Joyner JNSZ1100TR-T4, Owner'S Manual

Page 1: ...RMATION 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 an...

Page 2: ...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...

Page 3: ...6 6 LUBRICATING DEVICE 147 7 CYLINDER HEAD 148 7 CYLINDER HEAD 149 8 COVER VALVE CHAMBER 150 9 OIL PAN 151 10 VALVE MECHANISM 152 10 VALVE MECHANISM 153 10 VALVE MECHANISM 154 11 IGNITION DEVICE 155 1...

Page 4: ...4 SHIFT FORK SHIFT FORK SHAFT 166 5 SHIFT CONTROLMACHINSM 168 6 DRIVEN GEAR ASSY 170 3 CHASSIS 171 18 HYDRAULIC PUMPASSEMBLY OF FOOT BRAKE 202 19 HYDRAULIC PUMPASSEMBLY OF PARKING BRAKE 203 20 CLUTCH...

Page 5: ...ING 1 8 372 1307041 WATER PUMP WASHER 1 9 372 1307018 SEAL STRIP 2 1 10 Q1840825 BOLT 11 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 THERMOS...

Page 6: ...372 1002044 CYLINDER HEAD SEAL PLUG 4 5 Q1840830 HEXAGON FLANGE BOLT 1 6 372 1002060 KNOCK SENSOR 1 7 372 1002036 POSITION PIN 2 8 S11 3810010 OIL PRESSURE SWITCH 1 9 11G10GB308 BALL 2 10 372 1002024...

Page 7: ...005032 WOODRUFF KEY 1 8 472 1005010 CRANKSHAFT ASSY 1 9 372 1005016 STOPPER PLATE 2 10 S11 1601101 COVER SET BOLT 6 12 372 1005036 PIN DOWEL 1 13 372 1005030 REAR OIL SEAL 1 14 372 1005021 REAR OIL SE...

Page 8: ...KET EXHAUST MANIFOLD 1 2 472 1008031 EXHAUST MANIFOLD 1 3 Q1200825F3 STUD 6 4 Q33008 HEXAGON NUT 6 5 472 1008044 HEAT INSULATOR 1 6 Q1460612 HEXAGON HEAD BOLT 4 7 S11 1205110JA OXYGEN SENSOR 1 8 Q1200...

Page 9: ...INTAKE TEMPERATUREAND PRESSURE SENSOR 1 7 Q1400416 HEXAGON HEAD BOLT 1 8 472 1008011 UPPER INTAKE MANIFOLD 1 9 Q1420645 HEXAGON HEAD BOLT 2 10 S11 1121012JA OIL GUIDE 1 11 480EF 1112010 INJECTOR 1 6L...

Page 10: ...TOR 1 22 472 1014121 CRANKCASE VENTILATION PIPE 1 1 23 Q1840816 HEXAGON FLANGE BOLT 5 24 372 1014130 CRANKCASE VENTILATION PIPE 3 1 25 Q1840820 HEXAGON FLANGE BOLT 2 26 S11 1108210DA CABLE ACCL 1 27 4...

Page 11: ...055 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 9 Q1420612 HEXAGON HEAD BOLT 17 10 372 1010017 OIL STRAINER WASHER 1 11 Q120061...

Page 12: ...AMSHAFT POSITION SENSOR 1 7 Q1400816 HEXAGON HEAD BOLT 1 8 372 1003023 GUIDE VALVE 16 9 372 1003022 EXHAUST VALVE SEAT INSERT 8 10 372 1003021 INTAKE VALVE SEAT INSERT 8 11 472 1003040AB GASKET CYLIND...

Page 13: ...OSITION COVER 10 18 S11 3808010 WATER TEMP SENSOR SET 1 19 372 1003201BA REAR HINGER 1 20 372 1003026 PLUG 3 21 372 1003024 PLUG 1 22 372 1003028 PLUG 1 23 372 1003038 STUD 1 24 372 1003076 SLEEVE 1 2...

Page 14: ...BER No Part number Name Quantity 1 372 1003090 OILING PORT COVER ASSY 1 2 Q2540616 SCREW 8 3 472 1003075 COVER 1 4 472 1003030 VALVE CHAMBER 1 5 472 1003036 GASKET VALVE CHAMBER 1 6 Q1460625 HEXAGON H...

