Parts Manual JNSZ1100SV READ THIS MANUAL CAREFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION. MINIMUM RECOMMENDED OPERATOR AGE:

Transcript

1 0 Parts Manual JNSZ00SV READ THIS MANUAL CAREFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION. MINIMUM RECOMMENDED OPERATOR AGE: FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for off-road use only. USA only: It does not confirm to federal motor vehicle safety standards, and operation on Public streets, roads, or highways is illegal

2 CONTENTS PARTS MANUAL.... ENGINE....TRANSSMISSION.... CHASSIS... Wearing parts.... Body....Engine... 9.Transmission Standard part... 9 PREPARATION ATTACH INSTRUCTION Remove packing... 9.Install the front suspension arm... 9.Attach front shock absorber... 9.Attach the rod end and front wheel... 9.Attach tie rod and front wheel... 9.Attach the rear suspension arm Attach driver shaft Attach driver shaft Attach rear shock absorber Attach rear wheel Attach rear bumper bar... 0.Attach of spotlight and aluminum roof rack... 0.Check vehicle... 0

3 PARTS MANUAL. ENGINE. COOLING SYSTEM No Part number Name Quantity Q00 BOLT,HEXAGON HEAD WATER PUMP PULLEY Q00 BOLT,HEXAGON FLANGE Q0 BOLT(MX) Q0 BOLT,HEXAGON FLANGE PUMP SET,WATER RING, O WATER PUMP WASHER SEAL STRIP 0 Q0 BOLT SEAL STRIP SEAL STRIP GB0- RING,'O' RUBBER 7-00 SEAT - THERMOSTAT OUTER THERMOSTAT ASSY THERMOSTAT ASSY 7 Q00 BOLT,HEXAGON FLANGE 7-00 INNER SEAT-THERMOSTAT ASSY OUTER SEAT-THERMOSTAT ASSY PIPE

4 9.CYLINDER BLOCK No Part number Name Quantity CYLINDER BLOCK ASSY POSITION PIN CRANKCASE VENTILATION PIPE CYLINDER HEAD SEAL PLUG Q00 BOLT,HEXAGON FLANGE KNOCK SENSOR POSITION PIN S-000 SWITCH,OIL PRESSURE 9 G0GB0 BALL PLUG BOLT COVER-OIL CONTROL 7-00 TIE-IN-OIL FILTER VENT PIPE

5 0.CRANKSHAFT No Part number Name Quantity PULLEY BOLT TORSION SHOCK ABSORBER ASSY CRANKSHAFT TIMING GEAR TOOTHED BELT BAFFLE CRANKSHAFT FRONT OIL SEAL BEARING,NEEDLE WOODRUFF KEY CRANKSHAFT ASSY STOPPER PLATE 0 S-00 BOLT,COVER SET PIN - DOWEL REAR OIL SEAL REAR OIL SEAL BRACKET Q00 BOLT,HEXAGON FLANGE FLYWHEEL ASSY BOLT,LOCK-FLY WHEEL S-007 SENSOR,CRANKSHAFT POSITION 0 9 S-000CA COVER-CLUTCH 0 S-000CA DRIVEN DISK ASSY

6 . EXHAUST MANIFOLD (for Europe) 7 9 (for Europe) No Part number Name Quantity GASKET-EXHAUST MANIFOLD EXHAUST MANIFOLD Q00F STUD Q00 NUT,HEXAGON HEAT INSULATOR Q0 BOLT,HEXAGON HEAD 7 S-00JA OXYGEN SENSOR Q00F STUD 9 S-7 BRACKET,OXYGEN SENSOR

7 .INTAKE SYSTEM No Part number Name Quantity Q0 BOLT,HEXAGON HEAD S-900JA THROTTLE S-90JA GASKET-THROTTLE Q00 BOLT,HEXAGON FLANGE ACCELERATOR PULLING WIRE BRACKET S-09 INTAKE TEMPERATUREAND PRESSURE SENSOR 7 Q00 BOLT,HEXAGON HEAD UPPER INTAKE MANIFOLD 9 Q0 BOLT,HEXAGON HEAD 0 S-0JA OIL GUIDE S-00JA INJECTOR Q00F STUD Q00F STUD GASKET-INTAKE MANIFOLD Q00F STUD INTAKE MANIFOLD FRONT BRACKET

8 .INTAKE SYSTEM No Part number Name Quantity INTAKE MANIFOLD REAR BRACKET 7-00 BRACKET 9 Q00 BOLT,HEXAGON HEAD CRANKCASE VENTILATION PIPE () H-000 OIL AND AIR SEPARATOR 7-0 CRANKCASE VENTILATION PIPE () Q0 BOLT,HEXAGON FLANGE 7-00 CRANKCASE VENTILATION PIPE () Q00 BOLT,HEXAGON FLANGE S-00DA CABLE-ACCL GASKET-INTAKE MANIFOLD INTAKE MANIFOLD LOWER TIE-IN PIPE S-09BA TUBE

