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Joyner JNSZ800MVA, Owner'S Manual

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Joyner JNSZ800MVA Owner'S Manual Download Page 150

2. 4T08A2 TRANSSMISSION ILLUSTRATION 

1.CASE&ACCESSORY 

 

 

 

No 

ERP CODE 

Code name   

Description

 

Qty  

1 

02.DLJ.QR512-1701101 

QR512-1701101 CASE.CLUTCH 

1 

2 

02.DLJ.4T08A1-1701111 

4T08A1-1701111 CASE.TRANSMISSION 

1 

3 

02.DLJ.5T07-1701020 

5T07-1701020 SIDE 

COVER 

1 

4 

02.DLJ.5T07-1702010 

5T07-1702010 DECLUTCH 

BEARING 

1 

5 

02.DLJ.5T07-1702020A 

5T07-1702020A DECLUTCH 

FORK 

1 

6 

02.DLJ.5T07-1702004 

5T07-1702004 

SLEEVE.CLUTCH FORK 2 

1 

7 

02.DLJ.5T07-1702030 

5T07-1702030 SEAL.CLUTCH 

FORK 

2 

8 

02.DLJ.5T07-1702001 

5T07-1702001 

SLEEVE.CLUTCH FORK 1 

1 

9 

02.DLJ.QR512-1701103 QR512-1701103 

DOUBLE-SCREW 

ROD 

2 

10 

02.DLJ.GB/T5789-1986 

GB/T5789-1986 BOLT 

AM8×40 

12 

11 

02.DLJ.5T07-1701001 

5T07-1701001 LOCATING 

PIN 

2 

12 

02.DLJ.5T07-1701002 

5T07-1701002 PLUG 

SCREW.OIL 

1 

13 

02.DLJ.5T07-1701003 

5T07-1701003 WASHER.PLUG 

SCREW.OIL 

2 

 
 
 

Summary of Contents for JNSZ800MVA

Page 1: ...PORTANT SAFETY INFORMATION MINIMUM RECOMMENDED OPERATOR AGE FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only It does not confirm to federal motor vehicle safety st...

Page 2: ...e 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...

Page 3: ...NE 135 2 4T08A2 TRANSSMISSION ILLUSTRATION 150 3 CHASSIS 163 Wearing parts 204 1 Body 204 2 Engine 205 3 Transmission 206 4 Standard part 207 PREPARATION ATTACH INSTRUCTION 208 1 Remove Packing 208 2...

Page 4: ...WARRANTY POLICY...

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Page 14: ...contains important safety and maintenance information Failure to follow the warnings contained in this manual can result in serious injuries Be sure to follow the recommended maintenance schedule and...

Page 15: ...must use your own good judgment You will find important safety information in a variety of forms including Safety Labels On the Off highway recreational vehicle Safety Messages Preceded by a safety a...

Page 16: ...highway recreational vehicle Safety Institute Check with your dealer for more information on training courses Be Alert for Off Road Hazards The terrain can present a variety of challenges when you dr...

Page 17: ...dations to help you drive your Off highway recreational vehicle safely Spend a few moments to read these pages The labels are considered permanent parts of the Off highway recreational vehicle If a la...

Page 18: ...shirt or jacket whenever you drive Although complete protection is not possible wearing proper wear can reduce the chance of injury when you drive The following suggestions will help you choose the pr...

Page 19: ...creational vehicle turning over could lead to serious injury or death Never support with your hands to ground when the Off highway recreational vehicle will turn over Age Recommendation It is strongly...

Page 20: ...ing can cause a crash in which you can be seriously hurt even die Always perform a pre drive inspection before every drive and correct each problem Pre drive Inspection Check the following items befor...

Page 21: ...ational vehicle on pavement Operating this Off highway recreational vehicle on paved surfaces may seriously affect handling and control of the Off highway recreational vehicle and may cause the vehicl...

Page 22: ...isibility and other operating conditions plus your own skills and experience Operating this Off highway recreational vehicle at excessive speeds increases your changes of losing control of the Off hig...

Page 23: ...y rough slippery or loose terrain until you have learned and practiced the skills necessary to control the Off highway recreational vehicle on such terrain Always be especially cautious on these kinds...

Page 24: ...d Engine oil SAE 10W 30 Gear oil GL 4 75W 90 CAPACITIES Maximum load 200kg Fuel tank 31L Engine oil 2900ml Gear oil 2000ml Coolant 5500ml Starting 5s Climbing 20 25 Battery 12V45Ah Head Light 12V 55 5...

Page 25: ...t your dealer for assistance Brake Pedal Applying pressure to the brake pedal instead of the accelerator pedal with your foot will slow down and or stop the vehicle Riding or resting your foot on the...