Page 15: ...151 9 OIL PAN No Part number Name Quantity 1 472 1009010 OIL PAN ASSY 1 2 Q1420612 HEXAGON HEAD BOLT 17 3 372 1009017 SEAL WASHER OIL DRAIN THREADED PLUG 1 4 372 1009014 MAGNET PLUG 1 1 1 2 1 3 1 4 1...

Page 16: ...ELD SHAFT SPRING RING 1 8 372 1006032 SADDLE FLIP WASHER 1 9 372 1006031 DRIVE RING 1 10 372 1006040 GEAR DERIVEN INTAKE CAMSHAFT 1 11 372 1006030 GEAR MAIN INTAKE CAMSHAFT 1 12 472 1006020 GEAR MAIN...

Page 17: ...07019 VALVE LOCK BLOCK 32 23 372 1007021 EDDY SLEEVE 16 24 372 1007014BA VALVE SPRING UPPER SEAT 16 25 372 1007013 SPRING VALVE 16 26 372 1007020 VALVE SEAL 16 27 372 1007016 LOWER VALVE SPRING SEAT 1...

Page 18: ...Name Quantity 33 372 1007014 VALVE SPRING UPPER SEAT 1 34 Q673B155 CLAMP 1 35 472 1007042 LOWER COVER TIMING GEAR 1 36 480 1011062 BOLT 1 1 2 3 4 5 6 35 36 29 34 33 28 27 26 25 24 21 23 22 20 32 19 1...

Page 19: ...R UNIT 3 3 S11 3705001CA BRACKET IGNITION COIL 1 4 S11 3707100 SPARK PLUG ASSY 4 5 Q1460820 HEXAGON HEAD BOLT 3 6 S11 3707020BA HI TENSION CORD NO 1 1 7 S11 3707030BA HI TENSION CORD NO 2 1 8 S11 3707...

Page 20: ...PISTON AND CONNECTING ROD DEVICE No Part number Name Quantity 1 372 1004031 PISTON PIN 4 2 372 1004021AC PISTON 4 3 372 1004110 CONNECTING ROD ASSY 4 4 372 1004116 BEARING CONNECTING ROD 8 1 1 2 1 3...

Page 21: ...cushion 1 7 S11 1200011BA Single Exhaust Gasket 1 8 6170 M12 1 75 Hex nut M12 1 75 1 9 93 SW12 Spring Washer 12 1 10 97 1 W12 Washer 12 1 11 70 1 M12 1 75 75 25 Hex socket head bolt M12 1 75 75 25 1 1...

Page 22: ...158 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...

Page 23: ...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 se...

Page 24: ...058A 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 0...

Page 25: ...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...

Page 26: ...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 17012...

Page 27: ...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 3...

Page 28: ...60 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 Q...

Page 29: ...chronizer 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 17017...

Page 30: ...ork 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...

Page 31: ...ar 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...

Page 32: ...SM Ref Part No Part Description Qty Comments 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 spr...

Page 33: ...op 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 re...

Page 34: ...aft 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 d...

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Page 66: ...nection 2 5 TR1100 07 01 01 02B Right inlet hose of front caliper 1 6 ZJ509 05 00R Right caliper assy 2 7 TR1100 07 01 01 03B T4 Right inlet hose of rear caliper 1 8 TR1100 07 01 01 04B T4 Left inlet...

Page 67: ...02 01 02A Right outlet hose of T connection 1 4 ZJ509 05 00R Right caliper assy 1 5 ZJ609 F02 01 T connection 1 6 TR1100 07 02 01 03A Left outlet hose of T connection 1 7 ZJ509 05 00L Left caliper ass...

Page 68: ...10 05 00 19 Lower cylinder of clutch 1 2 TR1100 07 04 01 01 T4 Outlet hose of Master cylinder 1 3 ZJ709 04 00 16 Master cylinder 1 4 ZJ610 05 05 Ripple boot 1 5 ZJGS 01 02 Hose bolt M10x1 25 2 6 ZJGS...