9 .LUBRICATING DEVICE No Part number Name Quantity OIL FILTER ASSY OIL DIP STICK ASSY OIL DIP STICK PIPE ASSY 7-00 SEAL STRIP 7-00 OIL PUMP WASHER OIL PUMP ASSY 7 Q0 BOLT Q0 BOLT(MX) 9 Q0 BOLT,HEXAGON HEAD OIL STRAINER WASHER Q00 STUD Q00 NUT,HEXAGON OIL STRAINER ASSY Q00 BOLT,HEXAGON FLANGE Q00 BOLT,HEXAGON FLANGE

10 7.CYLINDER HEAD No Part number Name Quantity SPARK PLUG SLEEVE Q00 BOLT,HEXAGON HEAD BOLT,CYLINDER HEAD CYLINDER HEAD BOLT WASHER 0 S-00 SENSOR,WATER TEMP. S-0009 SENSOR,CAMSHAFT POSITION 7 Q00 BOLT,HEXAGON HEAD GUIDE - VALVE EXHAUST VALVE SEAT INSERT INTAKE VALVE SEAT INSERT AB GASKET-CYLINDER HEAD 7-000RA HANGER - FRONT ENGINE Q0 BOLT,HEXAGON FLANGE BLOCK COVER CAMSHAFT OIL SEAL CYLINDER HEAD

11 7.CYLINDER HEAD No Part number Name Quantity CAMSHAFT BEARING CAP POSITION COVER 0 S-000 SENSOR SET,WATER TEMP BA REAR HINGER PLUG PLUG PLUG STUD SLEEVE PLUG

12 7. COVER-VALVE CHAMBER No Part number Name Quantity OILING PORT COVER ASSY Q0 SCREW COVER VALVE CHAMBER GASKET-VALVE CHAMBER Q0 BOLT,HEXAGON HEAD

13 9.OIL PAN No Part number Name Quantity OIL PAN ASSY Q0 BOLT,HEXAGON HEAD SEAL WASHER-OIL DRAIN THREADED PLUG PLUG,MAGNET

14 9 0.VALVE MECHANISM No Part number Name Quantity TENSIONING PULLEY ASSY Q00 BOLT,HEXAGON HEAD Q00 BOLT,HEXAGON HEAD TIMING GEAR COVER ASSY Q0 BOLT,HEXAGON HEAD 9 Q00 BOLT,HEXAGON HEAD 7 Q0 RING,SHIELD-SHAFT SPRING SADDLE FLIP WASHER DRIVE RING GEAR (DERIVEN) - INTAKE CAMSHAFT GEAR (MAIN ) - INTAKE CAMSHAFT GEAR (MAIN ) - INTAKE CAMSHAFT BOLT,HEXAGON FLANGE SPROCKET,TIMING BELT NUT,LOCK-CLUTCH HUB Q00 BOLT,INNER HEXGON HEAD

15 0 0.VALVE MECHANISM No Part number Name Quantity COUPLING FLANGE EXHAUST CAMSHAFT GEAR EXHAUST CAMSHAFT GEAR ADJUSTMENT WASHER VALVE LIFTER VALVE LOCK BLOCK EDDY SLEEVE BA UPPER SEAT,VALVE SPRING SPRING - VALVE SEAL,VALVE LOWER VALVE SPRING SEAT VALVE,EXHAUST TOOTHED TIMING BELT VALVE,INLET PIN PIN

16 0.VALVE MECHANISM No Part number Name Quantity UPPER SEAT,VALVE SPRING Q7B CLAMP LOWER COVER-TIMING GEAR 0-00 BOLT

17 .IGNITION DEVICE No Part number Name Quantity S-700JA IGNITION COIL Q0 SCREW AND WASHER UNIT S-7000CA BRACKET-IGNITION COIL S SPARK PLUG ASSY Q00 BOLT,HEXAGON HEAD S-70700BA CORD NO.,HI.TENSION 7 S-70700BA CORD NO.,HI.TENSION S-70700BA CORD NO.,HI.TENSION 9 S-70700BA CORD NO.,HI.TENSION 0 S-7 CLIP

18 .PISTON AND CONNECTING ROD DEVICE No Part number Name Quantity PISTON PIN 7-000AC PISTON CONNECTING ROD ASSY 7-00 BEARING-CONNECTING ROD

19 . OTHER ACCESSORY No Part number Name Quantity S-70CS Engine Harness S-000JA 7 ECU S-70 Shift Bracket S-00JA PCV,carbon can S-700GA Starter assembly S-7000 lower Steel cushion 7 S-000BA Single Exhaust Gasket GB/T M*.7 Hex nut M*.7 9 GB/T Spring Washerφ 0 GB/T97. standard- Washerφ GB/T M*.7*7* Hex socket head bolt M*.7*7* QB Bolt * Q0 Bolt * Upper steel cushion S-70 locating dowel Q0 Bolt * 7 Q00 Bolt *0 S-000 Electric odometer sensor assy

