Owner’s Manual

Repair Manual JNSZ800MVA

Parts manual
READ THIS MANUAL CAREFULLY.
IT CONTAINS IMPORTANT SAFETY INFORMATION.

16
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 standards, and operation on
public streets, roads, or highways is illegal.
 INTRODUCTION

Thank you for choosing JOYNER JNSZ800MVA. 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.
 CONTENTS
Warranty policy ................................................................................................................ 4
OWNER’S MANUAL...................................................................................................... 14
1.FOREWORD ........................................................................................................ 14
2.A FEW WORDS ABOUT SAFETY ....................................................................... 15
3.IMPORTANT SAFETY INFORMATION ................................................................ 16
4.SAFETY LABELS ................................................................................................. 17
5.ARE YOU READY TO DRIVE? ............................................................................ 18
6.IS YOUR VEHICLE READY TO DRIVE? ............................................................. 20
7.SAFE DRIVING PRECAUTIONS ......................................................................... 21
8.SPECIFICATIONS................................................................................................ 24
9.OPERATION INSTRUCTION ............................................................................... 25
10.MAINTENANCE ................................................................................................. 29
PARTS MANUAL ......................................................................................................... 135
1.ENGINE ............................................................................................................. 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.Install the front suspension arm.......................................................................... 209
3.Attach front shock absorber ............................................................................... 210
4.Attach tie rod end and front wheel ...................................................................... 212
5.Attach tie rod and front wheel ............................................................................. 213
6.Attach the rear suspension arm.......................................................................... 214
7.Attach drive shaft................................................................................................ 215
8.Attach rear shock absorber ................................................................................ 217
9.Attach rear wheel ............................................................................................... 218
10.Check vehicle ................................................................................................... 219
DEALER PRE-DELIVERY INSPECTION .................................................................... 220
WARRANTY POLICY
OWNER’S MANUAL
1.FOREWORD

Thank you for choosing our Off highway recreational vehicle. We hope
you will have fun with it. Before you drive the Off highway recreational
vehicle, please read through this Owner’s Manual carefully as it 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 service

your kart accordingly. Preventive maintenance is extremely important to the
longevity of your Off highway recreational vehicle.

We hope you will have a pleasant experience with our products and
thanks again for choosing US.
2.A FEW WORDS ABOUT SAFETY
In order to keep everyone safe, you must take responsibility for the safe operation of your Off
highway recreational vehicle.

To help you make informed decisions about safety, we have provided operating procedures and
other information on labels and in this manual. This information alerts you to potential hazards that
could hurt you or others.

It is not practical or possible to warn you about all hazards associated with operating or maintaining
a Off highway recreational vehicle. You 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 alert symbol and one of two signals: WARNING, or
CAUTION.

These signal words mean:

Physical harm may result from failure to adhere to the instructions that are described within the
WARNING labels.

Safety Headings---It means important safety reminders or important safety precautions.

Safety Section --- It means Off highway recreational vehicle safety.

Instructions --- how to use this Off highway recreational vehicle correctly and safely.

This entire manual is filled with important safety information----please read it carefully.
3.IMPORTANT SAFETY INFORMATION
Your Off highway recreational vehicle will provide you with many years of service and pleasure.
Providing you take responsibility for your own safety and understand the challenges you can meet
while driving.

There is much that you can do to protect yourself when you drive. You’ll find many helpful
recommendations throughout this manual. The following are a few that we consider most important.
Follow the Age Recommendation
It is strongly recommended that no one under the age of 16 be permitted to drive this Off highway
recreational vehicle without adult supervision.

Always Wear a Helmet

It’s a proven fact: helmets significantly reduce the number and severity of head injuries. Always
wear an approved motorcycle helmet. We also recommend that you wear eye protection, sturdy
boots, gloves, and other protective gear.

Drive Off-Road Only

Your Off highway recreational vehicle is designed and manufactured for off-road use only. The tires
are not made for pavement, and the Off highway recreational vehicle does not have some features
required for use on public roads.

Take Time to Learn & Practice

Even if you have derived other Off highway recreational vehicle, take time to become familiar
with how this Off highway recreational vehicle works and handles. Practice in a safe area until you
build your skills and get accustomed to this Off highway recreational vehicle’s size and weight.
Because many accidents involve inexperienced or untrained drives, we urge all drivers to take a
training course approved by the Off 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 drive off-road. Continually “read” the
terrain for unexpected turns, drop-offs, rocks, ruts, and other hazards. Always keep your speed low
enough to allow time to see and react to hazards.

Drive within Your Limits

Pushing limits is another major cause of Off highway recreational vehicle accidents. Never drive
beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs,
fatigue, and inattention can significantly reduce your ability to make good judgments and driver safely.

Don’t Drink and drive

Alcohol and driving don’t mix. Even one drink can reduce your ability to respond to changing
conditions, and your reaction time gets worse with every additional drink. So don’t drink and drive,
and don’t let your friends drink and drive either.

Never run your Off highway recreational vehicle indoors.

The exhaust from the engine contains a tasteless, odorless and poisonous gas called carbon
monoxide.

Keep away from moving parts of the Off highway recreational vehicle
The operator of the Off highway recreational vehicle should never place their hands or other
parts of their body near any moving part of the Off highway recreational vehicle. Failure to adhere to
this warning will cause physical harm to your body.

Skidding or Sliding
The terrain surface can be a major factor affecting turns, Skidding a turn is more likely to occur
on slippery surfaces such as snow, ice, mud and loose gravel. If you skid on ice, you may lose all
directional control. To avoid skidding on slippery terrain, keep you speed low and drive carefully.
4.SAFETY LABELS
This section presents some of the most important information and recommendations 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 label
comes off or becomes hard to read, contact your dealer for warning labels replacements.
5.ARE YOU READY TO DRIVE?
Before each drive, you need to make sure you and your Off highway recreational vehicle are both
ready to drive. To help get you prepared, this section discusses how to evaluate your driving
readiness, what items you should check on your Off highway recreational vehicle, and adjustments to
make for your comfort, convenience, or safety.

Before you drive your Off highway recreational vehicle for the
first time, we urge you to:
Read this owner’s manual and the labels on your Off highway recreational vehicle carefully.
Make sure you understand all the safety messages.
Know how to operate all the controls.
Have adult present if under 16 years old.

Before each drive, be sure:

You feel well and are in good physical and mental condition.
You are wearing an approved motorcycle helmet (with chin strap tightened securely), eye
protection, and other protective clothing.
You don’t have any alcohol or drugs in your system.

Protective Apparel
For your safety, we strongly recommend that you always wear an approved motorcycle helmet, eye
protection, boots, gloves, long pants, and long-sleeved shirt or jacket whenever you drive.
Although complete protection is not possible, wearing proper wear can reduce the chance of injury
when you drive.
The following suggestions will help you choose the proper driving wear.
Helmets and Eyes Protection
Your helmet is your most important piece of driving gear because it offers the best protection
against head injuries. A helmet should fit your head comfortably and securely.
An open-face helmet offers some protection, but a full-face helmet offers more. Regardless of the
style, look for a DOT (Department of Transportation) sticker in any helmet you buy. Always wear a
face shield or goggles to protect your eyes and help your vision.

Operating this Off highway recreational vehicle without wearing an approved

motorcycle helmet, eye protection, and protective clothing could increase your
chances of head and/or eye injury, possibly death in the event of severe
accident.
Always wear approved motorcycle helmet that fits properly and wear eye
protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket
and long pants.

Additional Driving Wear

In addition to a helmet and eye protection, we also recommend:
Sturdy off-road motorcycle boots to help protect your feet, ankles, and lower legs Off-road
motorcycle gloves to help protect your hands.
 Driving pants with knee and hip pads, a driving jersey with padded elbows, and a chest/shoulder
protector.

Drive Training
Developing your driving skills is an on-going process. Even if you have derived other Off
highway recreational vehicles, take time to become familiar with how this Off highway recreational
vehicle works and handles. To build skills, practice driving the Off highway recreational vehicle in a
safe area, do not drive in rough terrain until you get accustomed to the Off highway recreational
vehicle’s controls, and feel comfortable with its size and weight.

Operating Off highway recreational vehicle without proper instruction could

increase your risk of an accident, which could lead to serious injury or death.

Attempt supporting with your hands to the ground when the Off highway
recreational 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 recommended that no one under the age of 16 be permitted this Off highway
recreational vehicle without adult supervision.

A child driving a Off highway recreational vehicle that is not recommended for
his/her age could lose Off highway recreational vehicle control and result in severe
injury or death.A child under 16 should have adult supervision when operate on the
Off highway recreational vehicle.

No Alcohol or Drugs
Alcohol, drugs and Off highway recreational vehicles don’t mix. Even a small amount of alcohol
can impair your ability to operate a Off highway recreational vehicle safely. Likewise, drugs-even if
prescribed by a physician-can be dangerous while operating a Off highway recreational vehicle.
Consult your doctor to be sure it is safe to operate a vehicle after taking medication.
 Operating this Off highway recreational vehicle after alcohol or drugs can seriously
affect your judgment, cause you to react more slowly, affect your balance and
perception, and could result in serious injury or death.
Never consume alcohol or drugs before or while operating this Off highway
recreational vehicle.

6.IS YOUR VEHICLE READY TO DRIVE?

Before each drive, it is important to inspect your Off highway recreational vehicle and make sure
any problems are away. A pre-drive inspection is necessary, not only for safety, but also for comfort.
Because any a breakdown, or even a flat tire, can be a major inconvenience.

If your Off highway recreational vehicle has overturned or has been involved in a collision, do not
drive it until your dealer has inspected your Off highway recreational vehicle, There may be damages
or other problems you cannot see.

Improperly maintaining this Off highway recreational vehicle or failing to correct a

problem before driving 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 before you get on the Off highway recreational vehicle:

■ Engine Oil
Check the oil level and add oil if needed. Check for leaks.

■ Fuel
Check the fuel level and add fuel if needed. Also make sure the fuel fill cap is securely fastened.
Check for leaks.

■ Tires
Use a gauge to check the air pressure. Adjust if needed. Also look for signs of damages or
excessive wear.

■ Nuts & Bolts

Check the wheels to see that the axle nuts are tightened, Use a wrench to make sure all accessible
nuts; bolts, and fasteners are tight.

■ Under body & Exhaust System

Check for and remove any dirt, vegetation or other debris that could be fire hazard or interfere with
the proper operation of the Off highway recreational vehicle.

■ Air Cleaner Housing Drain Tube

Check for deposits in the drain tube. If necessary, clean the tube and check the air cleaner housing.

■ Leaks, Loose Parts

Walk around you Off highway recreational vehicle and look for anything that appears unusual, such
as a leak or loose cable.
■ Lights
Make sure the headlight; brake light and taillight are working properly.

■ Throttle
Check the free play and adjust if needed. Press the throttle to make sure it moves smoothly without
sticking, and snaps back automatically when it is released.

■ Brakes
Press the brake pedal several times, check for proper brake pedal free play. Make sure there is no
brake fluid leakage.

■ Steering Wheel
Check that the wheels turn properly as you turn the steering wheel.

■ Cable
Check the cable housing for wear. Check the fittings for looseness. Replace or tighten as needed.

■ Tie rod
Check the tie rod housing for wear. Check the fittings for looseness. Replace or tighten as needed.
7.SAFE DRIVING PRECAUTIONS

Off-Road Use Only

Your Off highway recreational vehicle and its tires are designed and manufactured for off-road use
only, not for pavement. Driving on pavement can affect handling and control. You should not drive
your Off highway recreational 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
vehicle to go out of control.
Never operate the Off highway recreational vehicle on any paved surfaces, including
sidewalks, driveways, parking lots and streets.

When driving off-road, also remember to always obey local off-road driving laws and regulations.
Obtain permission to drive on private property. Avoid posted areas and obey “no trespassing” signs.

You should never drive your Off highway recreational vehicle on public streets, roads or
highways, even if they are not paved. Drivers of street vehicles may have difficulty seeing and
avoiding you, which could lead to a collision. In many states it is illegal to operate Off highway
recreational vehicles on public streets, roads and highways.

Operating this Off highway recreational vehicle on pulic streets, roads or highways can
cause collision with other vehicle. Never operate this Off highway recreational
vehicle on any public streets, roads or highways, even dirt or gravel one.
Keep Hands and Feet on Controls
Always keep both hands on the steering wheel and both feet on the foot controls. When driving
your Off highway recreational vehicle. It is important to maintain your balance and to control of the Off
highway recreational vehicle. Removing hands or foot away from the controls can reduce your ability
to react control of the kart.

Removing hand from Steering wheel or feet from foot controls during operation
can reduce your ability to control the Off highway recreational vehicle or could
cause you to lose your balance and fall off the Off highway recreational vehicle.
Always keep both hand on the steering wheel and both feet on the foot controls
of your Off highway recreational vehicle during operation.

Control Speed
Driving at excessive speed increases the chance of an accident. In choosing a proper speed, you
need to consider the capability of your Off highway recreational vehicle, the terrain, visibility 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 highway recreational vehicle, which can result in an
accident.
Always drive at a speed that is proper for your Off highway recreational vehicle, the
terrain, visibility and other operating conditions, and your experience.

Use Care on Unfamiliar or Rough Terrain

Before driving in a new area, always check the terrain thoroughly. Don’t drive fast on unfamiliar
terrain or when visibility is limited. (It’s sometimes difficult to see obstructions like hidden rocks,
bumps, or holes in time to react).

Failure to use extra care when Operating this Off highway recreational vehicle on
unfamiliar terrain could result in the Off highway recreational vehicle overturning or
going out of control.
Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert
to changing terrain conditions when operating the Off highway recreational vehicle.

Never drive past the limit of visibility. Maintain a safe distance between your Off highway
recreational vehicle and other off-road vehicles. Always exercise caution and use extra care on rough,
slippery and loose terrain.

Failure to use extra care when operating on excessively rough, slippery or loose
terrain could cause loss of traction or vehicle control, which could result in an
accident, including an overturn.
Do not operate on excessively 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 of terrain.

Do Not Perform Stunts

You should always operate your Off highway recreational vehicle in a safe and reasonable manner.
When driving, always keep all four wheels on the ground.

Attempting wheelies, and other stunts increases the chance of an accident, including
an overturn.
Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
 8.SPECIFICATIONS
DIMENSIONS
Overall Length-------------------------------------------------------------------------------------------------------------113 in. (2880mm)
Overall Width ----------------------------------------------------------------------------------------------------------------68in. (1740mm)
Overall Height -------------------------------------------------------------------------------------------------------------- 67in. (1700mm)
Wheelbase -------------------------------------------------------------------------------------------------------------------- 82 in. (2090mm)
Front Track ---------------------------------------------------------------------------------------------------------------------- 58 in. (1475mm)
Rear Track ----------------------------------------------------------------------------------------------------------------------58in.(1470mm)
Ground Clearance -------------------------------------------------------------------------------------------------------- 12 1/2in. (320mm)

ENGINE
Type ---------------------------------------------------------------------------------------------------- 3-Bore, 4-Stroke, Liquid-cooled
Bore x Stroke ------------------------------------------------------------------------------------------------------------- 72mm×66.5mm
Displacement -------------------------------------------------------------------------------------------------------------------------- 812cc
Corrected compression ratio -------------------------------------------------------------------------------------------------------- 9.5:1
Carburetor ----------------------------------------------------------------------------------------------------------------- Electric Fuel Injection
Output Maximum Power --------------------------------------------------------------------------------------------------------------------37KW
Maximum Torque ---------------------------------------------------------------------------------------------------------------------------- 70NW
Starting ---------------------------------------------------------------------------------------------------------------------------------------- Electric
Ignition ------------------------------------------------------------------------------------------------------------------------------------------- C.D.I
Lubrication ------------------------------------------------------------------------------------------------------------------------- Force & Splash
Transmission ------------------------------------------------------------------------------------------------- manual clutch, 4 shift/Reverse
Fuel type ------------------------------------------------------------------------------------------------------------------------ RQ93 (unleaded)
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 55/55W/Both
Tail Light ------------------------------------------------------------------------------------------------------------------12V10W/5W/21W/Both
Spot light ----------------------------------------------------------------------------------------------------------------------------12V35W/Four
Main Fuse -----------------------------------------------------------------------------------------------------------------------------------------50A
Brake Track ------------------------------------------------------------------------------------------------------------------- < 7m @ 20miles/h
Top speed ------------------------------------------------------------------------------------- 60miles/h (or limited as customers require)

CHASSIS
Front, Rear brake ------------------------------------------------------------------------------------------- Hydraulic disc, right foot control
Front tire -------------------------------------------------------------------------------------------------------------------------- 25×8-12(Option)
Front tire -------------------------------------------------------------------------------------------------------------------------- 27×8-12
Rear tire ------------------------------------------------------------------------------------------------------------------------- 25×11-12(Option)
Rear tire --------------------------------------------------------------------------------------------------------------------------- 27×11-12
Front Suspension --------------------------------------------------------------------------------------------------- Independent Dual A-Arm
Rear Suspension ---------------------------------------------------------------------------------------------------- Longitudinal Control Arm
Final Drive ------------------------------------------------------------------------------------------------------------------------------ shaft driven

TIRE PRESSURE
Front ------------------------------------------------------------------------------------------------------------------ 103kpa,1.05kg/c ㎡ 15psi
Rear -------------------------------------------------------------------------------------------------------------------103kpa,1.05kg/c ㎡ 15psi

WEIGHT
Net Weight -------------------------------------------------------------------------------------------------------------------------------------480kg

Warranty (factory limited scope) ----------------------------------------------------------------------------------------------- 90 Days

9.OPERATION INSTRUCTION
WARNING-Do not attempts to start or operate the engine until completely familiar with the location
and use of each control necessary to operate this vehicle. Operator must know how to stop this
machine before starting and driving it.
Control pedal
Accelerator Pedal: Changes engine rpm and vehicle ground speed. Press down on the
accelerator pedal with your foot to increase speed and let up on the pedal to decrease speed. (See
figure 1)

Each time prior to starting the engine, check the throttle assembly to ensure that
when pedal is pushed all the way forward the assembly is working smoothly and
returns to idle when released. Do not operate if pedal or engine throttles linkage fail to
return to idle. If unable to correct the problem through lubrication, adjustment or
replacement of worn parts, contact your dealer for assistance.