Page 26: ...work Press the bottom of button down and the left turning light work Set the button in neutral while moving in line See figure 5 Head light switch control the headlight far beam or lower beam Press th...

Page 27: ...icle on level ground to get an accurate reading The fuel tank is empty when the fuel gauge needle points to 0 and full when the needle points to 1 See figure 8 Oil pressure gauge Indicates oil pressur...

Page 28: ...teering wheel and the remote stop button See figure 10 Pull seat adjustment handle upward to disengage seat slide Move seat to desired position Be sure seat adjustment handle snaps back into place and...

Page 29: ...Tire inflation Chart below for correct tire pressure Shift Adjustment After a long time of use it is necessary to adjust the shift cable to make shift clear screw the thin nut show in the following f...

Page 30: ...peration during this break in period will help assure maximum life and performance from your new vehicle The following guidelines explain proper break in procedures After the engine starts the engine...

Page 31: ...s when you replace the front wheels See Fig 15 Tighten the nuts after replacing the wheels Rear Wheel Replacement Do not disassemble the center castle nuts when you replace the rear wheels See Fig 16...

Page 32: ...chock nitrogen needs to be added to get more nitrogen pressure the recommended nitrogen pressure is 1 0MPa 145psi 2 Adjust the shock refer to the following drawing 3 Loose the lock nut on the top of...

Page 33: ...he transmission case lay down these carefully Caution When fix the four bolts in the transmission case you must tighten them according to the prescribed torque 45 55N M See Fig 21 24 Q1840845 Q1841245...

Page 34: ...Clutch assy remove the six bolts on the Clutch pressure plate now It s clear Caution When fix the six bolts in the Clutch pressure plate you must tighten them according to the prescribed torque 28 N...

Page 35: ...sy fix the six bolts on the Clutch pressure plate tighten them according to the prescribed torque 28 N M See Fig 32 33 6 Fix parts according to reverse operation to the disassembly S11 1601020 S11 160...

Page 36: ...ts on both sides of Front Tie Rods To make Dimension B smaller turn the rod to the left Turn the rod to the right to make Dimension B larger After adjusted to desired length tighten the lock nut again...

Page 37: ...t do the following see Pic 1 Pic 6 Pic 1 Pic 2 Pic 3 Engine relay Fuel pump relay Fan relay Spot light relay R gear indicator fuse Gauge and indicator fuse Brake indicator fuse Engine fuse ECU normal...

Page 38: ...off the bulb you need to replace through turning the bulb counter clockwise about a half round and replace a new one Put all the parts back with reversing step 1 2 Cleaning Instructions Keep your Off...

Page 39: ...l through the spark plug hole into the cylinder Crank the engine slowly to spread oil and replace spark plug 3 Do not save or store gasoline over winter Using old gasoline which has deteriorated from...

Page 40: ...ENGINE WIRING DIAGRAM...

Page 41: ...MAIN WIRING DIAGRAM DJ7013 6 3 21 DJ7021 1 5 11 DJ7041 1 5 11 DJ7021 1 5 11 DJ7041 1 5 11 DJ7031 1 5 11 DJ7031 1 5 11 DJ7021 1 5 11 DJ7031 1 5 11 4 4 4...

Page 42: ...verse light switch IGN 1 interface flag 2 Head light relay interface flag 2 Fuse 5A IGN 1 Fuse 15A interface flag 2 Spot light switch 1 High beam R High beam L Dipping switch 1 dipped beam R dipped be...

Page 43: ...e filter cover and replace with a new air filter 2 Engine Lubrication Engine oil replacement You must change the oil in the crankcase after the first 10 hours of operating of your new engine and after...

Page 44: ...and prevent costly repairs due to excessive wear See Fig 39 Put the vehicle on the level ground Shut down the engine put a collecting oil plate under the transmission oil outlet Loosen the oil outlet...

Page 45: ...ator 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 op...

Page 46: ...tachometer adjust the throttle to limit the idle speed The standard value is 800 900RPM Adjust the screw and adjust the idle speed to an ideal value Repeat step 5 2 until the RPM of engine stables Sp...

Page 47: ...spark plug with a special spanner torque 25Nxm 18 4Ft Lb Connect high voltage wire in order Engine damage or working unsteadily may occur if Not install the spark plug correctly Use a forbidden spark...

Page 48: ...seness 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 loosen the flange bolt...

Page 49: ...ENGINE MECHANICAL SYSTEMS...

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Page 93: ...ELECTRIC INJECTION SYSTEM...

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Page 135: ...RING 1 8 02 DLJ 372 1307041 372 1307041 WATER PUMP WASHER 1 9 02 DLJ 372 1307018 372 1307018 SEAL STRIP 2 1 10 02 DLJ Q1840825 Q1840825 BOLT 3 11 02 DLJ 372 1307019 372 1307019 SEAL STRIP 3 1 12 02 D...