20 . OTHER ACCESSORY No Part number Name Quantity S-700BB Alternator S-70BA Alternator bracket S-00BA Rear bracket S-70 V-ribbed belt

21 .TRANSSMISSION.CASE&ACCESSORY No Part number Name Quantity QR-700 CASE.CLUTCH QR-70 CASE.TRANSMISSION T SIDE COVER T DECLUTCH BEARING T A DECLUTCH FORK T SLEEVE.CLUTCH FORK 7 T SEAL.CLUTCH FORK T SLEEVE.CLUTCH FORK 9 QR-700 DOUBLE-SCREW ROD 0 GB/T79-9 BOLT AM 0 T LOCATING PIN T PLUG SCREW.OIL

22 7.CASE&ACCESSORY No Part number Name Quantity T WASHER.PLUG SCREW.OIL T SWITCH.BACK-UP LIGHT T07-700A DOUBLE-SCREW ROD T STOP PLATE.BEARING 7 T OIL-STOP PLATE GB/T79-9 AM /BOLT AMX 9 GB/T7-97 /WASHER 0 T OIL GROOVE ASSY T A ROCKER.CLUTCH GB/T79-9 AM /BOLT AMX GB/T NUT M T BOLT.SIDE COVER QR-0 RELEASE SPRING.DECLUTCH

23 .COUNTERSHAFT No Part number Name Quantity T0A-700 COUNTERSHAFT QR-700 DRIVEN GEAR ASSY.FIRST GEAR QR-700 DRIVEN GEAR ASSY.SECOND GEAR QR-70 DRIVEN GEAR.THIRD GEAR QR-70 DRIVEN GEAR.FOURTH GEAR T BEARING.OUTPUT SHAFT.FRONT 7 T NEEDLE BEARING.ST GEAR&ND GEAR QR-709 OUTER RING.SYNCHRONIZER.ST GEAR&ND GEAR 9 QR-700 MID RING.SYNCHRONIZER.ST GEAR&ND GEAR 0 QR-70 INNER RING.SYNCHRONIZER.ST GEAR&ND GEAR QR-700 SYNCHRONIZER.ST GEAR&ND GEAR

24 9.COUNTERSHAFT No Part number Name Quantity QR-70 SPRING.SYNCHRONIZER.ST GEAR&ND GEAR QR-70 GEAR-HUB.SYNCHRONIZER.ST GEAR&ND GEAR QR-70 GEAR-SLEEVE.SYNCHRONIZER.ST GEAR&ND GEAR QR-70 GUIDE BLOCK.SYNCHRONIZER.ST GEAR&ND GEAR T RETAINER.SYNCHRONIZER.ST GEAR&ND GEAR 7 T SPACER.RD GEAR&TH GEAR T REAR BEARING.OUTPUT SHAFT 9 QR-707 ADJUSTING WASHER. REAR BEARING.OUTPUT SHAFT Demand 0 T0A-700 SLEEVE.COUNTERSHAFT MQC-709 NUT.COUNTERSHAFT T0A-7000 COUNTERSHAFT ASSY

25 0.INPUT SHAFT ASSY No Part number Name Quantity QR-700 INPUT SHAFT T SEAL.INPUT SHAFT T0-700 BEARING 0/YA/P QR-700 DRIVE GEAR ASSY.RD GEAR T NEEDLE BEARING.RD GEAR&TH GEAR QR-707 RING.SYNCHRONIZER.RD GEAR&TH GEAR&TH GEAR 7 QR-700 SYNCHRONIZER ASSY.RD GEAR&TH GEAR QR-70 GEAR-HUB.SYNCHRONIZER. RD GEAR&TH GEAR 9 QR-70 GEAR-SLEEVE.SYNCHRONIZER. RD GEAR&TH GEAR 0 QR-70 SPRING.SYNCHRONIZER.RD GEAR&TH GEAR&TH GEAR QR-70 GUIDE BLOCK.SYNCHRONIZER. RD GEAR&TH GEAR T RETAINER.SYNCHRONIZER. RD GEAR&TH GEAR

26 .INPUT SHAFT ASSY No Part number Name Quantity QR-70 WAVEFORM WASHER RING.SYNCHRONIZER QR-700 DRIVING GEAR ASSY.TH GEAR T BACK BEARING/INPUT SHAFT QR-707 ADJUSTING WASHER. BACK BEARING/INPUT SHAFT Demand 7 T0A-700 SLEEVE.INPUT SHAFT QR-7000 INPUT SHAFT ASSY 9 QR-709 NUT.SYNCHRONIZER.TH GEAR 0 QR-7070 IDLE GEAR ASSY T RETAINER.REVERSING IDLE GEAR T07-700A SHAFT.REVERSING IDLE GEAR T A BOLT.REVERSING IDLE GEAR T WAHSHER. REVERSE-GREAR SHAFT