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 pedal unnecessary will
wear the brakes out prematurely. (See figure 1)
Clutch Pedal: Applying pressure to the clutch pedal with your left foot will make gearbox to
declutch and let up the pedal to clutch. (See figure 1)

Accelerator Pedal

Clutch Pedal Brake Pedal

FIGURE 1

Park brake lever and shift selector

Park Brake Lever: Sets and releases the park brakes. Do not drive vehicle with park brake
lever set. (See figure 2)
• Set park brakes: pull-up on the park brake lever until the lever is tight.
• Release park brakes: Pull-up on the park brake lever, depress the release button and push the
lever
Shift Selector: Changes trans-axle gears from neutral to forward or reverse. Always start
engine in neutral. (See figure 3)
• Pull up on shift selector collar and move lever to position “1” “2” “3” “4”, the vehicle will move
forwards at different speed.
 • Pull up on shift selector collar and move lever to center position to place trans-axle in neutral.
• Pull up on shift selector collar and move lever to position “R”, the vehicle will move backwards.

Shift Selector

Park brake lever

FIGURE 2 FIGURE 3
Switch
Ignition Switch: Pull firmly up on the park brake lever with your hand until the lever is tight. Set
shift selector in neutral. Insert the key into key-switch, turn the key clockwise, and release the key
when the engine starts. (Warning: Don’t crank starter more than 5 seconds at one time). (See figure
4)
Turning-light switch: control the turning- light. Press the top of button down and the right
turning light 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 the lower-beam button
down and the head light work as lower beam, the far-beam button and work as far beam. (See figure
5)
Head light switch

Ignition Switch Turning-light Spot light switch

FIGURE 4 FIGURE 5

Park Brake Light switch: control the 4 turning lights on or off. Pull the park-brake-light switch
out and the 4 turning lights illuminate together. (See figure 6)
Horn Switch: control the horn. Press the horn button down and hold, the horn buzz. (See figure
7)
Spot light switch: control the 4 spot- lights on or off.

Park Brake Light switch

Horn Switch

FIGURE 7
Indicating and gauges
Speedometer: Indicates the speed vehicle is moving at. It warns you to drive at proper speed.
(See figure 8)
Tachometer: Indicates the RPM of engine. (See figure 8)
Coolant temperature indicator: indicate the temperature of coolant, if the temperature is
above 1200C/2480 F. Stop engine immediately. Check coolant lever and add if low, see authorized
JOYNER dealer if temperature indicator stay on and overflow tank is full of coolant. (See figure 8)
Voltmeter: Indicates battery is charging. Check battery if voltmeter registers a charge that is
lower than normal. See your authorized JOYNER dealer if battery is good and voltmeter still register
low charge (See figure 8)
Fuel level gauge: The fuel gauge displays approximately how much fuel you have in the fuel
tank. Always park the vehicle 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 pressure. If the needle point to red area, stop engine
immediately. Check oil level and add if low. See authorized Joyner dealer if needle stays on and
engine is full of oil. (See figure 8)
Reverse gear light: indicate reverse gear engaged if illuminated. (See figure 9)
Battery charge light:If indicater light is on,stop and check battery or charging. If it is off,
indicate battery is charging. (See figure 9)
Coolant temperature light: indicate coolant temperature is above 1200C. (See figure 9)
Oil pressure light: Indicates low/high oil pressure when illuminated, see authorized JOYNER
dealer if necessary. (See figure 9)

Voltmeter

Speedometer

Tachometer

Fuel level gauge

Oil pressure gauge Coolant temperature indicator

FIGURE 8

Reverse gear light Coolant temperature light

Battery charge light

Oil pressure light
 FIGURE 9

Passengers
The vehicle allows for two riders only. Make sure you brief your passenger on proper safety
procedures like keeping hands, arms, feet and other bodily appendages inside the vehicle.
Passengers should only be transported in factory-supplied seating.
Operator and passenger are responsible for deciding if their situation warrants using Seat Belts.

Seat
The seats must always be securely fastened in the position which best affords the operator control
of the foot pedals, steering 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
tha
t seat is locked into position.

Seat adjustment handle

FIGURE 10

Before attempting to adjust the seat ensure that engine of the Off highway
recreational vehicle is stopped.

Never operate this Off highway recreational vehicle when the provided seat is not
securely fastened, to do so could result in a strong possibility of severe personal injury
or loss of life. Before attempting to adjust the seat ensure that engine of Off highway
recreational vehicle is stopped.
10.MAINTENANCE
Chassis Maintenance
Tire Maintenance
Use only tires recommended by Joyner. It is important for your safety and the safety of others that
the tires have correct air pressure. Check air pressure in four tires before each use. Visually inspect
tires for loss of air throughout each day of operation. See Tire inflation Chart below for correct tire
pressure.

Tire Inflation Chart

Tire Inflation PSI
Front Tires 15
Rear Tires 15

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 figure clockwise or counter clockwise to move the shift cable at a proper
position where you can shift clearly and smoothly, and then tighten the shin nut.(See figure 11,12)

Back Forth

Adjustment nut

FIGURE 11

Back Forth

Adjustment nut

FIGURE 12
Parking Adjustment
Pull the park brake lever up so that the unit can engage park brake. To release the unit, press
button on front end of parking lever then push the parking lever to the bottom. Adjust the parking
cable if necessary. (See figure 13)

NUT #1

NUT #2

FIGURE 13

Break-in
The first month is most important in the life of your vehicle. Proper operation during this break-in
period will help assure maximum life and performance from your new vehicle. The following
guidelines explain proper break-in procedures.
After the engine starts, the engine is not allowed in high speed in the neutral gearshift.
Drive vehicle from stop to low speed slowly.
Avoid braking strongly.
Do not exceed the vehicle speed on the below schedule.

The speed of vehicle The first 1000 km

1st Gear 25km/h
2nd Gear 45km/h
Max speed in each gear
3rd Gear 70 km/h
4th Gear 90km/h
Front Wheel Replacement
Do not disassemble the center castle nuts when you replace the front wheels
(See Fig. 15). Tighten the nuts after replacing the wheels.

FIGURE 15

Rear Wheel Replacement

Do not disassemble the center castle nuts when you replace the rear wheels
(See Fig. 16). Tighten the nuts after replacing the wheels.

FIGURE 16
.Shock adjustment
1. After a long time use, the shock need to be adjusted for more tension refer to maintenance and
service log, adjust the shock with a special spanner. In other case, the chock nitrogen needs to be
added to get more nitrogen pressure; the recommended nitrogen pressure is 1.0MPa/145psi.
2. Adjust the shock refer to the following drawing.

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

Lock nut Pushing nut

Special spanner

Clock wise

Special spanner
Clutch replacement
Remove two bolts, and demount Starter-assembly carefully. (See Fig. 17-20)

Q1840845

Q1841245
FIGURE 17 FIGURE 18

S11-3708111

S11-3708110G

FIGURE 20 FIGURE 19

2. Remove four bolts on the transmission case, lay down these carefully. Caution: When fix the four
bolts in the transmission case; you must tighten them according to the prescribed torque
45-55N.M. (See Fig. 21-24)
Q1841240 Q218B1245
Q1841245

FIGURE 22 FIGURE 21
 FIGURE 23 FIGURE 24

3. Remove upper steel cushions and lower steel cushion. (See Fig. 25-26)

372-100203 S11-170010

FIGURE 25 FIGURE 26

4.Insert a spine-shaft into the hole of the Clutch assy , remove the six bolts on the Clutch pressure
plate, now It’s clear. Caution: When fix the six bolts in the Clutch pressure plate;
you must tighten them according to the prescribed torque 28 N.M. (See Fig. 27-31)

Spline-shaft

FIGURE 27 FIGURE 28
 S11-1601020 S11-1601030

FIGURE 29 FIGURE 30

FIGURE 31

5. Insert a spline-shaft into the hole of the Clutch assy , fix the six bolts on the Clutch pressure plate ,
tighten them according to the prescribed torque 28 N.M . (See Fig. 32-33)

FIGURE 32 FIGURE 33
6. Fix parts according to reverse operation to the disassembly.
Front Wheel Alignment
Put the vehicle on level ground.
The “tie-in” of the front wheels should be 0.63 inches. To check alignment, measure distance A and
B between the centerline (CL) of the wheels. The proper toe-in dimension A should be 0.63 inches
greater than dimension B.
To adjust the alignments, loose the lock nuts 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 against the rod end. Recheck the dimensions for proper
alignment.

Front tie rod

Lock nut

FIGURE 34 FIGURE 35

Fuse and relay

To check or replace fuses:
1.Take off the cover of the fuse box. Press the hook down and pull off the cover.
2.Check and replace the fuse according the fuses and relays diagram.

Press the hook down

 Engine relay Fuel pump relay Fan relay Spot light relay

R gear indicator fuse Engine fuse Flash fuse Fuel pump fuse

Gauge and indicator fuse ECU normal open circuits fuse Fan fuse

Brake indicator fuse

Bulb replacement
To replace the bulb of the sport light, do the following, see Pic 1-Pic 6:

Pic 1 Pic 2 Pic 3

 Pic 4 Pic 5 Pic 6

4. Loose the 2 crews at the bottom of the head light, and take off the 2 hoops around the head light.
5. Separate the head light as the picture.
6. Unscrew the screw that fixes the bulb, and take off the bulb carefully.
7. Disconnect the bulb from the wiring.
8. Connect a new bulb with the same specification to the wiring.
9. Put all the parts disassembled above with reversing step 1～4.
To replace the bulb of the taillight, do the following, see Pic 7-Pic 8
- Unscrew the 6 screws from the taillight.

Pic 7 Pic 8
- Separate the taillight cover from the taillight body.
- Take 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 highway recreational vehicle clean. With a clean rag, wipe off any dirt and oil from
around controls. Wipe off any spilled fuel and oil. Keep the engine clean of foreign object and be sure
to check that air intake fan is free of debris for proper cooling.

Off highway recreational vehicle Lubrication

Lubricate vehicle every 90 days of use, Apply several drops of oil in specific points.

Storage Instruction
In the event your Off highway recreational vehicle is not to be operated for periods in excess of
30 days or at the end of each driving season prepare for storage as follows:
1.Drain fuel tank by allowing engine to run out of fuel, or use a fuel stabilizer.
2.Lubricate engine cylinder by removing the spark plug and pour one ounce of clean lubricating oil
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 storage,
will cause hard starting and affect engine performance.

Do not drain fuel while engine is hot. Be sure to move Off highway
recreational vehicle outside before draining fuel.
ENGINE WIRING DIAGRAM
MAIN WIRING DIAGRAM

DJ7021-1.5-11
前左转向灯
DJ7041-1.5-11
左大灯

DJ7013-6.3-21
小φ4

小φ4

DJ7021-1.5-11
前右转向灯
右大灯
DJ7041-1.5-11

φ4

机油压力传感器

后左转向灯
DJ7031-1.5-11

左尾灯

DJ7031-1.5-11

后右转向灯
DJ7021-1.5-11

右尾灯

DJ7031-1.5-11
Electrical schematic diagram
IGN 2

Start motor M ST Fuse 7.5A

Ignition switch Speed meter

Spot light switch 1

I/p wiring conn 23

spot light*4 Tachometer

I/p wiring conn 21

Battery
IGN 1 Fuel meter
High beam R High beam switch 1 IGN 2
ST Fuelsensor
High beam L
Oil pressure guage
oil pressure
Speed sensor
dipped beam R Dipping switch 1 sensor

Water temperauter meter

dipped beam L
I/p wiring conn 30

High beam switch 2

Clearance lamp Voltage meter
Spot light switch 2
side light *4
Dipping switch 2
T
u
r
i2
n
n
g
s
i
g
n
a
l

Body wiring conn 28 Charge indicator

R
*

scintillator water temperture Swich

Turn signal G water temperatuer

T
u
r
n
i
n
g
s
i
g
n
a
l

switch
Fuse 5A
warning
L
*
2

oil pressure switch

I/p wiring conn oil pressure
warning
Reverse light switch
Body wiring conn 67 ING 2
Reverserwarning
Power for ECU Body wiring conn 82
Fuse 20A
Main relay

Body wiring conn 69 Body wiring conn 82

IGN 1
interface flag 2 Head light relay
Fuel pump M
Fuse 15A
Fuel pump relay
interface flag 1 interface flag 2 High beam switch 1
Fuse 7.5A High beam indication
interface flag 1

Cooling fan High beam switch 3 High beam

Fuse 15A
IGN 1 Fuse 5A switch
Fan relay
High beam switch 2

Horn button Master switch

Horn button Fuse 5A
High beam switch 3 Dipping switch 1

Brakes light switch Dipping beam

Dipping beam
Brakes light R indication

switch
IGN 1
Brakes light L Fuse 5A + - Dipping switch 2

Battery interface flag 2 Spot light switch 1

Fuse 15A
Spot light signal Spot light
switch
Spot light switch 2

Wire's colour symbol

RS---red/grey B---black R---red U---blue RU---red/blue P---purple S---grey W---white YG---yellow/green L---Cambridge blue N---brown K---pink NB---brown/black NR---brown/red
UW---blue/white RB---red/black GY---green/yellow SB---grey/black BR---black/red Y---yellow WG---white/green GB---green/black WR---white/red BW---black/white
Engine maintenance
1. Service Air Filter
Service air filter every 80 hours
NOTE: Service more often under dusty conditions.
Cover Filter

FIGURE 35

Remove filter cover (See Fig. 35). Check the filter cover and the air filter, if the filter cover and the
air filter are dusty, please clear the 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 40 hours of use thereafter. That will insure proper lubrication of internal parts and prevent
costly repairs due to excessive wear. (See Fig. 36-38)

Oil intlet
Oil inlet plug

Oil measure
Oil measure
FIGURE 36

Oil outlet
FIGURE 37

FIGURE 38
 With the engine warm, put the vehicle on the level ground.
Shut down the engine, put a collecting oil plate under the engine oil outlet. Let the engine oil out
fully (see Fig. 38).
Tighten the engine oil outlet plug.
Remove the oil filler cap (see Fig. 36), fill oil (SAE 10W/30-50 ) about 3.86 liters to the engine.
Pull out the engine oil dip stick (see Fig. 36), confirm the corrective oil level in the crankcase (see
Fig. 37).
Check engine oil and recharge
If the color of engine oil changes, you need to replace the engine oil as above.
Check the engine oil level; charge from 2.1.4 as above if the oil level is lower than “L”,

3. Transmission lubrication
Oil replacement
You must change the oil in the transmission refer to preventative maintenance log after the first 10
hours of operating of your new engine and after 40 hours of use thereafter. That will insure proper
lubrication of internal parts and prevent costly repairs due to excessive wear (See Fig. 39).