Page 136: ...372 1002060 372 1002060 KNOCK SENSOR 1 7 02 MV800 06 04 0001 MV800 06 04 00 01 POSITION PIN 2 8 02 DLJ 372 1002070 372 1002070 OIL PRESSURE SWITCH 1 9 02 DLJ 372 1000410 372 1000410 ENGINE ASSY 1 10 0...

Page 137: ...5010 CRANKSHAFT ASSY 1 9 02 DLJ 372 1005016 372 1005016 STOPPER PLATE 2 10 02 DLJ S11 1601101 S11 1601101 COVER SET BOLT 4 11 02 DLJ 372 1DF1005010 372 1DF1005010 BEARING CRANKSHAFT 4 12 02 DLJ 372 10...

Page 138: ...2 100801BA EXHAUST MANIFOLD 1 3 02 DLJ Q1200825F3 Q1200825F3 STUD 4 4 02 DLJ Q33008 Q33008 HEXAGON NUT 6 5 02 DLJ 372 1008044 372 1008044 HEAT INSULATOR 1 6 02 DLJ Q1460612 Q1460612 HEXAGON HEAD BOLT...

Page 139: ...DLJ 372 1008013 372 1008013 AIR INTAKE MANIFOLD 1 9 02 DLJ Q1420645 Q1420645 HEXAGON HEAD BOLT 2 10 02 DLJ S11 1112030 S11 1112030 OIL RAIL 1 11 02 DLJ S11 1112010 S11 1112010 INJECTOR ASSY 3 12 02 DL...

Page 140: ...72 1011021 OIL PUMP GASKET 1 6 02 DLJ 372 1011030 372 1011030 OIL PUMP ASSY 1 7 02 DLJ Q1840825 Q1840825 BOLT 1 8 02 DLJ Q1840855 Q1840855 BOLT M8X55 2 9 02 DLJ Q1420612 Q1420612 HEXAGON HEAD BOLT 17...

Page 141: ...T 6 10 02 DLJ 372 1003021 372 1003021 INTAKE VALVE SEAT INSERT 6 11 02 DLJ 372 1003040 372 1003040 CYLINDER HEAD GASKET 1 12 02 DLJ 372 1003202 372 1003202 FRONT TRUNNION 1 13 02 DLJ Q1840816 Q1840816...

Page 142: ...090 372 1003090 OIL CAP 1 2 02 DLJ Q2540616 Q2540616 SCREW 6 3 02 DLJ 372 1003075 372 1003075 ENGINE TRIMING COVER ASSY 1 4 02 DLJ 372 1003030 372 1003030 ROCKER COVER ASSY 1 5 02 DLJ 372 1003036 372...

Page 143: ...e Part No Part Description Qty 1 02 DLJ 372 1009010 372 1009010 OIL PAN ASSY 1 2 02 DLJ Q1420612 Q1420612 HEXAGON HEAD BOLT 17 3 02 DLJ 372 1009017 372 1009017 OIL PLUG WASHER 1 4 02 DLJ 372 1009014 3...

Page 144: ...2 DLJ 372 1006032 372 1006032 SADDLE FLIP WASHER 1 9 02 DLJ 372 1006031 372 1006031 DRIVE RING 1 10 02 DLJ 372 1006041 372 1006041 INTAKE CAMSHAFT SUB GEAR 1 11 02 DLJ 372 1006030 372 1006030 INTAKE C...

Page 145: ...2 DLJ 372 1007013 372 1007013 VALVE SPRING 12 26 02 DLJ 372 1007020 372 1007020 VALVE SEAL 12 27 02 DLJ 372 1007016 372 1007016 LOWER VALVE SPRING SEAT 12 28 02 DLJ 372 1007012 372 1007012 EXHAUST VAL...

Page 146: ...02 DLJ S11 3705001 S11 3705001 IGNITION COIL BRACKET 1 4 02 DLJ S11 3707100 S11 3707100 SPARK PLUG ASSY 3 5 02 DLJ Q1460820 Q1460820 HEXAGON HEAD BOLT 1 6 02 DLJ S11 3707040 S11 3707040 HI TENSION CO...

Page 147: ...ion Qty 1 02 DLJ 372 1DE1004030 372 1DE1004030 PISTON RING ASSY 1 2 02 DLJ 372 1004031 372 1004031 PISTON PIN 3 3 02 DLJ 372 1004021 372 1004021 PISTON 3 4 02 DLJ 372 1004110 372 1004110 CONNECTING RO...

Page 148: ...11 1700103 S11 1700103 lower Steel cushion 1 7 02 DLJ S11 1200011CA S11 1200011CA Single Exhaust Gasket 1 8 02 DLJ Q1841245 Q1841245 Hex socket head bolt M12x45 1 9 02 DLJ Q218B1245 Q218B1245 Bolt 12x...