27 .SHIFT FORK& SHIFT- FORK SHAFT No Part number Name Quantity QR-70 SHIFT FORK.ST GEAR&ND GEAR T07-700A SHIFT FORK.RD GEAR&TH GEAR GB/T0-00 STELL BALL 7.97 T07-700A SHIFT FORK.TH GEAR T07-700A SHIFT FORK.RD GEAR&TH GEAR T0A-700 A STOP BLOCK 7 QR-70 PIN.X0 QR-70 SHIFT-FORK SHAFT.ST GEAR&ND GEAR 9 T SPRING.SHIFT SHAFT

28 .SHIFT FORK& SHIFT- FORK SHAFT No Part number Name Quantity 0 QR-70 SHIFT SHAFT.RD GEAR&TH GEAR QR-70 SHAFT. SHIFT FORK.TH GEAR QR-70 SHAFT. SHIFT FORK.REVERSE GEAR T07-70 SCREW PLUG.SHIFT-FORK SHAFT T07-70 WASHER. SCREW PLUG.SHIFT-FORK SHAFT QR-70 SHIFT-FORK PIN.REVERSE GEAR T SPRING.SHIFT BLOCK 7 T A SHIFT ARM ASSY GB/T9-97 WASHER 9 T07-70A BOLT.SHIFT ARM

29 .SHIFT CONTROL MACHANISM No Part number Name Quantity T A SHIFT-SELECT SHAFT ASSY T07-700A SHIFT-SELECTING SHAFT QR-70 SNAP RING.STOP PLATE.SHIFT INTERLOCK T RELEASE-SPRING SEAT.ST GEAR&ND GEAR T RELEASE-SPRING.ST GEAR&ND GEAR T SPRING-STOP PLATE 7 T A STOP PLATE.SHIFT INTERLOCK T07-700A SHIFT-SELECT ARM. 9 QR-70 SPRING PIN.X 0 T PIN.SHIFT-SELECT ARM. T07-70A RELEASE-SPRING.TH GEAR&REVERSE GEAR T07-70 RELEASE-SPRING SEAT.TH GEAR&REVERSE GEAR GB/T PIN X T07-700A SPRING SEAT.REVERSE GEAR

30 .SHIFT CONTROL MACHANISM No Part number Name Quantity T A LIMITING SPRING.REVERSE GEAR QR-70A LIMITING CAM.REVERSE GEAR 7 GB/T PIN X QR GUIDE CASE ASSY. SHIFT-SELECT SHAFT 9 QR-7007 GUIDE CASE. SHIFT-SELECT SHAFT 0 T STOP PLATE.RELEASE SPRING.TH@REVERSE GB/T79-9 BOLT AMX QR-707 OIL SEAL.SHIFT-SELECT SHAFT T ANTI-DUST COVER. SHIFT-SELECT SHAFT T LIMITING BOLT.REVERSE GEAR QR-709 WASHER.LIMITING BOLT.REVERSE GEAR GB/T9-000 PIN B X 7 GB/T79-9 BOLT AM X T07-700A LIMITING BOLT.SHIFT

31 .SHIFT CONTROL MACHANISM No Part number Name Quantity 9 QR-709 WASHER.STOP SCREW.REVERSE GEAR 0 T SUPPORT ASSY.SHIFT ARM GB/T79-9 BOLT AM X0 T ANTI-DUST WASHER.SHIFT ARM T SHIFT ARM.COMP T SMALL WASHER.SHIFT ARM T BIG WASHER.SHIFT ARM GB/T NUT M 7 T ANTI-DUST COVER.SHIFT-SELECT SHAFT T PUSHING BLOCK.SHIFT 9 T SHIFT ARM COMP 0 GB/T PIN X QR-70 LIFTING HOOK

32 7.DRIVEN GEAR ASSY.SPEED REDUCER No Part number Name Quantity T0A-7000 DRIVEN GEAR ASSY.SPEED REDUCER T FRONT BEARING.DIFFERENTIAL QR-700 DRIVING GEAR.ODOMETER T0A-700 FRONT BEARING.OUTPUT SHAFT T0A-700 OUTPUT SHAFT T0A-700 CONNECTING DISC 7 T0A-700 DRIVEN GEAR.SPEED REDUCER T0A-700 REAR BEARING.OUTPUT SHAFT 9 T REAR BEARING.DIFFERENTIAL 0 T FLANGE BOLT MQC-00 RETAINER RING T RIGHT SEAL ASSY.DIFFERENTIAL T LEFT SEAL ASSY.DIFFERENTIAL QR-700 ADJUSTING WASHER. RIGHT SEAL ASSY.DIFFERENTIAL Demand