Oil outlet

Oil inlet

FIGURE 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 plug in the transmission. Let the transmission oil out fully
(see Fig. 36、38).
Remove the iron dust plug, this plug has a magnet on it. Iron dust caused by moving parts will stick
to the plug. Clean the iron dust from this dust plug (see Fig. 38).
Tighten the transmission oil outlet plug and the iron dust plug(see Fig. 38).
Remove the plug (see Fig. 39), fill oil (API 80(75) W-90 GL-3/ GL-5 Gear Oil ) about 2.0 liters.
Check transmission oil
If the color of transmission oil changes, you need to replace oil. Replace transmission oil as above.
4. Engine Coolant
Add Coolant
You must check the coolant for level and leaks. If it is low, you need to refill coolant into the radiator
(approximately 6000 ml). The lack of coolant will cause the engine to overheat. This can cause
engine damaged. (See Fig. 40)
The coolant should always be topped up, since the coolant can evaporate.
 Reserve Cap
coolant
tank

FIGURE 40 FIGURE
41
5. Put the vehicle on level ground.
Turn the coolant cap counterclockwise and open the cap (see Fig. 40).
Pour fresh coolant to filler neck, Start the engine at idle.Increase the engine rev’s a few
times.Repeat 2,3,4 till the coolant is at neck and no bubbles come up.Refit the coolant cap, turn it
clockwise and tighten it.
Turn the reserve coolant case cap counterclockwise and open the cap (see Fig. 41).
Pour fresh coolant of the specified type into the reserve coolant tank till the coolant reaches 2/5 to
3/5 of the reserve coolant tank volume.
Close the reserve coolant case cap, turn it clockwise and tighten it.

Opening the radiator cap while the engine is hot can be hazardous.
Opening the radiator cap can spray the high temperature coolant in your eyes,
face and any parts of your body. This can result in severe injury.
Never open the radiator cap while the engine is hot.

New and used coolant can be hazardous.

Children and pets may be harmed by new or used coolant.
Continuous or brief contact with coolant may be dangerous for your
health.
Keep new and used coolant away from the children and pets. To
minimize your exposure to new and used coolant, wear a long sleeve shirt
and moisture-proof gloves (such as dishwashing gloves) when you
change coolant. If coolant contacts your skin, wash thoroughly with soap
and water. Wash any clothing or rags if wet with coolant. Recycle or
properly dispose of used coolant.
 Harm or damage may occur if using coolant does not meet the
specification that is 50% standard green coolant and 50% distill water.

6. Idle Speed
Adjustment
Never make unnecessary adjustments. The factory recommended settings are correct for most
applications. It’s not necessary to disassemble the screw unless the idle speed needs to adjustment.
(See Fig. 43)
Warm up the engine (5~10min)
Connect the 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.

FIGURE
42

Spark plug inspection

7. Clean spark plug
1. Check spark plug refer to Preventative maintenance and service log, if too much carbon adhered,
which will weaken the spark.
2. Clear the carbon adhered with a dry brush, and scratch the carbon adhered to insulating lay
carefully with a file. And blow of dust with dry and clear air. And adjust the space to 0.9～
1.1mm/0.035～0.043inch see Pic 7.9.
Spark plugs replacement
The spark plugs should be replaced every 30000km/18641miles, or 18 months. Do the following step
by step.

Unscrew 8 screws and take off spark plug plastic cover.

Clean the dust in the spark plug seat.
Pull off the high-voltage wire，remove the spark plug with a special spanner.
Insert a new spark plug or a cleaned spark plug, and turn a few rounds clockwise, if retardarce
happen, take it off and try it again to make sure screw engaged correctly.
Tighten 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 plug.
To avoid damage, follow the following items:
Tighten spark plug to a required torque (25Nxm), over tightening will damage the screw.
Removing or installing a spark plug, make sure the slot aligned.
Do not pull the high-voltage wire, pulling the tube wrapping the high-voltage wire is allowed.
Other brands of spark plug are forbidden.
Make sure spark plugs hole lip is clear.
The spark plugs is hot after a long-time driving, make sure the spark plugs is not hot before operation.
Wedge belt figure
Correct installation and the proper tension will ensure electrical generator and air conditioner work
well. If chap, tear, wear，or looseness happen, contact Joyner dealer and replace it immediately.
Check the belt tension:
Apply a pressure (about 100N/22.48lbf) on the belt, if the movement is more than 10mm/0.4inch,
loosen the flange bolt and change the position of starter to tension the belt and fasten the bolt. If the
belt has been wearing heavily, it is necessary to replace a new one.
ENGINE MECHANICAL SYSTEMS
ELECTRIC INJECTION SYSTEM
PARTS MANUAL
1.ENGINE

1.1 Cooling system

Ref ERP Code Part No. Part Description Qty

1 02.DLJ.Q1400612 Q1400612 HEXAGON HEAD BOLT 4
2 02.DLJ.372-1307014 372-1307014 WATER PUMP PULLEY 1
3 02.DLJ.Q1840840 Q1840840 HEXAGON FLANGE BOLT 1
4 02.DLJ.Q1840855 Q1840855 BOLT（M8X55） 1
5 02.DLJ.Q1840865 Q1840865 HEXAGON FLANGE BOLT 1
6 02.DLJ.372-1307010 372-1307010 WATER PUMP SET 1
7 02.DLJ.372-1307015 372-1307015 ‘O’ 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.DLJ.372-1307012 372-1307012 SEAL STRIP 1 1
13 02.DLJ.GB50-18 GB50-18 'O' RUBBER RING 1
14 02.DLJ.372-1306016 372-1306016 SEAT-THERMOSTAT OUTER 1
15 02.DLJ.372-1306020 372-1306020 THERMOSTAT ASSY 1
16 02.DLJ.372-1306001 372-1306001 SEAT-THERMOSTAT 1
17 02.DLJ.Q1840850 Q1840850 HEXAGON FLANGE BOLT 2
18 02.DLJ.372-1306012 372-1306012 SEAT-THERMOSTAT INNER 1
19 02.DLJ.372-1306018 372-1306018 SEAT–THERMOSTAT 1
1.2 Cylinder block

Ref ERP Code Part No. Part Description Qty

02.DLJ.372-1002010 372-1002010 CYLINDER BLOCK ASSY 1
1
02.DLJ.372-1002037 372-1002037 POSITION PIN 6
2
02.DLJ.372-1002046 372-1002046 CRANKCASE VENTILATION PIPE 1
3
02.DLJ.372-1002044 372-1002044 CYLINDER HEAD SEAL PLUG 2
4
02.DLJ.Q1840830 Q1840830 HEXAGON FLANGE BOLT 1
5
02.DLJ.372-1002060 372-1002060 KNOCK SENSOR 1
6
02.MV800.06.04.0001 MV800.06.04.00.01 POSITION PIN 2
7
02.DLJ.372-1002070 372-1002070 OIL PRESSURE SWITCH 1
8
02.DLJ.372-1000410 372-1000410 ENGINE ASSY 1
9
02.DLJ.11G10GB308 11G10GB308 BALL-STEEL 1
10
02.DLJ.372-1002023 372-1002023 BOLT-MAIN BEARING CAP 8
11
02.DLJ.372-1002045 372-1002045 CAP-OIL CONTROL 1
12
02.DLJ.372-1012021 372-1012021 CONNECTOR-OIL FLITER 1
13
02.DLJ.372-1014110BA 372-1014110BA PIPE-CRANKCASE VENTILATION 1
14
02.DLJ.372-1014130BA 372-1014130BA PIPE(3)-CRANKCASE VENTILATION 1
15
1.3 Crankshaft

Ref ERP Code Part No. Part Description Qty

02.DLJ.372-1005031 372-1005031 PULLEY BOLT 1
1
02.DLJ.372-1005040 372-1005040 TORSION SHOCK ABSORBER ASSY 1
2
02.DLJ.372-1005018 372-1005018 CRANKSHAFT TIMING GEAR 1
3
02.DLJ.372-1005017 372-1005017 TOOTHED BELT BAFFLE 1
4
02.DLJ.372-1005015 372-1005015 CRANKSHAFT FRONT OIL SEAL 1
5
02.DLJ.372-1005033 372-1005033 NEEDLE BEARING 1
6
02.DLJ.372-1005032 372-1005032 WOODRUFF KEY 1
7
02.DLJ.372-1005010 372-1005010 CRANKSHAFT ASSY 1
8
02.DLJ.372-1005016 372-1005016 STOPPER PLATE 2
9
02.DLJ.S11-1601101 S11-1601101 COVER SET BOLT 4
10
02.DLJ.372-1DF1005010 372-1DF1005010 BEARING–CRANKSHAFT 4
11
02.DLJ.372-1005036 372-1005036 PIN–DOWEL 1
12
02.DLJ.372-1005030 372-1005030 REAR OIL SEAL 1
13
02.DLJ.372-1005021 372-1005021 REAR OIL SEAL BRACKET 1
14
02.DLJ.Q1840820 Q1840820 HEXAGON FLANGE BOLT 5
15
02.DLJ.372-1005050 372-1005050 FLYWHEEL ASSY 1
16
02.DLJ.372-1005054 372-1005054 LOCK-FLY WHEEL BOLT 6
17
02.DLJ.S11-1005117 S11-1005117 CRANKSHAFT POSITION SENSOR 1
18
19 02.DLJ.S11-1601020CA S11-1601020CA COVER-CLUTCH 1

20 02.DLJ.S11-1601030CA S11-1601030CA DRIVEN DISK ASSY 1

1.4 Exhaust manifold

Ref ERP Code Part No. Part Description Qty

02.DLJ.372-1008033 372-1008033 EXHAUST MANIFOLD WASHER 1
1
02.DLJ372-100801BA 372-100801BA EXHAUST MANIFOLD 1
2
02.DLJ.Q1200825F3 Q1200825F3 STUD 4
3
02.DLJ.Q33008 Q33008 HEXAGON NUT 6
4
02.DLJ.372-1008044 372-1008044 HEAT INSULATOR 1
5
02.DLJ.Q1460612 Q1460612 HEXAGON HEAD BOLT 4
6
02.DLJ.S11-1205110 S11-1205110 OXYGEN SENSOR 1
7
02.DLJ.Q1200835F3 Q1200835F3 STUD 1
8
02.DLJ.S11-3724863 S11-3724863 OXYGEN SENSOR BRACKET 1
9
1.5 Intake system

Ref ERP Code Part No. Part Description Qty

1 02.DLJ.Q1420625 Q1420625 HEXAGON HEAD BOLT 4

2 02.DLJ.372-1107011CA 372-1107011CA BODY–THROTTLE 1
3 02.DLJ.372-1107012 372-1107012 THROTTLE BODY WASHER 1
4 02.DLJ.Q1840620 Q1840620 HEXAGON FLANGE BOLT 2
5 02.DLJ.372-1008043 372-1008043 ACCELERATOR PULLING WIRE BRACKET 1
6 02.DLJ.S11-1109411 S11-1109411 INTAKE TEMPERATURE AND PRESSURE SENSOR 1
7 02.DLJ.Q1400416 Q1400416 HEXAGON HEAD BOLT 1
8 02.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.DLJ.Q1200835F3 Q1200835F3 STUD 2
13 02.DLJ.Q1200828F3 Q1200828F3 STUD 4
14 02.DLJ.372-1008021 372-1008021 INTAKE MANIFOLD GASKET 1
15 02.DLJ.Q1200840F3 Q1200840F3 STUD 1
16 02.DLJ.372-1008041 372-1008041 INTAKE MANIFOLD FRONT BRACKET 1
17 02.DLJ.372-1008042 372-1008042 INTAKE MANIFOLD REAR BRACKET 1
18 02.DLJ.Q1840816 Q1840816 HEXAGON FLANGE BOLT 2
19 02.DLJ.Q1840820 Q1840820 HEXAGON FLANGE BOLT 2
20 02.DLJ.372-1107051 372-1107051 THROTTLE POSITION SENSOR 1
1.6 Lubricating device

Ref ERP Code Part No. Part Description Qty

02.DLJ.372-1012010 372-1012010 OIL FILTER 1
1
02.DLJ.372-1009130 372-1009130 OIL DIP STICK 1
2
02.DLJ.372-1009120 372-1009120 OIL DIP STICK PIPE 1
3
02.DLJ.372-1011055 372-1011055 SEAL STRIP 1
4
02.DLJ.372-1011021 372-1011021 OIL PUMP GASKET 1
5
02.DLJ.372-1011030 372-1011030 OIL PUMP ASSY 1
6
02.DLJ.Q1840825 Q1840825 BOLT 1
7
02.DLJ.Q1840855 Q1840855 BOLT（M8X55） 2
8
02.DLJ.Q1420612 Q1420612 HEXAGON HEAD BOLT 17
9
02.DLJ.372-1010017 372-1010017 OIL STRAINER WASHER 0
10
02.DLJ.Q1200616 Q1200616 STUD 2
11
02.DLJ.Q33006 Q33006 HEXAGON NUT 2
12
02.DLJ.372-1010010 372-1010010 OIL STRAINER ASSY 1
13
02.DLJ.Q1840610 Q1840610 HEXAGON FLANGE BOLT 1
14
02.DLJ.Q1840830 Q1840830 HEXAGON FLANGE BOLT 3
15
1.7 Cylinder head

Ref ERP Code Part No. Part Description Qty

1 02.DLJ.372-1003074 372-1003074 SPARK PLUG SLEEVE 3
2 02.DLJ.Q1400638 Q1400638 HEXAGON HEAD BOLT 17
3 02.DLJ.372-1003051 372-1003051 CYLINDER HEAD BOLT 8
4 02.DLJ.372-1003052 372-1003052 CYLINDER HEAD BOLT WASHER 8
5 02.DLJ.S11-3808013 S11-3808013 WATER TEMP SENSOR 1
6 02.DLJ.S11-1003069 S11-1003069 CAMSHAFT POSITION SENSOR 1
7 02.DLJ.Q1400816 Q1400816 HEXAGON HEAD BOLT 1
8 02.DLJ.372-1003023 372-1003023 VALVE GUIDE 12
9 02.DLJ.372-1003022 372-1003022 EXHAUST VALVE SEAT INSERT 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 HEXAGON FLANGE BOLT 2
14 02.DLJ.372-1003067 372-1003067 BLOCK COVER 1
15 02.DLJ.372-1003066 372-1003066 CAMSHAFT OIL SEAL 1
16 02.DLJ.372-1003010 372-1003010 CYLINDER HEAD 1
17 02.DLJ.372-1003063 372-1003063 CAMSHAFT BEARING CAP POSITION COVER 8
18 02.DLJ.S11-3808010 S11-3808010 WATER TEMP SENSOR 0
19 02.DLJ.372-1003001 372-1003001 CYLINDER HEAD ASSY 1
20 02.DLJ.372-1003024 372-1003024 BOWL SHAPE PLUG 1
21 02.DLJ.372-1003028 372-1003028 PLUG 1
22 02.DLJ.372-1003038 372-1003038 STUD 1
23 02.DLJ372-1003076 372-1003076 WATER PROOF BUSH 1
1.8 Cover-valve chamber

Ref ERP Code Part No. Part Description Qty

02.DLJ.372-1003090 372-1003090 OIL CAP 1
1
02.DLJ.Q2540616 Q2540616 SCREW 6
2
02.DLJ.372-1003075 372-1003075 ENGINE TRIMING COVER ASSY 1
3
02.DLJ.372-1003030 372-1003030 ROCKER COVER ASSY 1
4
02.DLJ.372-1003036 372-1003036 CYLINDER HEAD COVER GASKET 1
5
02.DLJ.Q1460625 Q1460625 HEXAGON HEAD BOLT 5
6
1.9 Oil pan

Ref ERP Code Part No. Part Description Qty

02.DLJ.372-1009010 372-1009010 OIL PAN ASSY 1
1
02.DLJ.Q1420612 Q1420612 HEXAGON HEAD BOLT 17
2
02.DLJ.372-1009017 372-1009017 OIL PLUG WASHER 1
3
02.DLJ.372-1009014 372-1009014 DRAIN PLUG 1
4
1.10 Valve mechanism

Ref ERP Code Part No. Part Description Qty

1 02.DLJ.372-1007030 372-1007030 TENSIONING PULLEY 1

2 02.DLJ.Q1401045 Q1401045 HEXAGON HEAD BOLT 1
3 02.DLJ.Q1400616 Q1400616 HEXAGON HEAD BOLT 3
4 02.DLJ.372-1007040 372-1007040 TIMING GEAR COVER 1
5 02.DLJ.Q1460625 Q1460625 HEXAGON HEAD BOLT 2
6 02.DLJ.Q1460650 Q1460650 HEXAGON HEAD BOLT 2
7 02.DLJ.Q43140 Q43140 SHIELD-SHAFT SPRING RING 1
8 02.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 CAMSHAFT MAIN GEAR 1
12 02.DLJ.372-1006020 372-1006020 INTAKE CAMSHAFT ASSY 1
13 02.DLJ.372-1006071 372-1006071 HEXAGON FLANGE BOLT 2
14 02.DLJ.372-1006066 372-1006066 TIMING BELT SPROCKET 1
15 02.DLJ.372-1006064 372-1006064 LOCK-CLUTCH HUB NUT 1
16 02.DLJ.Q2180620 Q2180620 INNER HEXGON HEAD BOLT 4
17 02.DLJ.372-1006063 372-1006063 COUPLING FLANGE 1
18 02.DLJ.372-1006062 372-1006062 TEXHAUST CAMSHAFT GEAR 1
 1.10 Valve mechanism