Page 149: ...art No Part Description Qty 1 02 DLJ S11 3701110BB S11 3701110BB Alternator 1 2 02 DLJ S11 3701211BA S11 3701211BA Alternator bracket 1 3 02 DLJ S11 1001415BA S11 1001415BA Rear bracket 1 4 02 DLJ S11...

Page 150: ...G 1 5 02 DLJ 5T07 1702020A 5T07 1702020A DECLUTCH FORK 1 6 02 DLJ 5T07 1702004 5T07 1702004 SLEEVE CLUTCH FORK 2 1 7 02 DLJ 5T07 1702030 5T07 1702030 SEAL CLUTCH FORK 2 8 02 DLJ 5T07 1702001 5T07 1702...

Page 151: ...GB T5789 1986 GB T5789 1986 AM6 12 BOLT AM6X12 2 19 02 DLJ GB T7246 1987 GB T7246 1987 6 WASHER 6 4 20 02 DLJ 5T07 1701400 5T07 1701400 OIL GROOVE ASSY 1 21 02 DLJ 5T07 1702080A 5T07 1702080A ROCKER C...

Page 152: ...2 DLJ 4T08A1 1701461 4T08A1 1701461 DRIVEN GEAR FOURTH GEAR 1 6 02 DLJ 5T07 1701610 5T07 1701610 BEARING OUTPUT SHAFT FRONT 1 7 02 DLJ 5T07 1701240 5T07 1701240 NEEDLE BEARING 1ST GEAR 2ND GEAR 2 8 02...

Page 153: ...512 1701432 GUIDE BLOCK SYNCHRONIZER 1ST GEAR 2ND GEAR 3 16 02 DLJ 5T07 1701205 5T07 1701205 RETAINER SYNCHRONIZER 1ST GEAR 2ND GEAR 1 17 02 DLJ 5T07 1701202 5T07 1701202 SPACER 3RD GEAR 4TH GEAR 1 18...

Page 154: ...DLJ QR512 1701257 QR512 1701257 RING SYNCHRONIZER 3RD GEAR 4TH GEAR 5TH GEAR 2 7 02 DLJ QR512 1701250 QR512 1701250 SYNCHRONIZER ASSY 3RD GEAR 4TH GEAR 1 8 02 DLJ QR512 1701252 QR512 1701252 GEAR HUB...

Page 155: ...ING INPUT SHAFT D em and 17 02 DLJ 4T08A 1701202 4T08A 1701202 SLEEVE INPUT SHAFT 1 18 02 DLJ 4T08A1 1701200 4T08A1 1701200 INPUT SHAFT ASSY 1 19 02 DLJ QR512 1701298 QR512 1701298 NUT SYNCHRONIZER 5T...

Page 156: ...DLJ GB T308 2002 GB T308 2002 STELL BALL 7 9375 6 4 02 DLJ 5T07 1702042A 5T07 1702042A SHIFT FORK 5TH GEAR 1 5 02 DLJ 5T07 1702061A 5T07 1702061A SHIFT FORK 3RD GEAR 4TH GEAR 1 6 02 DLJ 4T08A 1702001...

Page 157: ...SHIFT FORK REVERSE GEAR 1 13 02 DLJ 5T07 1702234 5T07 1702234 SCREW PLUG SHIFT FORK SHAFT 3 14 02 DLJ 5T07 1702233 5T07 1702233 WASHER SCREW PLUG SHIFT FORK SHAFT 3 15 02 DLJ QR512 1702341 QR512 1702...

Page 158: ...G 1ST GEAR 2ND GEAR 1 6 02 DLJ 5T07 1702104 5T07 1702104 SPRING STOP PLATE 2 7 02 DLJ 5T07 1702107A 5T07 1702107A STOP PLATE SHIFT INTERLOCK 1 8 02 DLJ 5T07 1702105A 5T07 1702105A SHIFT SELECT ARM 1 9...

Page 159: ...ELECT SHAFT 1 20 02 DLJ 5T07 1702072 5T07 1702072 STOP PLATE RELEASE SPRING 5TH REVERSE 1 21 02 DLJ GB T5789 1986 GB T5789 1986 BOLT AM6X12 2 22 02 DLJ QR512 1702227 QR512 1702227 OIL SEAL SHIFT SELEC...

Page 160: ...1 35 02 DLJ 5T07 1702046 5T07 1702046 BIG WASHER SHIFT ARM 1 36 02 DLJ 5T07 1702045 5T07 1702045 SMALL WASHER SHIFT ARM 1 37 02 SV1100 05 02 02 SV1100 05 02 02 00 SHIFT ARM COMP 1 38 02 SV1100 05 02 0...