33 . CHASSIS Frame No. Code name Description SV Frame component Q'ty

34 9 Engine mount assy No. P/N ENGLISH Q'ty SV front engine mount 9-WΦ0 washer? 0( *0*) 9-SWΦ0 spring washer? 0 77-M0*.*0 bolt-washer M0*.*0 0 D engine rubber bumper M0X. nut-washer M0x. 7 7 SV engine(7) SV left engine mount 9 SV rear engine mount 0 9-WΦ washer? 9-SWΦ spring washer? 77-M*0 bolt-washer M*0 77-M0*.*0 bolt-washer M0*.*0 SV Clutch action arm D A small engine rubber bumper

35 0 Gear-shift mechanism No. Code name Description 77-M* SV A M* bolt plastic cover S shifter control assembly S rubber shifter indication S rubber shifter cover S control framework 7 SV orientation metal sheet 70-M M nut(m=.) 9 -WΦ washer? (?.*? *.) 0 9-PΦ* cotter pin? * SV SV shifter soft shaft shifter soft shaft 77-MX Mx bolt Q'ty

36 9 0 Steering assy No Code name Description Q'ty 70-M* bolt M* DI plastic cover DI rubber cover DI rubber block -M*0 M*0 screw DI steering wheel 77.-M M self-locking nut DI steering wheel subassembly 9.-M*0 bolt M*0 7.-Φ? spring shim N integrated ignition switch D steering wheel shaft 9.-CΦ circlip?, internal 7-B90 90 bearing D steering column housing 7-B0 0 bearing 9.-CΦ circlip?, internal

37 9 0 Steering assy No Code name Description Q'ty 9.-CΦ?, external circlip D steering column assy 77.-M0*. M0*. nut 77-M0*.* M0*.* bolt 9-WΦ? washer(.**) 9-Φ? spring shim 7-M* M* bolt D steering universal rod D steering gear shaft 77-M*0 M*0 bolt D bearing cover D gear rack D rod end bearingposalh 7.-M*.7 jam nut M*.7LH D capping plate 7-M* socket head screw M* 9 7.-M*.7 jam nut M*.7

38 9 0 Steering assy No Code name D D D M*.*0 D M*.*0 77.-MX. D M0*. D D M0*.*0 77-M0*.*7 D D D D Description Q'ty spacer sleeve rod end bearingposa baffle plate M*.*0 bolt steering cross rod M*.*0 bolt Mx. nut dust guard plate M0*. nut bracket socket bolt M0*.*0 bolt M0*.*7 adding oil screw oiliness bearing c7** ball bearing 0** steering gear box

39 Throttle and park assy No Code name Description Q'ty SV disc brake with floating caliper,front SV disc brake with floating caliper,rear D hydraulic threeway valve SV hydraulic brake hose D hydraulic master cylinder SV hydraulic brake pads SV four caliper hydraulic brake assy D pushing bar 7.-M M nut D push rod holder 9-P.*0 cotter pin.*0 9-WΦ0? 0 washer(? 0.*? *?.) SV clutch pedal D pedal rubber cover SV cable, clutch

40 Throttle and park assy No Code name Description Q'ty 70.-M* M* socket head bolt 70-M M nut(m=.) D spring D ? 0*0 pin roll 9-PΦ* cotter pin? * 9-WΦ? washer D brake bar D ? *0 pin roll D ? 0*0 pin roll D throttle pedal SV throttle cable 77.-M M nut 77-M*0 M*0 bolt D park assy -WΦ? washer

41 Throttle and park assy No Code name Description 9-P.*0 cotter pin.*0 D axle * D parking brake connection 9-P.*0 cotter pin.*0 D M self-locking nut D bolt-washer M*0 D single hydraulic pump D single hydraulic oil cup D MV MV single hydraulic caliper single hydraulic park brake assy park brake cable steel bush D SV copper braking hose 77-MX flange bolt mx Q'ty

42 7 7 9 No Code name 0 0 Front susp assy Description S M*. wheel nut JD0000 rubber dirt-proof boot D H(F9) left wheel(*-) 9-P cotter pin 97-MX. castle nutmx. D washer 7 D spacer sleeve D axle bush 9 D ** grease seal 0 D ball bearing XX D spacer sleeve D A D A front hub D D Q'ty knurled screw M*. brake disk M bolt

43 7 9 No Code name Front susp assy Description SV brake calliper 7 D ** ball bearing D xx7 grease seal 9 7-M** M** bolt 0 D bushing D upper suspension arm,left D radial bearing 9.-C circlip D bushing.-m* M* nut 77-M*0 M*0 bolt 7 D A front axle left wheel D lower suspension arm,left 9 7-M*.*90 M*.*90 bolt 0 D front spacer shock sleeve Q'ty 9

44 9 7 9 No Code name Front susp assy 7 Description SV front shock absorber.-m*. M*. nut 7-M** M** bolt D control arm spacer sleeve D control arm rod end bearing 7.-M* jam nut M* 7 7-M*.*0 M*.*0 bolt 7-M**9 bolt M**9 9 D H(F9) right wheel(*-) 0 D upper suspension arm,right D A front axle right wheel D lower suspension arm,right S front rim * D H front tire *-,R D H front tire *-,L Q'ty 9