Ref ERP Code Part No. Part Description Qty

19 02.DLJ.372-1006060 372-1006060 EXHAUST CAMSHAFT ASSY 1
20 02.DLJ.372-1007017 372-1007017 ADJUSTMENT WASHER 12
21 02.DLJ.372-1007018 372-1007018 VALVE LIFTER 12
22 02.DLJ.372-1007019 372-1007019 VALVE LOCK BLOCK 24
23 02.DLJ.372-1007021 372-1007021 EDDY SLEEVE 12
24 02.DLJ.372-1007014BA 372-1007014BA UPPER VALVE SPRING SEAT 12
25 02.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 VALVE 6
29 02.DLJ.372-1007081 372-1007081 TOOTHED TIMING BELT 1
30 02.DLJ.372-1007011 372-1007011 INLET VALVE 1
31 02.DLJ.372-1006042 372-1006042 GEAR PIN 1
32 02.DLJ.372-1006067 372-1006067 STOPPER PIN 1
33 02.DLJ.372-1007014 372-1007014 UPPER VALVE SPRING SEAT 1
34 02.DLJ.Q673B155 Q673B155 CLAMP 1
35 02.DLJ.472-1007042 472-1007042 LOWER TIMING GEAR COVER 1
36 02.DLJ.480-1011062 480-1011062 BOLT 1
1.11 Ignition device

Ref ERP Code Part No. Part Description Qty

02.DLJ.S11-3705110JA S11-3705110JA IGNITION COIL 3
1
02.DLJ.Q2320525 Q2320525 SCREW AND WASHER UNIT 6
2
02.DLJ.S11-3705001 S11-3705001 IGNITION COIL BRACKET 1
3
02.DLJ.S11-3707100 S11-3707100 SPARK PLUG ASSY 3
4
02.DLJ.Q1460820 Q1460820 HEXAGON HEAD BOLT 1
5
02.DLJ.S11-3707040 S11-3707040 HI.TENSION CORD NO.3 1
6
02.DLJ.S11-3707030 S11-3707030 HI.TENSION CORD NO.2 1
7
02.S800.04.01.05 S800.04.01.05.00-R2 HI.TENSION CORD NO.1 1
8
02.DLJ.S11-3724183 S11-3724183 CLIP 0
9
1.12 Piston and connecting rod device

Ref ERP Code Part No. Part Description Qty

02.DLJ.372-1DE1004030 372-1DE1004030 PISTON RING ASSY 1
1
02.DLJ.372-1004031 372-1004031 PISTON PIN 3
2
02.DLJ.372-1004021 372-1004021 PISTON 3
3
02.DLJ.372-1004110 372-1004110 CONNECTING ROD ASSY 3
4
02.DLJ.372-1DF1004110 372-1DF1004110 CONNECTING ROD BEARING 6
5
1.13 Other accessory 1

15
11
1

10

9 12
8
2 12

13
14

3
6
4 5 7

Ref ERP Code Part No. Part Description Qty

02.DLJ.S11-3724180CA S11-3724180CA Engine Harness 1
1
02.DLJ. S11-BJ3605010TA S11-BJ3605010TA renovated ECU 1
2
02. SV1100.05.02.01 SV1100.05.02.01.00 Shifter Bracket 1
3
02.DLJ.S11-1206211 S11-1206211 carbon can PCV 1
4
02.DLJ.S11-3708110BA S11-3708110BA Starter 1
5
02.DLJ.S11-1700103 S11-1700103 lower Steel cushion 1
6
02.DLJ.S11-1200011CA S11-1200011CA Single Exhaust Gasket 1
7
02.DLJ.Q1841245 Q1841245 Hex socket head bolt M12x45 1
8
02.DLJ.Q218B1245 Q218B1245 Bolt 12x45 1
9
02.DLJ.Q1841240 Q1841240 Bolt 12x50 2
10
02.DLJ.372-1002030 372-1002030 Upper steel cushion 1
11
02.DLJ.S11-3708111 S11-3708111 locating dowel 2
12
02.DLJ.Q1840845 Q1840845 Bolt 8x45 2
13
02.DLJ.Q1840850 Q1840850 Bolt 8x50 1
14
02.DLJ.S11-3802020 S11-3802020 Electric odometer sensor assy 1
15
1.14 Other accessory 2

Ref ERP Code Part No. Part Description Qty

02.DLJ.S11-3701110BB S11-3701110BB Alternator 1
1
02.DLJ.S11-3701211BA S11-3701211BA Alternator bracket 1
2
02.DLJ.S11-1001415BA S11-1001415BA Rear bracket 1
3
02.DLJ.S11-3701315 S11-3701315 V-ribbed belt 1
4
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
1.CASE&ACCESSORY

No ERP CODE Code name Description Qty

14 02.DLJ.5T07-3729010 5T07-3729010 SWITCH.BACK-UP LIGHT 1
15 02.DLJ.5T07-1701058A 5T07-1701058A DOUBLE-SCREW ROD 1
16 02.DLJ.5T07-1701009 5T07-1701009 STOP PLATE.BEARING 1
17 02.DLJ.5T07-1701004 5T07-1701004 OIL-STOP PLATE 1
18 02.DLJ.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.CLUTCH 1
22 02.DLJ.GB/T5789-1986 GB/T5789-1986 AM8×35/BOLT AM8X35 1
23 02.DLJ.GB/T6177-2000 GB/T6177-2000 NUT M8 1
24 02.DLJ.5T07-1701603 5T07-1701603 BOLT.SIDE COVER 8
25 02.DLJ.QR512-1602113 QR512-1602113 RELEASE SPRING.DECLUTCH 1
26 02.DLJ.4T08A1-1700010 4T08A1-1700010 TRANSMISSION assy 1
2.COUNTERSHAFT

No ERP CODE Code name Description Qty

1 02.DLJ.4T08A-1701401 4T08A-1701401 COUNTERSHAFT 1
2 02.DLJ.QR512-1701410 QR512-1701410 DRIVEN GEAR ASSY.FIRST GEAR 1
3 02.DLJ.4T08A1-1701420 4T08A1-1701420 DRIVEN GEAR ASSY.SECOND GEAR 1
4 02.DLJ.4T08A1-1701441 4T08A1-1701441 DRIVEN GEAR.THIRD GEAR 1
5 02.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
OUTER RING.SYNCHRONIZER.1ST
8 02.DLJ.QR512-1701439 QR512-1701439
GEAR&2ND GEAR 2
MID RING.SYNCHRONIZER.1ST
9 02.DLJ.QR512-1701406 QR512-1701406
GEAR&2ND GEAR 2
INNER RING.SYNCHRONIZER.1ST
10 02.DLJ.QR512-1701435 QR512-1701435
GEAR&2ND GEAR 2
11 02.DLJ.QR512-1701430 QR512-1701430 SYNCHRONIZER.1ST GEAR&2ND GEAR 1
2.COUNTERSHAFT

No ERP CODE Code name Description Quantity

SPRING.SYNCHRONIZER.1ST
02.DLJ.QR512-1701433 QR512-1701433
12 GEAR&2ND GEAR 2
GEAR-HUB.SYNCHRONIZER.1ST
02.DLJ.QR512-1701434 QR512-1701434
13 GEAR&2ND GEAR 1
GEAR-SLEEVE.SYNCHRONIZER.1ST
02.DLJ.QR512-1701431 QR512-1701431
14 GEAR&2ND GEAR 1
GUIDE BLOCK.SYNCHRONIZER.1ST
02.DLJ.QR512-1701432 QR512-1701432
15 GEAR&2ND GEAR 3
RETAINER.SYNCHRONIZER.1ST
02.DLJ.5T07-1701205 5T07-1701205
16 GEAR&2ND GEAR 1
17 02.DLJ.5T07-1701202 5T07-1701202 SPACER.3RD GEAR&4TH GEAR 1
18 02.DLJ.5T07-1701250 5T07-1701250 REAR BEARING.OUTPUT SHAFT 1
ADJUSTING WASHER. REAR
19 02.DLJ.QR512-1701187
QR512-1701187 BEARING.OUTPUT SHAFT Demand
20 02.DLJ.4T08A-1701402 4T08A-1701402 SLEEVE.COUNTERSHAFT 1
21 02.DLJ.MQC4-1701219 MQC4-1701219 NUT.COUNTERSHAFT 1
22 02.DLJ.4T08A1-1701400 4T08A1-1701400 COUNTERSHAFT ASSY 1
3.INPUT SHAFT ASSY

No ERP CODE Code name Description Qty

1 02.DLJ.4T08A1-1701201 4T08A1-1701201 INPUT SHAFT 1
2 02.DLJ.5T07-1701080 5T07-1701080 SEAL.INPUT SHAFT 1
3 02.DLJ.4T08-1701130 4T08-1701130 BEARING 6204/YA/P63 1
4 02.DLJ.4T08A1-1701240 4T08A1-1701240 DRIVE GEAR ASSY.3RD GEAR 1
5 02.DLJ.5T07-1701150 5T07-1701150 NEEDLE BEARING.3RD GEAR&4TH GEAR 2
RING.SYNCHRONIZER.3RD GEAR&4TH
6 02.DLJ.QR512-1701257
QR512-1701257 GEAR&5TH GEAR 2
SYNCHRONIZER ASSY.3RD GEAR&4TH
7 02.DLJ.QR512-1701250
QR512-1701250 GEAR 1
GEAR-HUB.SYNCHRONIZER. 3RD
8 02.DLJ.QR512-1701252
QR512-1701252 GEAR&4TH GEAR 1
GEAR-SLEEVE.SYNCHRONIZER. 3RD
9 02.DLJ.QR512-1701251
QR512-1701251 GEAR&4TH GEAR 1
SPRING.SYNCHRONIZER.3RD
10 02.DLJ.QR512-1701254
QR512-1701254 GEAR&4TH GEAR&5TH GEAR 1
GUIDE BLOCK.SYNCHRONIZER. 3RD
11 02.DLJ.QR512-1701253
QR512-1701253 GEAR&4TH GEAR 3
RETAINER.SYNCHRONIZER. 3RD
12 02.DLJ.5T07-1701103
5T07-1701103 GEAR&4TH GEAR 1
3.INPUT SHAFT ASSY

No ERP CODE Code name Description Qty

WAVEFORM WASHER
02.DLJ.QR512-1701258
13 QR512-1701258 RING.SYNCHRONIZER 2
14 02.DLJ.4T08A1-1701260 4T08A1-1701260 DRIVING GEAR ASSY.4TH GEAR 1
15 02.DLJ.5T07-1701110 5T07-1701110 BACK BEARING/INPUT SHAFT 1
D
02.DLJ.QR512-1701287 ADJUSTING WASHER. BACK em
16 QR512-1701287 BEARING/INPUT SHAFT 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.5TH GEAR 1
20 02.DLJ.QR512-1701710 QR512-1701710 IDLE GEAR ASSY 1
21 02.DLJ.5T07-1701053 5T07-1701053 RETAINER.REVERSING IDLE GEAR 1
22 02.DLJ.5T07-1701061A 5T07-1701061A SHAFT.REVERSING IDLE GEAR 1
23 02.DLJ.5T07-1701057A 5T07-1701057A BOLT.REVERSING IDLE GEAR 1
24 02.DLJ.5T07-1701052 5T07-1701052 WAHSHER. REVERSE-GREAR SHAFT 1
4.SHIFT FORK& SHIFT- FORK SHAFT

No ERP CODE Code name Description Qty

1 02.DLJ.QR512-1702311 QR512-1702311 SHIFT FORK.1ST GEAR&2ND GEAR 1
2 02.DLJ.5T07-1702041A 5T07-1702041A SHIFT FORK.3RD GEAR&4TH GEAR 1
3 02.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 4T08A-1702001 STOP BLOCK 1
7 02.DLJ.QR512-1702231 QR512-1702231 PIN 4.5X20 1
SHIFT-FORK SHAFT.1ST GEAR&2ND
8 02.DLJ.QR512-1702411
QR512-1702411 GEAR 1
9 02.DLJ.5T07-1702067 5T07-1702067 SPRING.SHIFT SHAFT 3
4.SHIFT FORK& SHIFT- FORK SHAFT

Qt
No ERP CODE Code name Description
y
10 02.DLJ.QR512-1701421 QR512-1701421 SHIFT SHAFT.3RD GEAR&4TH GEAR 1
11 02.DLJ.QR512-1702431 QR512-1702431 SHAFT. SHIFT FORK.5TH GEAR 1
12 02.DLJ.QR512-1702441 QR512-1702441 SHAFT. SHIFT FORK.REVERSE GEAR 1
13 02.DLJ.5T07-1702234 5T07-1702234 SCREW PLUG.SHIFT-FORK SHAFT 3
WASHER. SCREW PLUG.SHIFT-FORK
14 02.DLJ.5T07-1702233
5T07-1702233 SHAFT
3
15 02.DLJ.QR512-1702341 QR512-1702341 SHIFT-FORK PIN.REVERSE GEAR 1
16 02.DLJ.5T07-1702068 5T07-1702068 SPRING.SHIFT BLOCK 1
17 02.DLJ.5T07-1702050A 5T07-1702050A SHIFT ARM ASSY 1
18 02.DLJ.GB/T93-1987 8 GB/T93-1987 WASHER 8 2
19 02.DLJ.5T07-1702232A 5T07-1702232A BOLT.SHIFT ARM 2
5.SHIFT CONTROL MACHANISM

No ERP CODE Code name Description Qty

1 02.DLJ.5T07-1702100A 5T07-1702100A SHIFT-SELECT SHAFT ASSY 1
2 02.DLJ.5T07-1702101A 5T07-1702101A SHIFT-SELECTING SHAFT 1
SNAP RING.STOP PLATE.SHIFT
3 02.DLJ.QR512-1702214
QR512-1702214 INTERLOCK 3
5T07-1702102 RELEASE-SPRING SEAT.1ST GEAR&2ND
4 02.DLJ.5T07-1702102
GEAR 1
5 02.DLJ.5T07-1702103 5T07-1702103 RELEASE-SPRING.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 02.DLJ.QR512-1702113 QR512-1702113 SPRING PIN 3.5X28 1
10 02.DLJ.5T07-1702106 5T07-1702106 PIN.SHIFT-SELECT ARM. 1
RELEASE-SPRING.5TH GEAR&REVERSE
11 02.DLJ.5T07-1702114A
5T07-1702114A GEAR 1
RELEASE-SPRING SEAT.5TH
12 02.DLJ.5T07-1702112
5T07-1702112 GEAR&REVERSE GEAR 1
13 02.DLJ.GB/T879,1-2000 GB/T879.1-2000 PIN 3X22 1
14 02.DLJ.5T07-1702108A 5T07-1702108A SPRING SEAT.REVERSE GEAR 1
5.SHIFT CONTROL MACHANISM

No ERP CODE Code name Description Qty

15 02.DLJ.5T07-1702109A 5T07-1702109A LIMITING SPRING.REVERSE GEAR 1
16 02.DLJ.QR512-1702111A QR512-1702111A LIMITING CAM.REVERSE GEAR 1
17 02.DLJ.GB/T879,1-2000 GB/T879.1-2000 PIN 5X22 1
GUIDE CASE ASSY. SHIFT-SELECT
18 02.DLJ.5T07-1702070A 5T07-1702070A SHAFT 1
19 02.DLJ.5T07-1702071A 5T07-1702071A GUIDE CASE. SHIFT-SELECT SHAFT 1
STOP PLATE.RELEASE
02.DLJ.5T07-1702072
20 5T07-1702072 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-SELECT SHAFT 1
ANTI-DUST COVER. SHIFT-SELECT
23 02.DLJ.5T07-1702062 5T07-1702062
SHAFT 1
24 02.DLJ.5T07-1702073 5T07-1702073 LIMITING BOLT.REVERSE GEAR 1
WASHER.LIMITING BOLT.REVERSE
02.DLJ.QR512-1702229
25 QR512-1702229 GEAR 1
26 02.DLJ.GB/T119-2000 GB/T119-2000 PIN B 6X12 2
27 02.DLJ.GB/T5789-1986 GB/T5789-1986 BOLT AM 8X25 4
28 02.DLJ.5T07-1702065A 5T07-1702065A LIMITING BOLT.SHIFT 1
5.SHIFT CONTROL MACHANISM

