No.2 of master cylinder 1 7 ZJ509.05-00L Left caliper assy 2 8 S800.07.01.01.04-R2 Outlet hose No.2 of “T”connection 1 9 S800.07.01.01.08-R4 Cuprum hose1 2 10 S800.07.01.01.06-R2 Inlet hose No.1 of rear caliper 1 11 S800.07.01.01.07-R2 Inlet hose No.2 of rear caliper 1 12 ZJ509.03-04 Hydraulic brake pad 4

13 ZJGS.01-02 Hose bolt M10x1.25 12 14 ZJGS.01-01 Seal washer 24 15 S800.07.01.01.09-R4 Flexible hose3 2 16 S800.07.01.01.10-R4 Cuprum hose2 2 17 S800.07.01.01.00-R4 Hydraulic pump assembly of foot brake 1 1~14

210

21 HYDRAULIC PUMP ASSEMBLY OF PARKING BRAKE


1 ZJ610.04-00/14 Master cylinder assy 1 2 S800.07.02.04.01-R2 Outlet hose of master cylinder 1 3 S800.07.02.04.02-R2 Right outlet hose of “T”connection 1 4 ZJ509.05-00R Right caliper assy 1 5 ZJ609.F02-01 “T” connection 1 6 S800.07.02.04.03-R2 Left outlet hose of “T”connection 1 7 ZJ509.05-00L Left caliper assy 1 8 ZJ509.03-04 Hydraulic brake pad 2 9 ZJGS.01-02 Hose bolt M10x1.25 6 10 ZJGS.01-01 Seal washer 12

11 S800.07.02.04.00-R2 Hydraulic pump assembly of parking brake 1 1~10

211

22 CLUTCH HYDRAULIC ASSEMBLY


1 ZJ610.04-00/19 Master cylinder assy of clutch 1 2 S800.07.04.01.01-R4 Outlet hose of Master cylinder 1 3 ZJ610.05-00/22 Lower cylinder of clutch 1 4 ZJ610.05-05 Ripple boot 1 5 ZJGS.01-02 Hose bolt M10x1.25 2 6 ZJGS.01-01 Seal washer 4 7 S800.07.04.01.00-R4 Clutch hydraulic pump assembly 1 1~6

JNSZ800UV-R4 - JMC Motors · Thank you for choosing JOYNER JNSZ800UV-R4. It ... 4 Q33008 HEXAGON...

Documents

Transcript of JNSZ800UV-R4 - JMC Motors · Thank you for choosing JOYNER JNSZ800UV-R4. It ... 4 Q33008 HEXAGON...