45 70 Fuel tank and gasoline pump No. Code name Description Q'ty D fuel filter clip D fuel pump D hoop (-) SV D fuel pipe( φxφx7) fuel filter D hoop (0-) 0 7 SV fuel pipe( φxφx0) D connector (7.9),fuel pipe 9 -M* M* cross groove head screw 0 -M*0 M*0 cross groove head screw 9-WΦ washer Ф 9-SWΦ spring washer Ф -M hex nut M SV fuel level meter SV fuel pipe(φxφx0)

46 7 Fuel tank and gasoline pump No. Code name Description D fuel press adjuster 7 SV fuel pipe (φxφx0) SV fuel pipe (φxφx0) 9 SV fuel press adjuster bracket 0 7-MX0 bolt MX0 9-SWΦ spring washer Ф 9-WΦ washer Ф SV fuel tank assy D rubber washer D fuel tank cap with key SV bare fuel tank 7 D A carbon can SV fuel pipe (φxφx0) 9 S-00JA Pressure Control Valve (PCV) 0 SV fuel pipe (φxφx0) SV fuel pipe (? X? ) Q'ty

47 7 Fuel tank and gasoline pump No. Code name Description Q'ty 77.-M washer nut M D carbon can bracket 77-M* bolt-washer M* D carbon can plate MV oil pressure sensor 7 SV connecting pipe N air cleaner jacket 9 D air cleaner 0 N hoop(-) SV air cleaner rubber sleeve 70.-M*0 M*0 socket head screw 97.-WΦ washer φ( φ*φ*.) D rear bumper bar D fuel tank strap 77.-M0*. nut-washer M0*.

48 7 Spot lights and radiator assy the frame in out 9 connect to radiator "out" connect to radiator cap 7 connect to engine connect to air outlet connect to thermostat outlet connect to radiator "in" connect to inlet of engine connect to thermostat outlet No. Code name Description Q'ty 77-M*0 bolt-washer M*0 77.-M self-locking nut M D aluminium radiator bracket D aluminium radiator D temperature detect switch(tds) D radiator fan 7 77-M*0 bolt-washer M*0 D hoop(-),water tube 9 D water outlet hose, engine 0 D water inlet hose, engine D underlying board D reserve tank D cap of reserve tank D airproof washer of reserve tank

49 7 Spot lights and radiator assy the frame in out 9 connect to radiator "out" connect to radiator cap 7 connect to engine connect to air outlet connect to thermostat outlet connect to radiator "in" No connect to inlet of engine connect to thermostat outlet Code name Description Q'ty D hoop(0-) 7 D00900 radiator connecting tube D oil separator 77-M* bolt-washer M* D cover, oil separator D air filter, oil separator SV hoop(-) D spotlight SV mount of spotlight 77-M0*0 bolt-washer M0*0 77.-M0 self-locking nut M0 77-M* bolt-washer M* D spacer SV aluminium roof rack

50 7 Spot lights and radiator assy the frame in out 9 connect to radiator "out" connect to radiator cap 7 connect to engine connect to air outlet connect to radiator thermostat connect to radiator "in" 0 0 connect to inlet of engine 9 connect to radiator thermostat No Code name Description Q'ty SV small cycle hose SV steel -way.small cycle D00900 hose φ*φ.overflow tank SV steel -way.air outlet SV water inlet hose, engine SV water outlet hose, engine SV hoop(-) D loop M0 D oil separator tank D reserve tank

51 7 Electrical appliance No. Code name Description Q'ty D headlight D D headlight bulb front blinker D front blinker D horn D spot light 7 D spot light bulb(0w) JD0000 washer 9 DS horn button 0 D four switch assy MV speedometer D tachometer

52 77 Electrical appliance No. Code name Description Q'ty MV coolant temperature indicator D voltmeter D fuel level gauge D oil pressure gauge 7 D battery (AH) D tail light assy 9 D0079A flasher apparatus 0 MV electrical wiring harness S-000JA- ECU MV fuse box MV relay box S-70CS engine wiring harness D0079 flasher coat D bracket

53 7 MUFFLER No. Code name Description Q'ty SV exhaust manifold gasket exhaust manifold S-00JA oxygen sensor SV seal washer 77- Mx nut-washer 7 9 SV A S-00JA 77.-M D catalac convertor oxygen sensor self-locking nut M U clamp 0 D U clamp mount

54 79 MUFFLER No Code name Description Q'ty D U clamp screw rod D B long muffler 77-M*0 JD9000A JD9000 bolt-washer M*0 muffler rubber cover spacer 9-WΦ** washer? ** 77.-M M self-locking nut SV muffler bracket 77-M* 77.-M bolt-washer M* M self-locking nut 77.-M nut-washer M SV wire clamp