No ERP CODE Code name Description Qty

WASHER.STOP SCREW.REVERSE
29 02.DLJ.QR512-1702229 QR512-1702229
GEAR 1
30 02.DLJ.GB/T5789-1986 GB/T5789-1986 BOLT AM 8X80 1
31 02.DLJ.5T07-1702063 5T07-1702063 PUSHING BLOCK.SHIFT 1
ANTI-DUST COVER.SHIFT-SELECT
32 02.DLJ.5T07-1702062 5T07-1702062
SHAFT 1
33 03.02.6170-M8/05 6170-M8 NUT M8 1
34 03.05. 93-Φ8/05 93-Φ8 Spring washer 8 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.SV1100.05.02.0003 SV1100.05.02.00.03 Copper bush 1
39 02.DLJ.5T07-1702047 5T07-1702047 ANTI-DUST WASHER.SHIFT ARM 1
40 02.DLJ.5T07-1702220 5T07-1702220 SUPPORT ASSY.SHIFT ARM 1
41 02.SV1100.05.02.04 SV1100.05.02.04.00 SHIFT ARM COMP 1
42 02.DLJ.GB/T879,1-2000 GB/T879.1-2000 PIN 5X28 1
43 02.SV1100.05.02.01 SV1100.05.02.01.00 Shifter soft shaft bracket 1
44 02.DLJ.QR512-1701656 QR512-1701656 LIFTING HOOK 1
6.DRIVEN GEAR ASSY.SPEED REDUCER

Qt
No ERP CODE Code name Description
y
1 02.DLJ.4T08A2-1701308 4T08A2-1701308 Differential case 1
2 02.DLJ.4T08A-1701604 4T08A-1701604 DRIVEN GEAR.SPEED REDUCER 1
3 02.DLJ.5T07-1701010 5T07-1701010 Differential seal assy (left) 1
4 02.DLJ.5T07-1701310 5T07-1701310 FRONT 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 (right) 1
8 02.DLJ.5T07-1701309 5T07-1701309 Bolt AM10×1.25×23 8
9 02.DLJ.5T07-1701303 5T07-1701303 Planet gear shaft 1
10 02.DLJ.QR512-1701621 QR512-1701621 Differential Planet gear 2
11 02.DLJ.QR512-1701631 QR512-1701631 Planet gear bush 2
12 02.DLJ.5T07-1701302 5T07-1701302 Planet gear washer 2
6.DRIVEN GEAR ASSY.SPEED REDUCER

13 02.DLJ.5T07-1701306 5T07-1701306 Half axle adjusting washer 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.MQC4-2303016 MQC4-2303016 RETAINER RING 4
18 02.DLJ.4T08A2-1701600 4T08A2-1701600 Differential assy 1
3.CHASSIS
1.Frame，aluminium board
frame ,aluminium board

2
3
7
15 12
13
16 4 14
18
17 19 5
6 20
21
22 24
23 25
11
10 26
9

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 pedal board 1
4 02. MVA800.01.02.0023 MVA800.01.02.00.23 seat board 1
5 02. MVA800.01.02.0024 MVA800.01.02.00.24 engine board 1
 6 02. MVA800.01.02.0025 MVA800.01.02.00.25 left side board 1
7 02. MVA800.01.02.0026 MVA800.01.02.00.26 right side board 1
8
9 03.01.D818-M6X16 D818-M6X16 Cross head screw M6X16 14
10 02.JD.0900008 JD0900008 Washer 6 14
11 03.02.6183,1-M6/05 6183,1-M6 Self-locking nut M6 14
12 03.01.D818-M6X16 D818-M6X16 Cross head screw M6X16 14
13 02.JD.0900008 02.JD.0900008 Washer 6 14
14 03.02.6183,1-M6/05 6183,1-M6 Self-locking nut M6 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 screw M6X16 16
19 02.JD.0900008 02.JD.0900008 Washer 6 16
20 03.02.6183,1-M6/05 6183,1-M6 Self-locking nut M6 16
21 03.01.D818-M6X16 D818-M6X16 Cross head screw M6X16 14
22 02.JD.0900008 02.JD.0900008 Washer 6 14
23 03.02.6183,1-M6/05 6183,1-M6 Self-locking nut M6 14
24 03.01.D818-M6X16 D818-M6X16 Cross head screw M6X16 12
25 02.JD.0900008 02.JD.0900008 Washer 6 12
26 03.02.6183,1-M6/05 6183,1-M6 Self-locking nut M6 12
2.Engine mount assy
Engine mount assy

16 7

14
2 8 1 2
6 3
3
13 12 11 10 4

5 5 15
5 2 6
6 3 9
4
6

No. ERP Code Code name Description Q'ty

1 02.SV800.04.01.02 SV800.04.01.02.00 front engine mount 1
2 03.03.95-Φ10X20X2/05 95-Φ10X20X2 asherΦ10X20X2 13
3 03.05.93-Φ10/05 93-Φ10 spring asher Φ10 13
4 03.01.5787-M10X30/05 5787-M10X1.5X30 bolt-asher M10X1.5X30 10
5 02.D650.04.01.0001 D650.04.01.00.01 engine 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.SV1100.04.01.04 SV1100.04.01.04.00 rear engine mount 1
10 03.03.95-φ8X16X1,5/05 95-φ8X16X1,5/05 asher Φ8 1
11 03.05.93-Φ8/05 93-SΦ8 spring asher Φ8 1
12 03.01.5787-M8X30/05 5787-M8X30 bolt-asher M8X30 1
13 03.01.5787-M10X1,25X30/05 5787-M10X1.25X30 bolt-asher M10X1.25X30 3
14 02.SV800.04.01.06 SV800.04.01.06.00 Clutch action arm 1
15 02.D650.04.01.0001A D650.04.01.00.01A small engine rubber bumper 1
16 02.DLJ.4T08A2-1700010 4T08A2-1700010 4T08A2 transmmision 1

3.Gear-shift mechanism
Gear-shift mechanism
1

4
3

5
13
12
6
7
9
10 10

8
9 11
9 10

No. ERP Code Code name Description Q'ty

1 03.01.5787-M6X12/05 5787-M6X12 M6X12 bolt 6
2 02.SV800.05.02.0001A SV800.05.02.00.01A plastic cover 1
3 02.S650.05.02.01 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 S650.05.02.01.03 control framework 1
7 02.SV800.05.02.0005 SV800.05.02.00.05 orientation metal sheet 1
8 03.02.2842-M6/05 2842-M6 M6 nut(m=5.2) 4
9 03.03.95-Φ8X16X1,5/05 95-Φ8X16X1,5 washer Φ8X16X1,5 3
10 03.08.91-φ2X25/05 91-Φ2x25 cotter pin Φ2X25 3
11 02.MV800.05.02.03 MV800.05.02.03.00 shifter soft shaft 2 1
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
4.Steering assy
Steering assy
7
6
8

17
5 16

12 13 14 15
4
9 10 11 18
3

2
1

29 30
27 28 3132 33 34 35

26 32
31
22 36
23 24 25 28
37

47 46 45 43 42 41 40 32
39
19 48 44 27
20 21
19 38
20 21

No. ERP Code Code name Description Q'ty

1 03.01.70,2-M6X20 70.2-M6X20 M6X20 screw 6
2 02.TR1100.05.01.0002-3 TR1100.05.01.00.02-3 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 subassembly 1
6 03.01.819,1-M6X10/05 819.1-M6X10 bolt M6X10 1
7 03.05.93-Φ6/05 93-Φ6 Φ6 spring shim 1
8 02.N650.06.00.18 N650.06.00.18.00 integrated ignition switch 1
9 02.D800.05.01.01.01 D800.05.01.01.01 steering wheel shaft 1
10 03.09.893,2-Φ26 893.2-Φ26 circlip Φ26, internal 1
11 02.276-B61902 276-B61902 61902 bearing 1
12 02.D800.05.01.01.02 D800.05.01.01.02 steering column housing 1
13 02.276-B61803 276-B61803 61803 bearing 1
14 03.09.893,22-Φ28 893.2-Φ28 circlip Φ28, internal 1
15 03.09.894,1-Φ15 894.1-Φ15 Φ15, external circlip 1
16 02. D650.05.01.01 D650.05.01.01.00 steering column assy 1
17 03.02.2842-M10X1,25/05 2842-M10X1.25 M10X1.25 nut 2
18 03.01.5787-M10X1,25X25/05 5787-M10X1.25X25 M10X1.25X25 bolt 2
19 03.03.95-Φ8X24X2/05 96-Φ8X24X2 Φ8 washer(8.4X24X2) 2
20 03.05.93-Φ8 93-Φ8 Φ8 spring shim 2
21 03.01.5782-M8X25/05 5782-M8X25 M8X25 bolt 2
22 02.D800.05.01.02 D800.05.01.02.00 steering universal rod 1
23 02.D800.05.01.03.02 D800.05.01.03.02 steering gear shaft 1
24 03.01.5787-M8X20/05 5787-M8X20 M8X20 bolt 4
25 02.D800.05.01.03.05 D800.05.01.03.05 bearing cover 1
26 02.D800.05.01.03.04 D800.05.01.03.04 gear rack 1
27 02.D800.05.01.0001 D800.05.01.00.01 rod end bearingPOSA12LH 2
28 03.02.6172,1-M12-L/05 6172.1-M12 jam nut M12X1.75LH 2
29 02.D800.05.01.03.03 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 sleeve 4
33 02.D800.05.01.0002 D800.05.01.00.02 rod end bearingPOSA12 2
34 02.D800.05.01.0004 D800.05.01.00.04 baffle plate 1
35 03.01.5782-M12X1.25X80/05 5782-M12X1.25X80
M12X1.25X80 bolt 2
36 02.D800.05.01.04 D800.05.01.04.00 steering cross rod 2
37 03.01.5787-M12X1,5X60/05 5787-M12X1.5X60 M12X1.5X60 bolt 2
38 03.02.2842-M12X1,5/05 2842-M12X1.5 M12x1.5 nut 2
39 02.D800.05.01.03.07 D800.05.01.03.07 dust guard plate 1
40 03.02.2842-M10X1,25/05 2842-M10X1.25 M10X1.25 nut 2
41 02.D800.05.01.03.06 D800.05.01.03.06 bracket 1
42 02.D800.05.01.03.01 D800.05.01.03.01 socket 1
43 03.01.5787-M10X10/05 5787-M10X10 bolt M10X1.5X10 2
44 03.01.5787-M10X1,25X75/05 5787-M10X1.25X75 bolt M10X1.25X75 2
45 02.D800.05.01.03.08 D800.05.01.03.08 adding oil screw 1
46 02.D800.05.01.03.10 D800.05.01.03.10 oiliness bearing 14c7X18X12 1

47 02.D800.05.01.03.09 D800.05.01.03.09 ball bearing 20X42X12 1

48 02.D800.05.01.03 D800.05.01.03.00 steering gear box 1
5.Throttle and park assy
Throttle and park assy

1
2 28
8 29
1 30
3 31
27 39
4 6
5 24 16 32
9 17 33
7 10 16 17 18
19 38
34
12
11 12
12 18
16 11 16
13 23 17 37
12 20 11 12
19 21
11 18 25
22
27 14

40 14
26 35
36

14

15
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 5787-M6X20 Bolt-washer M6X20 1
4 02.D1600.01.02.0008 D1600.01.02.00.08 support 1
5 03.02.2842-M6/05 2842-M6 nut M6 1
6 03.01.5787-M6X20/05 5787-M6X20 Bolt-washer M6X20 2
7 03.02.2842-M6/05 2842-M6 nut M6 2
 8 02.D650.07.01.0004A D650.07.01.00.04A pushing bar 2
9 03.02.6172,1-M8/05 6172.1-M8 nut M8 2
10 02.D650.07.01.00.03 D650.07.01.00.03 push rod holder 1
11 03.08.91-φ3,2X30/05 91-φ3,2X30 cotter pin 3.2X30 3
12 03.03.95-Φ10X28X2/05 95-Φ10X28X2 washer(Φ10.5XΦ18XΦ1.6) 3
13 02.SV1100.07.04.02 SV1100.07.04.02.00 clutch pedal 1
14 02.D650.07.01.0005 D650.07.01.00.05 pedal rubber cover 3
15 02.SV800.07.04.01 SV800.07.04.01.00 cable, clutch 1
16 03.01.70,1-M6X55/05 70.1-M6X55 M6X55 socket head bolt 4
17 03.02.6172,1-M6/05 6172.1-M6 M6 nut(m=5.2) 4
18 02.D250.10.003 D250.10.003 spring 3
19 03.07.882-Φ10X60/05 882-Φ10X60 Φ10X60 pin roll 2
20 03.08.91-φ2X25/05 91-Φ2X25 cotter pin Φ2X25 1
21 03.03.95-Φ6X18X1,5/05 95-Φ6X18X1.5 washer Φ6X18X1.5 1
22 02.D650.07.01.02 D650.07.01.02.00 brake pedal 1
23 03.07.882-6X40/05 882-6X40 Φ6X40 pin roll 1
24 03.07.882-10X105/05 882-10X105 Φ10X105 pin roll 1
25 02.D650.07.03.02 D650.07.03.02.00 throttle pedal 1
26 02.SV1100.07.03.01 SV1100.07.03.01.00 throttle cable 1
27 03.02.2842-M8/05 2842-M8 M8 nut 2
28 03.01.5787-M8X20/05 5787-M8X20 Bolt-washerM8X20 2
29 02.D650.07.02.01.00 D650.07.02.01.00 park assy 1
30 03.03.95-φ8X16X1,5/05 95-φ8X16X1,5 φ8 washer 1
31 03.08.91-φ3,2X30/05 91-φ3.2x30 cotter pin 3.2x30 1
32 02.D650.07.02.01.01 D650.07.02.01.01 axle 8x24 1
33 02. D650.07.02.0001 D650.07.02.00.01 parking brake connection 1
34 03.08.91-φ3,2X30/05 91-φ3.2x30 cotter pin 3.2x30 1
35 03.02.6183,1-M8/05 6183,1-M8 M8 self-locking nut 2
36 03.01.5787-M8X30/05 5787-M8X30 bolt-washer M8*30 2
37 02.MV800.07.02.03 MV800.07.02.03.00 parking brake assy 1
38 02.MV800.07.02.02 MV800.07.02.02.00 park brake cable 1
39 02.D800.07.02.0001 D800.07.02.00.01 steel bush 1
40 03.01.5787-M8X55/05 5787-M8X55 Bolt-washer M8X55 1
6.Brake assy
brake assy

5
2
4 8
3 9

5
1 10 11 7 To front right wheel

To rear right
wheel
8 1
8 12 9
5
9
To front left
6
15
wheel 8
16 9 14
13
To rear left
wheel
2
5

No. Erp code Code name Description Q'ty

1 02.SV800.07.01.01.01 SV800.07.01.01.01 disc brake with floating caliper,front 2
2 02.SV800.07.01.01.02 SV800.07.01.01.02 disc brake with floating caliper,rear 2
3 02.DN250.04.01.01 DN250.04.01.01.00 Master cylinder assy 1
4 02.JK613B JK613B hydraulic power brake valve 1
4
5 02.ZJ509.03-04 ZJ509.03-04 hydraulic brake pads
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.01-02 ZJGS.01-02 Hose bolt M10x1.25 10
9 02.ZJGS.01-01 ZJGS.01-01 Seal washer 20
10 02.MV800.07.01.01.05 MV800.07.01.01.05 hydraulic brake hose,front,left 1
11 02.MV800.07.01.01.06 MV800.07.01.01.06 hydraulic brake hose,front,right 1
12 02.MV800.07.01.01.04 MV800.07.01.01.04 hydraulic brake hose,middle 1
13 02.MV800.07.01.01.07 MV800.07.01.01.07 hydraulic brake hose,rear,left 1
14 02.MV800.07.01.01.08 MV800.07.01.01.08 hydraulic brake hose,rear,right 1
 15 02.D650.07.01.0004A D650.07.01.00.04A Master cylinder rod 2
16 02.MV800.07.01.01 MV800.07.01.01.00 four caliper hydraulic brake assy 1

7.Parking brake assy

parking brake assy

2
6
8 7 4

1 5 3

8.
No. Erp code Code name Description Q'ty
1 02.SV800.07.01.01.01 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 02.D650.07.02.03.04 D650.07.02.03.04 pipe 1
5 02.ZJ509.03-04 ZJ509.03-04 hydraulic brake pads 1 set
6 02.ZJGS.01-02 ZJGS.01-02 Hose bolt M10x1.25 1
7 02.ZJGS.01-01 ZJGS.01-01 Seal washer 2
8 02.MV800.07.02.03 MV800.07.02.03.00 parking brake assy 1
8.Front susp assy
Front susp assy
29
30
19 31 32
33
20 34
35
1 2 21
3 4 5 7 9 11 13 15 17 37
22
23 36
24
27 26 25 36 35 34 33

37
25
28
36 35 34 33
45 6 8 10 12 14 18
30
44 32 25
43 38 45
43
29
44
30
32 31 19
33 20
34
35 40
37 17 15 13 11 9 7 5 4 39 2 1
22
23
24
33 34 35 36 25 26 41