Page 161: ...RONT BEARING 6007 1 5 02 DLJ QR512 1701604 QR512 1701604 DRIVING GEAR ODOMETER 1 6 02 DLJ GB T879 1 2000 GB T879 1 2000 Needle bearing D5 36 1 7 02 DLJ 5T07 1701090 5T07 1701090 Differential seal assy...

Page 162: ...asher 2 14 02 DLJ 5T07 1701320 5T07 1701320 REAR BEARING 6207 1 15 02 DLJ 5T12H 1709506 5T12H 1709506 limited thrust ring 2 16 02 DLJ 4T08A2 1701611 4T08A2 1701611 output shaft 2 17 02 DLJ MQC4 230301...

Page 163: ...No ERP Code Code name Description Q ty 1 02 MVA800 01 01 MVA800 01 01 00 00 Frame component 1 2 02 MVA800 01 02 0021 MVA800 01 02 00 21 front motherboard 1 3 02 MVA800 01 02 0022 MVA800 01 02 00 22 pe...

Page 164: ...14 15 03 01 D818 M6X16 D818 M6X16 Cross head screw M6X16 12 16 02 JD 0900008 02 JD 0900008 Washer 6 12 17 03 02 6183 1 M6 05 6183 1 M6 Self locking nut M6 12 18 03 01 D818 M6X16 D818 M6X16 Cross head...

Page 165: ...ine rubber bumper 7 6 03 02 2842 M10X1 25 05 2842 M10X1 25 nut asher M10x1 25 17 7 02 DLJ 372 0000E01AA 372 0000E01AA engine 372 1 8 02 MV800 04 01 03 MV800 04 01 03 00 left engine mount 1 9 02 SV1100...

Page 166: ...01 S650 05 02 01 00 shifter control assembly 1 4 02 S650 05 02 01 01 S650 05 02 01 01 rubber shifter indication 1 5 02 S650 05 02 01 02 S650 05 02 01 02 rubber shifter cover 1 6 02 S650 05 02 01 03 S...

Page 167: ...12 02 MV800 05 02 02 MV800 05 02 02 00 shifter soft shaft 1 1 13 03 01 5787 M6X25 05 5787 M6X25 M6x25 bolt 4...

Page 168: ...0 02 3 plastic cover 1 3 02 TR1100 05 01 0002 TR1100 05 01 00 02 350steering wheel 1 4 03 02 6183 1 M6 05 6183 1 M6 M6 self locking nut 6 5 02 TR1100 05 01 TR1100 05 01 00 00 steering wheel subassembl...

Page 169: ...03 03 D800 05 01 03 03 capping plate 1 30 03 01 2672 M6X12 2672 M6X12 socket head screw M6X12 9 31 03 02 6172 1 M12 R 05 6172 1 M12 jam nut M12X1 75 2 32 02 D800 05 01 0003 D800 05 01 00 03 spacer sle...

Page 170: ...12 12 13 11 No Code name Code name Description Q ty 1 03 01 5787 M8X20 05 5787 M8X20 Bolt washer M8X20 8 2 02 MV800 07 01 01 MV800 07 01 01 00 four caliper hydraulic brake assy 1 3 03 01 5787 M6X20 05...

Page 171: ...ake pedal 1 23 03 07 882 6X40 05 882 6X40 6X40 pin roll 1 24 03 07 882 10X105 05 882 10X105 10X105 pin roll 1 25 02 D650 07 03 02 D650 07 03 02 00 throttle pedal 1 26 02 SV1100 07 03 01 SV1100 07 03 0...

Page 172: ...ic power brake valve 1 5 02 ZJ509 03 04 ZJ509 03 04 hydraulic brake pads 4 set 6 02 ZJ609 F02 01 ZJ609 F02 01 hydraulic threeway valve 1 7 02 TR1100 07 01 01 02 TR1100 07 01 01 02 clip 8 8 02 ZJGS 01...

Page 173: ...01 01 01 SV800 07 01 01 01 disc brake with floating caliper front 1 2 02 D650 07 02 03 02 D650 07 02 03 02 single hydraulic oil cup 1 3 02 D650 07 02 03 03 D650 07 02 03 03 single hydraulic pump 1 4...

Page 174: ...0360010 rubber dirt proof boot 2 3 02 S650 03 01 01A S650 03 01 01 00A left wheel 27X8 12 1 4 03 08 91 4X40 05 91 4X40 cotter pin 4X40 2 5 03 02 9457 M18X1 5 05 9457 M18X1 5 castle nutM18X1 5 2 6 02 D...

Page 175: ...1 5X190 bolt 2 30 02 D800 02 03 00 03 D800 02 03 00 03 front spacer shock sleeve 8 31 02 SV1100 02 03 01 SV1100 02 03 01 00 front shock absorber 2 32 03 01 6185 1 M15 05 6185 1 M15 M15 nut 2 33 03 01...