55 0 seat and safety belt J O Y N E J O Y N E R R J O Y N E R J O Y N E R No. Code name Description Q'ty SV SV D safty belt seat safty belt tube

56 Rear susp,left No. Code name Description S wheel nut M*. D H(F9) wheel(*-),bl 9-P*0 cotter pin *0 D slotted nut M*.,rear shaft D A disk base D A M*. bolt 7 D brake disk D M bolt,brake disk 9 9.-CΦ circlip,internal 0 D bearing(? 0*? 0*) 77-M*.*00* M*.*00* bolt D bush ring D bearing block 77.-M*. M*. nut 77-M*0 M*0 bolt SV brake caliper 7 N outer boot seal 00 steel cable baffle ring 9 N BIG band Q'ty

57 Rear susp,left No Code name Description Q'ty N inner boot seal N SMALL band N end motion type inboard joint SV solid bar,left N fixed enter type outboard joint SV left drive shaft 7-M*.*0*0 M*.*0*0bolt D spacer sleeve D rear shock absorber.-m*. M*. nut 77-M** M** bolt D grease seal,? D powdered spacer sleeve D spacer sleeve 77.-M* M* nut D A rear suspension arm,left D single hydraulic park brake assy 7-M*.** M*.**bolt S rear rim * D H rear tire X-,L

58 Rear susp,right No Code name Description Q'ty S wheel nut M*. D H wheel(*-),br (F9) 9-P*0 cotter pin *0 D slotted nut M*.,rear shaft D A disk base D A M*. bolt D brake disk D M bolt,brake disk 9.-C circlip,internal D bearing(? 0*? 0*) 77-M*.*00* M*.*00* bolt D bush ring D bearing block 77.-M-. M-. nut 77-M*0 M*0 bolt SV brake caliper N inner boot seal N small band N outer boot seal

59 Rear susp,right No Code name Description Q'ty N big band N fixed enter type outboard joint SV solid bar,right N end motion type inboard joint 00 steel cable baffle ring SV right drive shaft 7-M*.*0 D M*.*0 bolt spacer sleeve D rear shock absorber.-m*. M*. nut 77-M** M** bolt D grease seal,? D powdered spacer sleeve D spacer sleeve 77.-M* M* nut SV A rear suspension arm,right 7-M*.** M*.**bolt S rear rim * D H rear tire X-,R

60 Other parts J O Y N E R J O Y N E R No. 7 0 Code name Description Q'ty SV canvas roof D plastic zip tie 0 JN00000EU side view mirror,left JN00000EU side view mirror,right SV front cover plate SV rear fin side D rear panel D TOP panel D cloth cover for entire kart

61 Other parts J O Y N E R J O Y N E R No. Code name Description Q'ty SV left nerf bar SV right nerf bar D battery bracket D ECU plastic shield SV D ECU bracket battery cover 7 SV tube clip 0 SV engine bottom plate 9 SV envelopment

62 7 Other parts J O Y N E R J O Y N E R No. Code name Description Q'ty 0 SV foam cover fender bracket.left.front fender bracket.right.front fender bracket.left.rear fender bracket.right.rear D shock absorber coat.front 7 D shock absorber coat.rear SV rear fin side.left

63 Wearing parts. Body Num English name 件号 数量 rubber washer Φ JD radial bearing D bushing D rod end bearing,control arm D spacer sleeve,control arm D interner circlip φ (model B) GB/T shocker spacer sleeve D hub screw M0*. D wheel nut M0*. D ball bearing ** D ball bearing 0** D oil seal 0** D oil seal 0xx7 D bearing(0*0*) D slotted nut M*.,rear shaft D internal circlip Φ (model B) GB/T engine rubber bumper D rod end bearingposalh D rod end bearingposa D spacer sleeve D electric cable MV spotlight bulb D spotlight bulb D headlight bulb D headlight bulb D turning light bulb D tail light bulb D stoplight bulb D flasher apparatus D ignition switch assembly N cable SV brake caliper SV clutch cable SV air cleaner D brake pad SV brake Disc D fuel pump assy D inner boot seal N SMALL band N outer boot seal N big band N

64 drive shaft, right SV drive shaft, left SV four switch assy D FUSE E FUSE E FUSE E FUSE E FUSE E FUSE7 E FUSE E FUSE9 E FUSE0 E Engine Bolt main Plug valve-inlet valve-exhaust adjustment washer valve lifter seal valve bolt,cylinder head cylinder head bolt washer cylinder head cover gasket camshaft oil seal block cover the first Piston ring the second Piston ring oil control steel-ring scraper oil control steel-ring cushion bearing-connecting rod 7-00 upper bearing-cranksaft lower bearing-cranksaft cranksaft front oil seal stopper plate rear oil seal pulley bolt toothed timing belt intake camshaft assy exhaust camshaft assy valve seal intake manifold gasket Nut Q00 0 oil piug washer oil pump gasket