42
33 34 35 36
18 14 12 10 8 6
30
25 32 38

No. ERP Code Code name Description Q'ty

1 02.S650.03.01.0002 S650.03.01.00.02 M12X1.5 wheel nut 8
2 02.JD.0360010 JD0360010 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-φ4X40/05 91-φ4X40 cotter pin φ4X40 2
5 03.02.9457-M18X1,5/05 9457-M18X1.5 castle nutM18X1.5 2
6 02.D800.03.01.0010 D800.03.01.00.10 washer 2
7 02.D650.03.01.0008 D650.03.01.00.08 spacer sleeve 2
8 02.D800.03.01.0007 D800.03.01.00.07 axle bush 2
9 02.D800.03.01.0008 D800.03.01.00.08 30X52X8 grease seal 2
10 02.D800.03.01.0004 D800.03.01.00.04 ball bearing 25X52X15 2
11 02.D800.03.01.0006 D800.03.01.00.06 spacer sleeve 2
12 02.D800.03.01.0001A D800.03.01.00.01A front hub 2
13 02.D650.03.02.0003A D650.03.02.00.03A knurled screw M12X1.5 8
14 02.D650.03.02.0005 D650.03.02.00.05 brake disk 2
15 02.D650.03.02.0008 D650.03.02.00.08 M6 bolt 8
16
17 02.D800.03.01.0005 D800.03.01.00.05 30X62X16 ball bearing 2
18 02.D800.03.01.0009 D800.03.01.00.09 40x62x7 grease seal 2
19 03.01.5782-M16X85/05 5782-M16X85 M16X85 bolt 2
20 02.D800.02.01.0002 D800.02.01.00.02 bushing 8
21 02. N650.02.01.02 N650.02.01.02.00 upper suspension arm,left 1
22 02.D800.02.01.0001 D800.02.01.00.01 radial bearing 4
23 03.09.893,2-φ42 893.2-42 circlip φ42 4
24 02.D800.02.01.0002 D800.02.01.00.02 bushing 8
25 03.02.6185,1-M16/05 6185.1-M16 M16 nut 4
26
27 02.D800.03.01.0002A D800.03.01.00.02A front axle left wheel 1
28 02. N650.02.01.01 N650.02.01.01.00 lower suspension arm,left 1
29 03.01.5782-M15X1,5X190/05 5782-M15X1.5X190 M15X1.5X190 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 03.01.5782-M16X65/05 5782-M16X2X65 M16X2X65 bolt 8
34 02.D800.02.01.0004 D800.02.01.00.04 control arm spacer sleeve 16
35 02.D800.02.01.0003 D800.02.01.00.03 control arm rod end bearing 4
36 03.01.6172,1-M16/05 6172.2-M16 jam nut M16 8
37 03.02.5782-M15X210/05 5782-M15X210 M15X210 bolt 2
38 03.01.5782-M16X95/05 5782-M16X95 bolt M16X95 2
39 02.S650.03.01.04A S650.03.01.04.00A right wheel(27X8-12) 1
40 02. N650.02.01.03 N650.02.01.03.00 upper suspension arm,right 1
41 02.D800.03.01.0003B D800.03.01.00.03B front axle right wheel 1
42 02. N650.02.01.04 N650.02.01.04.00 lower suspension arm,right 1
43 02.S650.03.01.01.01 S650.03.01.01.01 front rim 12X6 2
44 02.D650.03.01.01.03 D650.03.01.01.03 valve cock 2
45 02.S650.03.01.01.02A S650.03.01.01.02A front tire 27X8-12 2
9.Fuel tank and gasoline pump
Fuel tank and gasoline pump

33
36
24
6
38 39 37 40 41

6
31 29
6
32
28

6
30 34 35

20
33 27 23
6
4 19
6 6
5 18
26
22 6
21
20 6 17
25 6 16
3 47
2
10 13
45 11 15 14 12
10 11
9
46
7
8
6

No. ERP Code Code name Description Q'ty

1
2 02.MV800.04.03.01 MV800.04.03.01.00 fuel tank 1
3 02.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 D650.04.03.00.04 hoop (10-16) 13
7 02.FTCARB-0816 FTCARB-0816 fuel hose(φ8xφ16) 0.3meter
8 02. TR1100.04.03.0008 TR1100.04.03.00.08 fuel filter 1
9 02.FTCARB-0816 FTCARB-0816 fuel hose(φ8xφ16) 0.1 meter
10 02.D1600.04.02.0006 D1600.04.02.00.06 hoop (16-25) 2
11 02.D650.04.03.0010 D650.04.03.00.10 fuel filter clip 3
 M6X30 cross groove head
12 03.01.D818-M6X30 818-M6X30
screw 1
13 03.03.95-φ6X13X1,5/05 95-φ6X13X1,5 washer φ6X13X1,5 3
14 03.05.93-Φ6/05 93-Φ6 spring washer Ф6 3
15 03.02.41-M6/05 41-M6 hex nut M6 3
M6X50 cross groove head
16 03.01.D818-M6X50 818-M6X50
screw 2
17 02.D1600.04.03.02 D1600.04.03.02.00 fuel pump 1
18 02. FTCARB-0816 FTCARB-0816 fuel hose(φ8xφ16) 0.2meter
19 02.D1600.04.03.03 D1600.04.03.03.00 fuel press adjuster 1
20 03.01.5782-M4X40/05 5782-M4X40 bolt M4X10 8
21 03.05.93-Φ4 93-Φ4 spring washer Ф4 2
22 03.03.95-Φ4 95-Φ4 washer Ф4 2
23 02. FTCARB-0816 FTCARB-0816 fuel hose(φ8xφ16) 0.5meter
24 02. S800.04.03.0008 S800.04.03.00.08 Express connector 1
25 02. FTCARB-0409 FTCARB-0409 fuel hose(φ4.5xφ9) 0.5meter
26 02.TR1100.04.06.01 TR1100.04.06.01.00 carbon canister 1
27 02.D800.04.03.0001 D800.04.03.00.01 connector 1
28 02. FTCARB-0613 FTCARB-0613 fuel hose(φ6xφ13) 0.1meter
29 02. FTCARB-0816 FTCARB-0816 fuel hose(φ8xφ16) 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-M6X16 bolt-washer M6X16 3
33 03.01.2842-M6/05 2842-M6 washer nut M6 4
34 02.MV800.06.04.0001 MV800.06.04.00.01 oil pressure sensor 1
35 02.SV800.04.07.0002 SV800.04.07.00.02 connecting pipe 1
36 03.01.5787-M6X35/05 5787-M6X35 bolt-washer M6X35 1
37 02.SV800.04.05.02 SV800.04.05.02.00 air cleaner bracket 1
38 02.N650.04.05.03 N650.04.05.03.00 air cleaner jacket 1
39 02.N650.04.05.01 N650.04.05.01.00 air cleaner 1
40 02.N650.04.05.0001 N650.04.05.00.01 hoop（65-82） 1
41 02.SV800.04.05.0002 SV800.04.05.00.02 air cleaner rubber sleeve 1
42 03.01.70,1-M12X30/05 70,1-M12X30 M12*30 socket head screw 4
43 03.03.95-φ12X24X2,5/05 95-φ12x24x2.5 washerφ12（φ13 xφ24 x 2.5） 4
44 02. MV800.01.02.01 MV800.01.02.01.00 rear bumper bar 1
45 03.01.5787-M10X20/05 5787-M10X20 bolt-washer M10X20 2
46 03.01.2842-M10/05 2842-M10 washer nut M10 4
47 02. FTCARB-0816 FTCARB-0816 fuel hose(φ8xφ16) 0.2meter
10.Muffler
MUFFLER

4 2

21

1
6 3

14
15
16
8 7

10
13 17
18

19
9 19
22

20
11
12

No. ERP Code Code name Description Q'ty

1 02.DLJ.472-1008033 472-1008033 exhaust manifold gasket 1
2 02.SV1100.04.04.03 SV1100.04.04.03.00 exhaust manifold 1
3 02.DLJ.S11-1205110JA S11-1205110JA oxygen sensor 1
4 02.SV1100.04.04.04 SV1100.04.04.04.00 seal washer 1
5 03.01.5787- M8X35/05 5787- M8X35 nut-washer 6
6 02.SV1100.04.04.02A SV1100.04.04.02.00A 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 1
10 02.D650.04.04.0008-1 D650.04.04.00.08-1 U clamp mount 1
11 02.D650.04.04.0008-2 D650.04.04.00.08-2 U clamp screw rod 1
12 02.D650.04.04.01B D650.04.04.01.00B long muffler 1
13 03.01.5787-M8X30/05 5787-M8X30 bolt-washer M8*30 2
14 02. JD1910003A JD1910003A muffler rubber cover 2
15 02.JD.1910002 JD1910002 spacer 2
16 03.03.95-Φ8X24X2 95-Φ8X24X2 washer Φ8X24X2 2
17 03.02.6183,1-M8/05 6183,1-M8 M8 self-locking nut 2
18 02.SV800.01.02.0003 SV800.01.02.00.03 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-Φ8X24X2 95-Φ8X24X2 washer Φ8X24X2 6
22 02.SV800.01.02.0006 SV800.01.02.00.06 wire clamp 1
11.Rear susp left
Rear susp,left
1 2

17

24 18
23 22
38
21
20
25 19

26 27 28 27 29
15
6 7 8 9 10
39
3
4 30 31 32 33
5
32 31 34
37
28

14
11 12 13

36

35

No. ERP Code Code name Description Q'ty

1 02.S650.03.01.0002 S650.03.01.00.02 wheel nut M12X1.5 4
2 02.S650.03.02.01A S650.03.02.01.00A wheel(27X11-12),BL 1
3 03.08.91-φ4X40/05 91-φ4X40 cotter pin 4X40 1
4 02.DLJ.JGC2202-K JGC2202-K slotted nut M22X1.5,rear shaft 1
5 02.D650.03.02.0004A D650.03.02.00.04A disk base 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-Φ55 893.2-Φ55 circlip55,internal 1
10 02.D650.03.02.0007 D650.03.02.00.07 bearing(φ30Xφ50X32) 1
11 03.01.5787-M12X1,5X100/05 5787-M12X1.5X100X25 M12X1.5X100X25 bolt 2
12 02.D800.02.02.0001 D800.02.02.00.01 bush ring 4
13 02.D650.03.02.00.01 D650.03.02.00.01 bearing block 1
14 03.02.2842-M12X1,5/05 2842-M12X1.5 M12X1.5 nut 2
15 02. D650.03.01.01.03 D650.03.01.01.03 valve cock 1
16
17 02.DLJ.BT-1045 BT-1045 outer boot seal 1
18 02.DLJ2303016 2303016 steel cable baffle ring 1
19 02.DLJ.SH07680 SH07680 BIG band 2
20 02.DLJ.BT-1085 BT-1085 inner boot seal 1
21 02.DLJ.SH07350 SH07350 SMALL band 2
22 02.DLJ.PT SZW5008 PT SZW5008 end motion type inboard joint 1
23 02.DLJ. PT SZ-9037 PT SZ-9037 solid bar,left 1
24 02.DLJ.PT SZW1003 PT SZW1003 fixed enter type outboard joint 1
25 02.MV800.03.02.01.00 MV800.03.02.01.00 left drive shaft 1
26 03.02.5782-M15X1.5X80/05 5782-M15X1.5X80X30 M15X1.5X80X30bolt 1
27 02.D800.02.03.0003 D800.02.03.00.03 spacer sleeve 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 D800.02.02.00.03 grease seal,φ46 4
32 02.D800.02.02.0002 D800.02.02.00.02 powdered spacer sleeve 4
33 02.D800.02.02.0004 D800.02.02.00.04 spacer sleeve 2
34 03.02.41-M16/05 41-M16 M16 nut 2
35 02. N650.02.02.02A N650.02.02.02.00A rear suspension arm,left 1
36 02. MV800.07.02.03 MV800.07.02.03.00 parking brake assembly 1
37 03.01.5782-M15X65/05 5782-M15X65X25 M15X65X25bolt 1
38 02.S650.03.02.01.02A S650.03.02.01.02A rear tire 27X11-12,L 1
39 02.S650.03.02.01.01 S650.03.02.01.01 rear rim 12X8 1
12.Rear susp,right
Rear susp,right

17

24

18 19
23 20

30 31 32 22

33 32 31 34 15
25
37
21
38

9
8
10 7
35 6
5
4
3
26 27 28 27 29 11 12 13 14

1
36
29
2

No. ERP Code Code name Description Q'ty

1 02. S650.03.01.0002 S650.03.01.00.02 wheel nut M12X1.5 4
2 02.S650.03.02.04A S650.03.02.04.00A wheel(27X11-12),BR (F938) 1
3 03.08.91-φ4X40/05 91-φ4X40 cotter pin 4X40 1
4 02.DLJ.JGC2202-K JGC2202-K slotted nut M22X1.5,rear shaft 1
5 02.D650.03.02.0004A D650.03.02.00.04A disk base 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-Φ55 893.2-Φ55 circlip55,internal 1
10 02.D650.03.02.00.07 D650.03.02.00.07 bearing(Φ30XΦ50X32) 1
11 03.01.5787-M12X1.5X100/05 5787-M12X1.5X100X25 M12X1.5X100X25 bolt 2
12 02.D800.02.02.0001 D800.02.02.00.01 bush ring 4
13 02.D650.03.02.0001 D650.03.02.00.01 bearing block 1
14 03.02.2842-M12X1.5/05 2842-M12X1.5 M12X1.5 nut 2
15 02. D650.03.01.01.03 D650.03.01.01.03 valve cock 1
16
17 02.DLJ.BT-1085 BT-1085 inner boot seal 1
18 02.DLJ.SH07350 SH07350 small band 2
19 02.DLJ.BT-1045 BT-1045 outer boot seal 1
20 02.DLJ.SH07680 SH07680 big band 2
21 02.DLJ.PT SZW1003 PT SZW1003 fixed enter type outboard joint 1
22 02.DLJ. PT SZ-9015 PT SZ-9015 solid bar,right 1
23 02.DLJ.PT SZW5008 PT SZW5008 end motion type inboard joint 1
24 02.DLJ.2303016 2303016 steel cable baffle ring 1
25 02. N650.03.02.02 N650.03.02.02.00 right drive shaft 1
26 03.01.5782-M15X1.5X80/05 5782-M15X1.5X80 M15X1.5X80 bolt 1
27 02.D800.02.03.0003 D800.02.03.00.03 spacer sleeve 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 D800.02.02.00.03 grease seal,φ46 4
32 02.D800.02.02.0002 D800.02.02.00.02 powdered spacer sleeve 4
33 02.D800.02.02.0004 D800.02.02.00.04 spacer sleeve 2
34 03.02.41-M16/05 41-M16 M16 nut 2
35 02. N650.02.02.01A N650.02.02.01.00A rear suspension arm,right 1
36 03.01.5782-M15X1.5X65/05 5782-M15X1.5X65X25 M15X1.5X65X25bolt 1
37 02.S650.03.02.01.01 S650.03.02.01.01 rear rim 12X8 1
38 02.S650.03.02.04.02A S650.03.02.04.02A rear tire 27X11-12,R 1
13.Cooling cycle
cooling cycle

40
41

42

30 32 1
31 33 2
34 3
33 32 36
4
23 34 6
30
24 15
21 5
29
22 34 7
28 8
25 14 9
17
26
18

27 14 12
10
13
16 38 39
15
11
14 14

38 39

37 38 39

No. ERP Code Code name Description Q'ty

1 03.01.D818-M6*16 818-M6X16 Cross head screw M6*16 1
2 02.D650.04.07.0003 D650.04.07.00.03 cover, oil separator 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 5787-M8X20 bolt-washer M8*20 2
7 03.02.6183，1-M8/05 6183，1-M8 self-locking nut M8 2
8 02.SV1100.04.07.0001 SV1100.04.07.00.01 Hose clip（19-29） 1
9 02. D650.04.02.0002 D650.04.02.00.02 water inlet hose 2, engine 1
10 02.S650.04.02.02 S650.04.02.02.00 Tee branch 1
11 02. D650.04.02.0002 D650.04.02.00.02 water inlet hose 1, engine 1
12 02. SV1100.04.02.0002 SV1100.04.02.00.02 small cooling cycle hose 1
13 02.D1600.04.02.0006 D1600.04.02.00.06 hoop(16-25) 2
14 02.D650.04.02.0003 D650.04.02.00.03 hoop(25-38),water tube 4
15 02.D650.04.02.0003 D650.04.02.00.03 hoop(25-38),water tube 4
16 02. D650.04.02.0001 D650.04.02.00.01 water outlet hose 1, engine 1
17 02. MV800.04.02.01 MV800.04.02.01.00 radiator support 1
18 03.02.6183,1-M8/05 6183,1-M8 self-locking nut M8 2
19
20
21 02.D800.04.02.02 D800.04.02.02.00 reserve tank 1
22 02.D800.04.02.0003 D800.04.02.00.03 reserve tank body 1
23 02.D800.04.02.0001 D800.04.02.00.01 cap of reserve tank 1
24 02.D800.04.02.0002 D800.04.02.00.02 airproof washer of reserve tank 1
25 02.D650.04.03.0004 D650.04.03.00.04 hoop(10-16) 3
26 02.WT-0611 WT-0611 tube Φ6xφ11 0.5meter
27 02.WT-0611 WT-0611 tube φ6xφ11 0.5meter
28 03.01.5787-M8X20/05 5787-M8X20 bolt-washer M8*20 2
29 03.02.6183，1-M8/05 6183.1-M8 self-locking nut M8 2
30 03.01.5787-M8X20/05 5787-M8X20 bolt-washer M8*20 4
31 03.01.5787-M8X20/05 5787-M8X20 bolt-washer M8*20 4
32 03.02.6183，1-M8/05 6183.1-M8 self-locking nut M8 4
33 02. D800.01.02.0005 D800.01.02.00.05 bracket 2
34 03.02.6183，1-M8/05 6183.1-M8 self-locking nut M8 4
35
36 02. D800.04.02.03 D800.04.02.03.00 aluminium radiator 1
37 02.D1600.04.02.02 D1600.04.02.02.00 radiator fan 1
38 03.03.95-Φ6 95-W6 Washer 6 4
39 03.01.5787-M6X20/05 5787-M6X20 Bolt-washer M6*20 4
40 02.LS2.04.02.0101 LS2.04.02.0101 cover 1
41 02.D800.04.02.03.01 D800.04.02.03.01 radiator body 1
42 02.D800.04.02.03.02 D800.04.02.03.02 radiator fan support 1
14.Electical appliance
Electrical appliance
1
17 3
5
17
2