Page 176: ...2 SR2000 04 03 0003A SR2000 04 03 00 03A fuel tank cap 1 4 02 MVA800 04 03 03 MVA800 04 03 03 00 fuel level sensor 1 5 02 SR2000 04 03 03 01 SR2000 04 03 03 01 rubber washer 1 6 02 D650 04 03 0004 D65...

Page 177: ...FTCARB 0816 FTCARB 0816 fuel hose 8x 16 0 2meter 30 02 D650 04 06 0001 D650 04 06 00 01 carbon can bracket 1 31 02 D650 04 06 0002 D650 04 06 00 02 carbon can plate 1 32 03 01 5787 M6X16 05 5787 M6X1...

Page 178: ...04 04 02 00A catalac convertor 1 7 02 C1100 01 02 0005 C1100 01 02 00 05 guide board 1 for cooling 1 8 03 02 6183 1 M8 05 6183 1 M8 self locking nut M8 2 9 02 D650 04 04 0008 D650 04 04 00 08 U clamp...

Page 179: ...2 00 03 muffler bracket 1 19 03 01 5787 M8X25 05 5787 M8X25 bolt washer M8 25 2 20 03 02 6183 1 M8 05 6183 1 M8 M8 self locking nut 2 21 03 03 95 8X24X2 95 8X24X2 washer 8X24X2 6 22 02 SV800 01 02 000...

Page 180: ...ase 1 6 02 D650 03 02 0003A D650 03 02 00 03A M12X1 5 bolt 4 7 02 D650 03 02 0005 D650 03 02 00 05 brake disk 1 8 02 D650 03 02 0008 D650 03 02 00 08 M6 bolt brake disk 4 9 03 09 893 2 55 893 2 55 cir...

Page 181: ...28 02 N650 02 03 02 N650 02 03 02 00 rear shock absorber 1 29 03 02 6185 1 M15 05 6185 1 M15X1 5 M15X1 5 nut 2 30 03 01 5787 M16X125 05 5787 M16X125 M16X2X125 bolt 2 31 02 D800 02 02 0003 D800 02 02 0...

Page 182: ...0 03 02 0003A D650 03 02 00 03A M12X1 5 bolt 4 7 02 D650 03 02 0005 D650 03 02 00 05 brake disk 1 8 02 D650 03 02 0008 D650 03 02 00 08 M6 bolt brake disk 4 9 03 09 893 2 55 893 2 55 circlip55 interna...

Page 183: ...eve 4 28 02 N650 02 03 02 N650 02 03 02 00 rear shock absorber 1 29 03 02 6185 1 M15 05 6185 1 M15X1 5 M15X1 5 nut 2 30 03 01 5787 M16X125 05 5787 M16X125 M16X2X125 bolt 2 31 02 D800 02 02 0003 D800 0...

Page 184: ...or 1 3 02 D650 04 07 0002 D650 04 07 00 02 air filter oil separator 1 4 02 SV800 04 07 0001 SV800 04 07 00 01 hoop 21 38 1 5 02 D650 04 07 0001 D650 04 07 00 01 oil separator 1 6 03 01 5787 M8X20 05 5...

Page 185: ...nk 1 25 02 D650 04 03 0004 D650 04 03 00 04 hoop 10 16 3 26 02 WT 0611 WT 0611 tube 6x 11 0 5meter 27 02 WT 0611 WT 0611 tube 6x 11 0 5meter 28 03 01 5787 M8X20 05 5787 M8X20 bolt washer M8 20 2 29 03...

Page 186: ...17 17 18 18 20 23 21 22 24 25 26 No ERP Code Code name Description Q ty 1 02 D1600 06 11A D1600 06 11 00 00A headlight 2 2 02 D1600 06 11 0001 D1600 06 11 00 01 headlight bulb 2 3 02 D650 06 00 05 D65...

Page 187: ...00 06 Bracket of speedometer 1 1 8 02 D800 06 000012 D800 06 00 00 12 tail light assy 2 1 9 02 MV800 06 01 MV800 06 01 00 00 electrical wiring harness 1 2 0 02 MV800 01 02 03 MV800 01 02 03 00 ECU pla...

Page 188: ...2 top fin 1 8 02 MVA800 01 02 0001 MVA800 01 02 00 01 left side fin 1 9 02 MVA800 01 02 00 27 MVA800 01 02 00 27 Hinge 1 10 02 LS2 01 02 01 06 LS2 01 02 01 06 Power door locks 2 11 02 D818 M6X16 818 M...