65 90 oil pump water pump set water pump washer ring "o" seal strip seal strip seal strip cord NO., Hi.tension S-70700CA 0 cord NO., Hi.tension S-70700CA cord NO., Hi.tension S-70700CA cord NO., Hi.tension S-70700CA spark plug S ignition coil S-700JA injector S-00JA oil filter alternator S-700B alternator adjustment arm S-70BA 9 dextral hex bolt Q090 0 V-ribbed belt S-70 Starter assembly S-700GA Electric odometer sensor S-000 Crankcase ventilation pipe() 7-00 Crankcase ventilation pipe 7-0 Crankcase ventilation pipe 7-0 Crankcase ventilation pipe 7-0.Transmission DOUBLE-SCREW ROD T07-700A shift turning rod T A SHIFT-SELECT SHAFT T A SHIFT-SELECTING SHAFT T07-700A SNAP RING.STOP PLATE.SHIFT INTERLOCK QR-70 RELEASE-SPRING SEAT.ST GEAR&ND GEAR T RELEASE-SPRING.ST GEAR&ND GEAR T SPRING-STOP PLATE T SHIFT INTERLOCK STOP PLATE T A 0 SHIFT-SELECT ARM T07-700A SHIFT-SELECT ARM PIN T SPRING PIN.X QR-70 RELEASE-SPRING.TH GEAR&REVERSE GEAR T07-70A RELEASE-SPRINGSEAT.TH GEAR&REVERSE GEAR T07-70 SPRING SEAT.REVERSE GEAR T07-700A

66 LIMITING SPRING.REVERSE GEAR T A 7 LIMITING CAM.REVERSE GEAR QR-70A FRONT BEARING.OUTPUT SHAFT T REAR BEARING.OUTPUT SHAFT T FRONT BEARING.DIFFERENTIAL T ODOMETER DRIVING GEAR QR-700 REAR BEARING.DIFFERENTIAL T LOCATING PIN T INPUT SHAFT SEAL T RIGHT SEAL.DIFFERENTIAL T SEAL.CLUTCH FORK T LEFT SEAL.DIFFERENTIAL T BEARING 0/YA/P T DECLUTCH BEARING T BACK-UP LIGHT SWITCH T Standard part self-locking nut M GB/T self-locking nut M GB/T nut M0*. GB/T nut M0*. GB/T-000 cotter pin.*0 GB/T9-000 cotter pin *0 GB/T Bolt M*.*90 GB/T7-000 Bolt M*.*0 GB/T Bolt M*.*0 GB/T Bolt M*.* GB/T7-000 Nut M*. GB/T.-000 Bolt M** GB/T7-000 Bolt M**9 GB/T7-000 Bolt M** GB/T7-000 Nut M* GB/T.-000 bolt-washer M0*.*0 GB/T spring washer 0 GB/T

67 PREPARATION ATTACH INSTRUCTION. Remove packing 9

68 9.Install the front suspension arm D FL lower suspension arm D FL upper suspension arm D FR lower suspension arm D FR upper suspension arm No. Description Q'ty

69 9.Attach front shock absorber D front shocker absorber M*.*90 M*.*90 bolt D shocker spacer sleeve.-000 M*. M*. nut No. Description Q'ty

70 9.Attach the rod end and front wheel Attach tie rod end and front wheel forward steering cross rod left wheel axle,front S wheel nut M*. D H,FL wheel(*-) D rod end bearing,posalh D H wheel(*-),fr No. Description Q'ty. Install the shaft of outer tie rod end- to left wheel axle,front.. Install bolt,spacer sleeve,then tighen nut. Note: don't adjust outer tie rod end as wheel alignment is done before packing.. Attach the wheel(*-),fl- on the hub, tighten the nuts.. Attach the wheel(*-),fr- as described above.

71 .Attach tie rod and front wheel 9

72 97.Attach the rear suspension arm M* M* nut D spacer sleeve D powdered spacer sleeve D M** grease seal,? M** bolt D A left rear suspension arm SV A right rear suspension arm No. Description Q'ty

73 9. Attach driver shaft Attach drive shaft forward 00 steel cable baffle ring SV right drive shaft SV left drive shaft No. Description Q'ty.Check the steel cable baffle ring- in the groove of the output shaft of transmission.. Insert right drive shaft- onto the output shaft of transmission.. Attach the left side as figure.

74 7. Attach driver shaft 99

75 00.Attach rear shock absorber D rear shock absorber.-000 M*. M*. nut D shocker spacer sleeve M*.*0 M*.*0 bolt No. Description Q'ty

76 9. Attach rear wheel 0

77 0.Attach rear bumper bar 0

78 0.Attach of spotlight and aluminum roof rack SV aluminium roof rack M0*.*0 bolt-washer M0*.* M0*. self-locking nut M0*. D spacer D steel ring M0*. self-locking nut M0*. 77- M0*.*0 bolt-washer M0*.*0 SV mount of spotlight No. Description Q'ty

79 .Check vehicle 0