11 6
7
12
13
14 8
15
16 9

18
10

19 18

27 20
30
28
29
21

22

31
23
24
32 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 D650.06.00.05.00 front turning light,left 1
4 02.D650.06.00.15 D650.06.00.15.00 front turning light,right 1
 5 02.D650.06.00.09 D650.06.00.09.00 horn 1
6 02.D25007914A D25007914A flasher apparatus 1
7 02.D25007924 D25007924 flasher coat 1
8 02.JD.0460003 JD0460003 washer 1
9 02.DS250.10.000005 DS250.10.00.00.05 horn button 1
1 02.D1600.06.03A D1600.06.03.00.00A switch assy
1
0
1 02.MV800.06.02 MV800.06.02.00.00 speedometer
1
1
1 02.D1600.06.05 D1600.06.05.00.00 tachometer
1
2
1 02.MV800.06.03 MV800.06.03.00.00 Coolant temperature indicator
1
3
1 02.D1600.06.09 D1600.06.09.00.00 voltmeter
1
4
1 02. N650.06.04 N650.06.04.00.00 fuel level gauge
1
5
1 02.D1600.06.07 D1600.06.07.00.00 oil pressure gauge
1
6
1 02.D1600.01.02.0006 D1600.01.02.00.06 Bracket of speedometer
1
7
1 02.D800.06.000012 D800.06.00.00.12 tail light assy
2
8
1 02.MV800.06.01 MV800.06.01.00.00 electrical wiring harness
1
9
2 02. MV800.01.02.03 MV800.01.02.03.00 ECU plastic shield
1
0
2 02.SV800.01.02.0002 SV800.01.02.00.02 ECU bracket
1
1
2 02.DLJ. S11-BJ3605010TA S11-BJ3605010TA renovated ECU
1
2
2 03.01.5787-M6X20/05 5787-M6X20 M6X20 bolt
4
3
2 03.02.2842-M6/05 2842-M6 nut-washer M6
4
4
2 03.01.5787-M6X20/05 5787-M6X20 M6X20 bolt
2
5
2 03.02.2842-M6/06 2842-M6 nut-washer M6
2
6
2 02.D1600.01.02.08 D1600.01.02.08.00 battery bracket
1
7
2 02.D1600.08.01.0004 D1600.08.01.00.04 battery cover
1
8
2 03.02.2842-M8/05 2842-M8 nut-washer M8
2
9
3 03.01.5787-M8X140/05 5787-M8X140 bolt-washer M8X140
2
0
3 02.D1600.06.02 D1600.06.02.00.00 battery
1
1
3 02.SR2000.01.02.03 SR2000.01.02.03.00 battery case
1
2
15.Fin assy,front cover
fin assy,front cover

4
10
1 2 3
10

7
18
5 16 15

23
19
20
17
24 22
9

13 6
21

12
11
14 8

No. ERP Code Code name Description Q'ty

1 03.01.D818-M6X16 818-M6X16 Cross head screw M6X16 9
2 02.JD0900008 JD0900008 Washer 6 9
3 03.02.6183,1-M6/05 6183.1-M6 Self-locking nut M6 9
4 02. MVA800.01.02.0005 MVA800.01.02.00.05 front cover plate 1
5 02. MVA800.01.02.0007 MVA800.01.02.00.07 right side fin 1
6 02. MVA800.01.02.0003 MVA800.01.02.00.03 rear panel 1
7 02. MVA800.01.02.0002 MVA800.01.02.00.02 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-M6X16 Cross head screw M6X16 3
12 02.JD0900008 JD0900008-W6 Washer 6 3
13 03.02.6183,1-M6/05 6183.1-M6 Self-locking nut M6 3
14 03.10.12618-4X10 12618-4X10 rivet 4X10 11
15 03.01.D818-M6X16 818-M6X16 Cross head screw M6X16 3
16 02.JD.0900008 JD0900008-W6 Washer 6 3
17 03.02.6183,1-M6/05 6183.1-M6 Self-locking nut M6 3
18 03.10.12618-4X10 12618-4X10 rivet 4X10 11
19 03.01.D818-M6X16 818-M6X16 Cross head screw M6X16 3
20 02.JD0900008 JD0900008 Washer 6 3
21 03.02.6183,1-M6/05 6183.1-M6 Self-locking nut M6 3
22 03.10.12618-4X10 12618-4X10 rivet 4X10 14
23 03.10.12618-4X10 12618-4X10 rivet 4X10 14
24 02. MVA800.01.02.0028 MVA800.01.02.00.28 fin assy 1

16.Seat and safety belt

seat and safety belt

2
J
O
Y
N J
E O
R Y
N J
E O
R Y
N
J
E
O
R
Y
N
3 E
R

5
5
6
5

No. ERP Code Code name Description Q'ty

1 02.D650.08.01.0001A D650.08.01.00.01A safty belt 2
2 02.D650.08.01.0013 D650.08.01.00.13 safty belt tube 4
3 02.D650.08.01.03 D650.08.01.03.00 seat , left 1

4 02.D650.08.01.04 D650.08.01.04.00 seat , right 1

5 02.D650.08.01.03.01 D650.08.01.03.01 Track without release lever 3

6 02.D650.08.01.03.02 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 5787-M10X35 bolt-washer M10X35 4
3 02.D1600.01.02.0007 D1600.01.02.00.07 spacer 4
4 03.02.2842-M10/05 2842-M10 nut M10 4
5 02. MVA800.10.03 MVA800.10.03.00.00 Rack relative option 1set
18.Fender relative option
FENDER OPTION

15

No. ERP Code Code name Description Q'ty

1 02.C650.08.01.13 C650.08.01.13.00 fender 4
2 02. C800.02.01.02 C800.02.01.02.00 upper arm.left.front 1
3 02.C800.02.01.03 C800.02.01.03.00 upper arm.left.right 1
4 02.C800.02.02.02 C800.02.02.02.00 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 bracket.left.rear 1
8 02.C1100.08.01.06 C1100.08.01.06.00 fender bracket.right.rear 1
9 03.01.D818-M6x 16 D818-M6x 16 M6x 16 srew 16
10 02.JD.0900008 JD0900008 rubber-washer Φ6 16
11 03.01.5787-M8X25/05 5787-M8X25 M8X25 bolt 8
12 03.02.6183,1-M8/05 6183.1-M8 NUT.self-lock M8 8
 13 03.02.6183,1-M6/05 6183.1-M6 NUT.self-lock M6 16
14 02.C800.02.02.01 C1100.02.02.01.00 rear arm.right 1
15 02.MV800.10.01 MV800.10.01.00.00 Fender relative option 1set

19.Spotlight relative option

SPOTLIGHT OPTION

No. ERP Code Code name Description 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-φ0X20X1,5/05 95-φ10X20X1,5 washer-φ10X20X1,5 4
4 02.MV800.99.99.04 MV800.99.99.04.00 mount of spotlight 1
5 03.01.5787-M10*20/05 5787-M10*20 bolt-washer M10*20 4
6 03.02.2842-M10X1,25/05 2842-M10X1,25 nut-M10X1,25 4
7 03.02.2842-M10/05 2842-M10 nut-M10 4
8 02.MVA800.10.02 MVA800.10.02.00.00 Spottlight relative option 1 set
20.Nerf bar relative option
Nerf bar option

forward

3
1
4

No. ERP Code Code name Description 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 2842-M10 nut M10 8
5 02.MVA800.10.02 MVA800.10.02.00.00 Nerf bar relative option 1
 21.Long cobined handle option

No. ERP Code Code name Description Q'ty

02.SVB1100.08.05.01A SVB1100.08.05.01.00 1se
Long combined handle （Polishing）
A t
6 02.SVB1100.08.05.01B SVB1100.08.05.01.00 1se
Long combined handle（Anodizing）
B t
02.SVB1100.08.05.01.01 SVB1100.08.05.01.01
LONG HANDLE upper fixed（Polishing） 2
A A
1 02.SVB1100.08.05.01.01 SVB1100.08.05.01.01
LONG HANDLE upper fixed（Anodizing） 2
B B
02.SVB1100.08.05.01.02 SVB1100.08.05.01.02
LONG HANDLE lower fixed（Polishing） 2
A A
2 02.SVB1100.08.05.01.02 SVB1100.08.05.01.02
LONG HANDLE lower fixed（Anodizing） 2
B B
02.SVB1100.08.05.01.03 SVB1100.08.05.01.03
LONG HAND grip（Polishing） 1
A A
3 02.SVB1100.08.05.01.03 SVB1100.08.05.01.03
LONG HAND grip（Anodizing） 1
B B
4 03.01.70.2- M8X20/05 70.2- M8X20 socker bead-butt screw （standardized） 2
5 03.01.70.1- M5X12/05 70.1- M5X12 socket cap screw（standardized） 4
 22.Short combined handle option

No. ERP Code Code name Description Q'ty

SVB1100.08.05.03.00 1se
02.SVB1100.08.05.03A Short combined handle （Polishing）
A t
6 SVB1100.08.05.03.00 1se
02.SVB1100.08.05.03B Short combined handle （Anodizing）
B t
02.SVB1100.08.05.01.01 SVB1100.08.05.01.01
LONG HANDLE upper fixed（Polishing） 2
A A
1 02.SVB1100.08.05.01.01 SVB1100.08.05.01.01
LONG HANDLE upper fixed（Anodizing） 2
B B
02.SVB1100.08.05.01.02 SVB1100.08.05.01.02
LONG HANDLE lower fixed（Polishing） 2
A A
2 02.SVB1100.08.05.01.02 SVB1100.08.05.01.02
LONG HANDLE lower fixed（Anodizing） 2
B B
02.SVB1100.08.05.03.01 SVB1100.08.05.03.01
Short HAND grip（Polishing） 1
A A
3 02.SVB1100.08.05.03.01 SVB1100.08.05.03.01
Short HAND grip（Anodizing） 1
B B
4 03.01.70.2- M8X20/05 70.2- M8X20 socker bead-butt screw （standardized） 2
5 03.01.70.1- M5X12/05 70.1- M5X12 socket cap screw（standardized） 4

23.Big flag staff mount option

No. ERP Code Code name Description Q'ty

02.SVB1100.08.05.02A SVB1100.08.05.02.00A BIG FLAGSTAFF MOUNT（Polishing） 1set
6
02.SVB1100.08.05.02B SVB1100.08.05.02.00B BIG FLAGSTAFF MOUNT（Anodizing） 1set
02.SVB1100.08.05.02.01A SVB1100.08.05.02.01A FLAGSTAFF seat（Polishing） 1
1
02.SVB1100.08.05.02.01B SVB1100.08.05.02.01B FLAGSTAFF seat（Anodizing） 1
02.SVB1100.08.05.02.02A SVB1100.08.05.02.02A BIG FLAGSTAFF upper fixed（Polishing） 1
2 BIG FLAGSTAFF upper fixed
02.SVB1100.08.05.02.02B SVB1100.08.05.02.02B
（Anodizing） 1
02.SVB1100.08.05.02.03A SVB1100.08.05.02.03A BIG FLAGSTAFF lower fixed（Polishing） 1
3
02.SVB1100.08.05.02.03B SVB1100.08.05.02.03B BIG FLAGSTAFF lower fixed（Anodizing） 1
4 03.01.70.1- M5X12/05 70.1- M5X12 socket cap screw（standardized） 2
5 03.01.80-M4X12/05 80-M4X12 socket dent holding screw（standardized） 1
24.Alum combined handle option

Q't
No. ERP Code Code name Description
y
1se
02.SVB1100.08.05.05A SVB1100.08.05.05.00A Alum combined handle（Polishing）
t
6
1se
02.SVB1100.08.05.05B SVB1100.08.05.05.00B Alum combined handle（Anodizing）
t
02.SVB1100.08.05.05.01
A
SVB1100.08.05.05.01A foot seat（Polishing） 2
1 02.SVB1100.08.05.05.01
B
SVB1100.08.05.05.01B foot seat（Anodizing） 2
02.SVB1100.08.05.05.02
A
SVB1100.08.05.05.02A foot tube（Polishing） 1
2 02.SVB1100.08.05.05.02
B
SVB1100.08.05.05.02B foot tube（Anodizing） 1
02.SVB1100.08.05.05.03
A
SVB1100.08.05.05.03A foot filler piece（Polishing） 2
3 02.SVB1100.08.05.05.03
B
SVB1100.08.05.05.03B foot filler piece（Anodizing） 2
4 03.01.70.1-M6x16/05 70.1-M6x16 socket cap screw（standardized） 4
5 03.01.80- M4x12/05 80- M4x12 socket dent holding screw（standardized） 2

25.Alum combined pipe clamp option

No. ERP Code Code name Description Q'ty

02.SVB1100.08.05.04A SVB1100.08.05.04.00A ALUM COMBINED PIPE CLAMP 1set
4
02.SVB1100.08.05.04B SVB1100.08.05.04.00B ALUM COMBINED PIPE CLAMP 1set
02.SVB1100.08.05.04.01A SVB1100.08.05.04.01A upper tubing clip 1
1
02.SVB1100.08.05.04.01B SVB1100.08.05.04.01B upper tubing clip 1
02.SVB1100.08.05.04.02A SVB1100.08.05.04.02A lower tubing clip 1
2
02.SVB1100.08.05.04.02B SVB1100.08.05.04.02B lower tubing clip 1
3 70.1-2000 M8*16 GB/T 70.1-2000 socket cap screw 2
 26.Small flagstaff mount option

No
Code Code name Description Q'ty
.
02.SVB1100.08.05.0 SVB1100.08.05.06
SMALL FLAGSTAFF MOUNT（Polishing） 1set
6A .00A
3
02.SVB1100.08.05.0 SVB1100.08.05.06
SMALL FLAGSTAFF MOUNT（Anodizing） 1
6B .00B
02.SVB1100.08.05.0 SVB1100.08.05.02
FLAGSTAFF seat（Polishing） 1
2.01A .01A
1
02.SVB1100.08.05.0 SVB1100.08.05.02
FLAGSTAFF seat（Anodizing） 1
2.01B .01B
02.SVB1100.08.05.0 SVB1100.08.05.06
SMALL FLAGSTAFF fixed（Polishing） 1
6.01A .01A
2
02.SVB1100.08.05.0 SVB1100.08.05.06
SMALL FLAGSTAFF fixed（Anodizing） 1
6.01B .01B
27.Shock absorber 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 2
 28.Tools and bag kit option

12

NO. ERP Code Part No. Part Description Qty

1 02.D650.08.05.0001 D650.08.05.00.01 Open-jawed spanner 8~10 1
2 02.D650.08.05.0002 D650.08.05.00.02 Open-jawed spanner 12~14 1
3 02.D650.08.05.0003 D650.08.05.00.03 Open-jawed spanner 13~16 1
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 D650.08.05.00.07 “+” Screwdriver 1
8
9 02.D650.08.05.0005 D650.08.05.00.05 Long Nose Pliers 1
10 02.D650.08.01.13 D650.08.01.13.00 Tools bag 1
11 02.D650.08.06.0001 D650.08.06.00.01 Cable tie 1
12 02. SVB1100.10.04 SVB1100.10.04.00.00 Tools and bag kit option 1set
29.Envelopment and foam cover option