Page 189: ...0 01 02 0028 MVA800 01 02 00 28 fin assy 1 16 Seat and safety belt 5 5 5 6 1 3 4 seat and safety belt 1 J O Y N E R J O Y N E R J O Y N E R J O Y N E R 2 No ERP Code Code name Description Q ty 1 02 D6...

Page 190: ...02 D650 08 01 03 02 Track with release lever 1 17 Rack relative option rack No ERP Code Code name Description Q ty 1 02 MVA800 99990110 MVA800 99 99 01 10 aluminium roof rack 1 2 03 01 5787 M10X35 05...

Page 191: ...0 rear arm left 1 5 02 C1100 08 01 03 C1100 08 01 03 00 fender bracket left front 1 6 02 C1100 08 01 04 C1100 08 01 04 00 fender bracket right front 1 7 02 C1100 08 01 05 C1100 08 01 05 00 fender brac...

Page 192: ...Q ty 1 02 D1600 06 10A D1600 06 10 00 00A spotlight 4 2 02 D1600 06 10 0001 D1600 06 10 0001 Spotlight bulb 30W 4 3 03 03 95 0X20X1 5 05 95 10X20X1 5 washer 10X20X1 5 4 4 02 MV800 99 99 04 MV800 99 9...

Page 193: ...cription Q ty 1 02 MV800 9999 02A MV800 99 99 02 00A left nerf bar 1 2 02 MV800 9999 03A MV800 99 99 03 00A right nerf bar 1 3 03 01 5787 M10X35 05 5787 M10X35 bolt washer M10X35 8 4 03 02 2842 M10 05...

Page 194: ...08 05 01 01 B SVB1100 08 05 01 01 B LONG HANDLE upper fixed Anodizing 2 2 02 SVB1100 08 05 01 02 A SVB1100 08 05 01 02 A LONG HANDLE lower fixed Polishing 2 02 SVB1100 08 05 01 02 B SVB1100 08 05 01 0...

Page 195: ...per fixed Polishing 2 02 SVB1100 08 05 01 01 B SVB1100 08 05 01 01 B LONG HANDLE upper fixed Anodizing 2 2 02 SVB1100 08 05 01 02 A SVB1100 08 05 01 02 A LONG HANDLE lower fixed Polishing 2 02 SVB1100...

Page 196: ...lishing 1 02 SVB1100 08 05 02 01B SVB1100 08 05 02 01B FLAGSTAFF seat Anodizing 1 2 02 SVB1100 08 05 02 02A SVB1100 08 05 02 02A BIG FLAGSTAFF upper fixed Polishing 1 02 SVB1100 08 05 02 02B SVB1100 0...

Page 197: ...0 08 05 05 01A foot seat Polishing 2 02 SVB1100 08 05 05 01 B SVB1100 08 05 05 01B foot seat Anodizing 2 2 02 SVB1100 08 05 05 02 A SVB1100 08 05 05 02A foot tube Polishing 1 02 SVB1100 08 05 05 02 B...

Page 198: ...PE CLAMP 1set 02 SVB1100 08 05 04B SVB1100 08 05 04 00B ALUM COMBINED PIPE CLAMP 1set 1 02 SVB1100 08 05 04 01A SVB1100 08 05 04 01A upper tubing clip 1 02 SVB1100 08 05 04 01B SVB1100 08 05 04 01B up...

Page 199: ...B SVB1100 08 05 06 00B SMALL FLAGSTAFF MOUNT Anodizing 1 1 02 SVB1100 08 05 0 2 01A SVB1100 08 05 02 01A FLAGSTAFF seat Polishing 1 02 SVB1100 08 05 0 2 01B SVB1100 08 05 02 01B FLAGSTAFF seat Anodizi...

Page 200: ...bsorber coat OPTION NO ERP Code Part No Part Description Qty 1 02 D800 08 01 00 04 1 D800 08 01 00 04 1 Front shock absorber coat 2 2 02 D800 08 01 00 04 2 D800 08 01 00 04 2 Rear shock absorber coat...

Page 201: ...4 02 D650 08 05 0004 D650 08 05 00 04 Open jawed spanner 17 19 1 5 02 JD 1400004 JD1400004 Thread locking anaerobic adhesive 1 6 02 D650 08 05 0006 D650 08 05 00 06 Screwdriver 1 7 02 D650 08 05 0007...

Page 202: ...cket side upper 2 3 02 MV800 08 01 02 03 MV800 08 01 02 03 Protect jacket srear upper 1 4 02 MV800 08 01 02 04 MV800 08 01 02 04 Protect jacket side front 2 5 02 D250 11770 D250 11770 foam cover 1 6 0...

Page 203: ...y absorber shock option NO ERP Code Part No Part Description Qty 1 02 MV800 02 03 01A MV800 02 03 01 00A front luxury absorber shock 2 2 02 MV800 02 03 02A MV800 02 03 02 00A Rear luxury absorber shoc...

Page 204: ...05 01 00 02 2 20 spacer sleeve 02 D800 05 01 0003 D800 05 01 00 03 8 21 electric cable 02 MV800 06 01 MV800 06 01 00 00 1 22 spotlight 02 D1600 06 10A D1600 06 10 00 00A 4 23 spotlight bulb 30W 02 D16...

Page 205: ...16 camshaft assy intake 02 DLJ 372 1006020 372 1006020 4 17 camshaft assy exhaust 02 DLJ 372 1006060 372 1006060 8 18 valve inlet 02 DLJ 372 1007011 372 1007011 5 19 valve exhaust 02 DLJ 372 1007012 3...

Page 206: ...tch pressure plate 02 DLJ S11 1601020 S11 1601020 64 clutch disc 02 DLJ S11 1601030 S11 1601030 3 Transmission 1 DOUBLE SCREW ROD 02 DLJ 5T07 1701058A 5T07 1701058A 1 2 shift turning rod 02 DLJ 5T07 1...

Page 207: ...self locking nut M8 03 02 6177 1 M8 05 GB T6183 1 2000 20 2 self locking nut M6 03 02 6177 1 M6 05 GB T6183 1 2000 20 3 nut M10 1 25 03 02 2842 M10 X 1 25 05 GB T 2000 20 4 nut M10 1 5 03 02 2842 M10...

Page 208: ...PREPARATION ATTACH INSTRUCTION 1 Remove Packing...

Page 209: ...1 Remove Packing 2 Unbolt both sides and top of crate carefully remove cut wire ties holding cart lift cart and slide remaining frame out from under 2 Install the front suspension arm...

Page 210: ...N650 02 01 03 N650 02 01 03 00 upper suspension arm FR 1 No Erp code Part name Description Q ty 1 Install the left upper suspension arm F 3 and the left lower suspension arm F 4 on the front of frame...

Page 211: ...5 5782 M15x190 M15 1 5 190 bolt 2 2 02 D800 02 03 0003 D800 02 03 00 03 spacer sleeve shocker 4 1 03 02 6185 1 M15 05 6185 1 M15x1 5 M15 1 5 nut 2 No Erp code Part name Description Q ty 1 Attach front...

Page 212: ...5 01 00 01 rod end bearing POSA12LH 1 1 02 S650 03 01 04 00A S650 03 01 04 00A right wheel 27 8 12 1 No Erp code Part name Description Q ty 1 Install the shaft of outer tie rod end 2 to left wheel axl...

Page 213: ...5 Attach tie rod and front wheel...

Page 214: ...25 05 5787 M16X125 M16 2 125 bolt 4 2 02 N650 02 02 02 00A N650 02 02 02 00A rear suspension arm left 1 1 02 N650 02 02 01 00A N650 02 02 01 00A rear suspension arm right 1 No Erp code Part name Descr...

Page 215: ...02 02 00 drive shaft right 1 1 02 MV800 03 02 01 MV800 03 02 01 00 drive shaft left 1 No Erp code Part name Description Q ty 1 Check the steel cable baffle ring 3 in the groove of the output shaft of...

Page 216: ...7 Attach drive shaft transmission Steel cable baffle ring 3 4 Caution the Steel cable baffle ring 3 must be confirmed in the groove both sides before attaching drive shaft...

Page 217: ...er 2 3 03 02 6185 1 M15 05 6185 1 M15 M15 1 5 nut 2 2 02 D800 02 03 0003 D800 02 03 00 03 spacer sleeve shocker 4 1 03 01 5782 M15X80 05 5782 M15X80 M15 1 5 80 30bolt 2 No Erp code Part name Descripti...

Page 218: ...hub tighten the nuts 3 2 Attach the left side as above 3 02 S650 03 01 0002 S650 03 01 00 02 wheel nut M12 1 5 8 2 02 S650 03 02 04A S650 03 02 04 00A wheel 27 11 12 BR 1 1 02 S650 03 02 01A S650 03...

Page 219: ...are tight 2 start engine make sure oil warning light goes out within 5 10 seconds run engine untile both radiator hoses are warm about 5 minutes 80 degree keeping watch coolant level at radiator fill...

Page 220: ...DEALER PRE DELIVERY INSPECTION...

Page 221: ...ge This will not be covered under warranty ADDITIONAL TERMS AND CONDITIONS OF SALE y PROMISE TO PAY By signing this contract Buyer agrees to pay Seller the TOTAL DUE y TIME OF ESSENCE Time is of the e...

Page 222: ...s any actual charges assessed by Seller s financial institution resulting from such returned check 5 ATTORNEYS FEES If it is necessary for Seller to take legal action to enforce any of Seller s rights...

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