1 4 8

1 2
2
3
4
3

6
5

NO. ERP Code Part No. Part Description Qty

1 02. MV800.08.01.02.01 MV800.08.01.02.01 Protect-jacket front, upper 1
2 02. MV800.08.01.02.02 MV800.08.01.02.02 Protect-jacket 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 02. D800.08.01.00.03 D800.08.01.00.03 Entire vehicle cover 1
7 02. MV800.08.01.00.02 MV800.08.01.00.02 canvas roof 1
8 02.MV800.08.01.02 MV800.08.01.02.00 Protect-jacket assy 1
30. luxury 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 shock 2
WEARING PARTS
1. Body
Num English name 代码 件号 数量
1 rubber washer Φ6 02.JD.090008 JD0900008 20
2 radial bearing GE25C 02.D800.02.01.0001 D800.02.01.00.01 4
3 bushing 02.D800.02.01.0002 D800.02.01.00.02 8
4 rod end bearing POSA16,control arm 02.D800.02.01.0003 D800.02.01.00.03 8
5 spacer sleeveφ16 ,control arm 02.D800.02.01.0004 D800.02.01.00.04 16
6 interner circlip φ55 (model B) 03.09.893,2-φ55 893.2-φ55 2
7 shocker spacer sleeve 02.D800.02.03.0003 D800.02.03.00.03 16
8 hub screw M12*1.5 02. D650.03.02.0003A D650.03.02.00.03A 16
9 wheel nut M12*1.5 02.S650.03.01.0002 S650.03.01.00.02 16
10 ball bearing 25*52*15 03.05.276-6205 276-6205 2
11 ball bearing 30*62*16 03.05.276-6206 276-6206 2
12 oil seal 30*52*8 02.D800.03.01.0008 D800.03.01.00.08 2
13 oil seal 40x62x7 02.D800.03.01.0009 D800.03.01.00.09 2
14 bearing(30*50*32) 02.D650.03.02.0007 D650.03.02.00.07 2
15 slotted nut M22*1.5,rear shaft 02.DLJ.JGC2202-K JGC2202-K 2
16 internal circlip Φ42 (model B) 03.09.893,2-φ55 893.2-φ55 2
17 engine rubber bumper 02.D650.04.01.0001 D650.04.01.00.01 8
18 rod end bearingPOSA12LH 02.D800.05.01.0001 D800.05.01.00.01 2
19 rod end bearingPOSA12 02.D800.05.01.0002 D800.05.01.00.02 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.D1600.06.10.0002 D1600.06.10.00.02 4
24 headlight 02.D1600.06.11A D1600.06.11.00.00A 2
25 Headlight BULB 35W/35W 02.D1600.06.11.0001 D1600.06.11.00.01 2
26 turning light BULB 5W 02.D650.06.0005.01 D650.06.00.05.01 4
27 tail light 02.D800.06.00.0012 D800.06.00.00.12 2
28 turning light BULB 10W 02.D650.06.0005.01 D650.06.00.05.01 2
29 tail light BULB 5W 02.D650.06.0004.02 D650.06.00.04.02 2
30 stoplight bulb 21W 02.D650.06.0004.03 D650.06.00.04.03 2
31 flasher apparatus 02.D250.07914A D25007914A 1
32 ignition switch assembly 02.N650.06.0018 N650.06.00.18.00 1
33 Throttle cable 02.MV800.07.03.01 MV800.07.03.01.00 1
34 disc brake with floating caliper,front 02.SV800.07.01.01.01 SV800.07.01.01.01 1
35 clutch cable 02.MV800.07.04.01 MV800.07.04.01.00 1
36 air cleaner 02.N650.04.05.01 N650.04.05.01.00 1
37 brake pad 02.DLJ.ZJ509,03-04 ZJ509.03-04 8
38 brake Disc 02.D650.03.02.0005 D650.03.02.00.05 4
39 fuel pump assy 02.D1600.04.03.02 D1600.04.03.02.00 1
40 fuel press adjuster 02.D1600.04.03.03 D1600.04.03.03.00 1
41 inner boot seal 02.DLJ.BT-1085 BT-1085 2
42 SMALL band 02.DLJ.SH07350 SH07350 4
43 outer boot seal 02.DLJ. BT-1045 BT-1045 2
44 big band 02.DLJ. SH07680 SH07680 4
45 Molybdenum Disulfide Lithium-based Grease 02.DLJ.LJZ LJZ 100kgx4
46 drive shaft, right 02.SV800.03.02.02 SV800.03.02.02.00 1
47 drive shaft, left 02.SV800.03.02.01 SV800.03.02.01.00 1
48 switch assy 02.D1600.06.03A D1600.06.03.00.00A 1
2.Engine
1 cylinder head cover gasket 02.DLJ.372-1003036 372-1003036 10
2 gasket-cylinder head 02.DLJ. 372-1003040 372-1003040 1
3 bolt,cylinder head 02.DLJ.372-1003051 372-1003051 8
4 camshaft oil seal 02.DLJ. 372-1003066 372-1003066 8
5 block cover 02.DLJ. 372-1003067 372-1003067 16
6 the first Piston ring 02.DLJ. 372-1004032 372-1004032 16
7 the second Piston ring 02.DLJ. 372-1004033 372-1004033 16
8 oil control steel-ring 02.DLJ. 372-1004040 372-1004040 10
9 bearing-connecting rod 02.DLJ. 72-1004116 372-1004116 10
10 upper bearing-cranksaft 02.DLJ. 372-1005013 372-1005013 1
11 lower bearing-cranksaft 02.DLJ. 372-1005014 372-1005014 1
12 cranksaft front oil seal 02.DLJ. 372-1005015 372-1005015 1
13 stopper plate 02.DLJ. 372-1005016 372-1005016 4
14 rear oil seal 02.DLJ. 372-1005030 372-1005030 4
15 pulley bolt 02.DLJ. 372-1005031 372-1005031 8
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 372-1007012 5
20 adjustment washer 02.DLJ. 372-1007017 372-1007017 1
21 valve lifter 02.DLJ. 372-1007018 372-1007018 2
22 seal,valve 02.DLJ. 372-1007020 372-1007020 1
23 tension pulley assy 02.DLJ. 372-1007030 372-1007030 1
24 timing gear cover assy 02.DLJ. 372-1007040 372-1007040 1
25 toothed timing belt 02.DLJ. 372-1007081 372-1007081 1
26 intake manifold washer 02.DLJ. 372-1008021 372-1008021 1
27 nut,hexagon 02.DLJ. Q33008 Q33008 16
28 stud 02.DLJ. Q1200855F3 Q1200855F3 1
29 stud 02.DLJ. Q1200825F3 Q1200825F3 16
30 bolt,hexagon head 02.DLJ. Q1420612 Q1420612 1
31 oil strainer washer 02.DLJ. 372-1010017 372-1010017 1
32 bolt 02.DLJ. Q1840612 Q1840612 1
33 bolt,hexagon flange 02.DLJ. Q1840610 Q1840610 1
34 oil pump washer 02.DLJ. 372-1011021 372-1011021 1
35 oil pump assy 02.DLJ. 372-1011030 372-1011030 1
36 seal strip 02.DLJ. 372-1011055 372-1011055 1
37 crankcase ventilation pipe(1) 02.DLJ. 372-1014110 372-1014110 1
38 crankcase ventilation pipe(3) 02.DLJ. 372-1014130 372-1014130 1
39 clamp 02.DLJ. Q673B155 Q673B155 1
40 seat-thermostat 02.DLJ. 372-1306001 372-1306001 1
41 thermostat assy 02.DLJ. 372-1306020 372-1306020 1
42 pump set ,water 02.DLJ. 372-1307010 372-1307010 1
43 seal strip 1 02.DLJ. 372-1307012 372-1307012 4
44 ring "o" 02.DLJ. 372-1307015 372-1307015 1
45 water pump washer 02.DLJ. 372-1307041 372-1307041 4
46 sensor,crankshaft position 02.DLJ. S11-1003069BA S11-1003069BA 1
47 intake temperature and pressure sensor 02.DLJ. 11-1109411BA S11-1109411BA 1
48 bolt,hexagon head 02.DLJ. Q1400416 Q1400416 1
49 ignition coil assy 02.DLJ. S11-3705000BA S11-3705000BA 1
50 bolt,hexagon head 02.DLJ. Q1460820 Q1460820 1
51 cord NO.1, Hi.tension 02.DLJ. S11-3707020 S11-3707020 1
52 cord NO.2, Hi.tension 02.DLJ. S11-3707030 S11-3707030 1
53 cord NO.3, Hi.tension 02.DLJ. S11-3707040 S11-3707040 1
54 spark plug assy 02.DLJ. S11-3707100 S11-3707100 1
55 coolant temperature sensor 02.DLJ. S11-3617011EA S11-3617011EA 1
56 stud 02.DLJ. Q1200840F3 Q1200840F3 1
57 stud 02.DLJ. 480-1008022 480-1008022
58 Starter assy 02.DLJ. S11-3708110B1 S11-3708110B1
59 electronic speedometer sensor assy 02.DLJ. S11-3802020 S11-3802020
60 Alternator assy 02.DLJ. S11-3701110B1 S11-3701110B1
61 oil filter assy 02.DLJ. 372-1012010 372-1012010
62 steel cable baffle ring 02.DLJ. 2303016 2303016
63 clutch 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. 5T07-1702090A 5T07-1702090A 1
3 SHIFT-SELECT SHAFT 02.DLJ. 5T07-1702100A 5T07-1702100A 1
4 SHIFT-SELECTING SHAFT 02.DLJ. 5T07-1702101A 5T07-1702101A 1
5 SNAP RING.STOP PLATE.SHIFT INTERLOCK 02.DLJ. QR512-1702214 QR512-1702214 3
RELEASE-SPRING SEAT.1ST GEAR&2ND
6 1
GEAR 02.DLJ. 5T07-1702102 5T07-1702102
7 RELEASE-SPRING.1ST GEAR&2ND GEAR 02.DLJ. 5T07-1702103 5T07-1702103 1
8 SPRING-STOP PLATE 02.DLJ. 5T07-1702104 5T07-1702104 2
9 SHIFT INTERLOCK STOP PLATE 02.DLJ. 5T07-1702107A 5T07-1702107A 2
10 SHIFT-SELECT ARM 02.DLJ. 5T07-1702105A 5T07-1702105A 1
11 SHIFT-SELECT ARM PIN 02.DLJ. 5T07-1702106 5T07-1702106 1
12 SPRING PIN 3.5X28 02.DLJ. QR512-1702113 QR512-1702113 1
RELEASE-SPRING.5TH GEAR&REVERSE
13 1
GEAR 02.DLJ. 5T07-1702114A 5T07-1702114A
RELEASE-SPRINGSEAT.5TH
14 1
GEAR&REVERSE GEAR 02.DLJ. 5T07-1702112 5T07-1702112
15 SPRING SEAT.REVERSE GEAR 02.DLJ. 5T07-1702108A 5T07-1702108A 1
16 LIMITING SPRING.REVERSE GEAR 02.DLJ. 5T07-1702109A 5T07-1702109A 1
17 LIMITING CAM.REVERSE GEAR 02.DLJ. QR512-1702111A QR512-1702111A 1
18 FRONT BEARING.OUTPUT SHAFT 02.DLJ. 5T07-1701610 5T07-1701610 1
19 REAR BEARING.OUTPUT SHAFT 02.DLJ. 5T07-1701250 5T07-1701250 1
20 FRONT BEARING.DIFFERENTIAL 02.DLJ. 5T07-1701310 5T07-1701310 1
21 ODOMETER DRIVING GEAR 02.DLJ. QR512-1701604 QR512-1701604 1
22 REAR BEARING.DIFFERENTIAL 02.DLJ. 5T07-1701320 5T07-1701320 1
23 LOCATING PIN 02.DLJ. 5T07-1701001 5T07-1701001 2
24 INPUT SHAFT SEAL 02.DLJ. 5T07-1701080 5T07-1701080 1
25 RIGHT SEAL.DIFFERENTIAL 02.DLJ. 5T07-1701090 5T07-1701090 1
26 SEAL.CLUTCH FORK 02.DLJ. 5T07-1702030 5T07-1702030 2
27 LEFT SEAL .DIFFERENTIAL 02.DLJ. 5T07-1701010 5T07-1701010 1
28 BEARING 6204/YA/P63 02.DLJ. 4T08-1701130 4T08-1701130 1
29 DECLUTCH BEARING 02.DLJ. 5T07-1702010 5T07-1702010 1
30 BACK-UP LIGHT SWITCH 02.DLJ. 5T07-3729010 5T07-3729010 1
31 Differential assy 02.DLJ. 4T08A2-1701600 4T08A2-1701600 1
4..Standard part
1 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-M10/05 GB/T-2000 5
5 cotter pin 3.2*30 03.08.91-3.2x 30/05 GB/T91-2000 3
6 cotter pin 4*40 03.08.91-4x 40/05 GB/T91-2000 4
7 Bolt M15*1.5*190 03.01.5782-M15X190/05 GB/T5782-2000 2
8 Bolt M15*1.5*210 03.01.5782-M15X210/05 GB/T5782-2000 2
9 Bolt M15*1.5*80 03.01.5782-M15X80/05 GB/T5782-2000 2
10 Bolt M15*1.5*65 03.01.5782-M15X65/05 GB/T5782-2000 2
11 Nut M15*1.5 03.02.6185,1-M15/05 GB/T6185.1-2000 8
12 Bolt M16*2*85 03.01.5782-M16X85/05 GB/T5782-2000 2
13 Bolt M16*2*95 03.01.5782-M16X95/05 GB/T5782-2000 2
14 Bolt M16*2*65 03.01.5782-M16X65/05 GB/T5782-2000 2
15 Nut M16*2 03.02.6185,1-M16/05 GB/T6185.1-2000 6
18 bolt-washer M10*1.5*30 G03.01.5787-M10X30/05 GB/T5787-1986 10
19 spring washer 10 03.05.93-Φ10/05 GB/T93-1987 10
、
、

、
、

PREPARATION ATTACH INSTRUCTION

1.Remove Packing
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

 w a rd
1
for

4 02.N650.02.01.01 N650.02.01.01.00 lower suspension arm,FL 1

3 02.N650.02.01.02 N650.02.01.02.00 upper suspension arm,FL 1
2 02.N650.02.01.04 N650.02.01.04.00 lower suspension arm,FR 1
1 02.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 as the figure above.
2. Install the right suspension arms as above .
Note: Before installing, put 3# Lithium-grease into the moving part .
3.Tighten the bolts and nuts with thread glue.

3.Attach front shock absorber

 a rd
w
fo r

1 2 3

4 02.MV800.02.03.01 MV800.02.03.01.00 front shocker absorber 2

3 03.01.5782-M15x190/05 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 shock absorber-4 on the frame , insert the bolt-3 and spacer
sleeve-2, tighten nuts-1 with thread glue.
4.Attach tie rod end and front wheel

a rd
w
fo r

3
1

steering cross rod

2

left wheel axle,front

4 02.S650.03.01.0002 S650.03.01.00.02 wheel nut M12*1.5 8

3 02. S650.03.01.01.00A S650.03.01.01.00A Left wheel(27*8-12) 1
2 02.D800.05.01.0001 D800.05.01.00.01 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 axle,front.
2. Install bolt,spacer sleeve,then tighen nut.
Note: don't adjust outer tie rod end as wheel alignment is done before
packing.
3. Attach the wheel(27*8-12),FL-3 on the hub, tighten the nuts.
4. Attach the wheel(27*8-12),FR-1 as described above .
5.Attach tie rod and front wheel
6.Attach the rear suspension arm

5
4 3
2

ard
w
for

7 03.02.2842-M16/05 2842-M16 M16*2 nut 4

6 02.D800.02.02.0004 D800.02.02.00.04 spacer sleeve 4
5 02.D800.02.02.0002 D800.02.02.00.02 powdered spacer sleeve 8
4 02.D800.02.02.0003 D800.02.02.00.03 grease seal,φ46 8
3 03.01.5787-M16X125/05 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 Description Q'ty

1. Attach rear suspension arm,right-1 on the rear part of frame. Insert the
M16*2*125 bolt-3, grease seal,φ46-4,powdered spacer sleeve-5 and spacer
sleeve-6 in order as above.Tighten the bolts-3 and nuts-7 with threads glue.
2. Attach rear suspension arm,left-2 as described above .
7.Attach drive shaft

2
3

d
war
r
fo
3 02.DLJ.2303016 2303016 steel cable baffle ring 2
2 02. N650.03.02.02 N650.03.02.02.00 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
transmission.
2. Insert right drive shaft-2 onto the output shaft of transmission.
3. Attach the left side as figure .
7.Attach drive shaft
transmission
Steel cable baffle ring

4 Caution: the Steel cable baffle ring-3 must be confirmed in the groove both
sides before attaching drive shaft.
8.Attach rear shock absorber

2
3

d
war
r
fo
4 02. N650.02.03.02 N650.02.03.02.00 rear shock absorber 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 Description Q'ty
9. Attach rear shock absorber-4 on the frame , tighten the bolt-1 and nuts-3 with
thread glue.
9.Attach rear wheel

ward
r
fo 2

1. Attach wheel (27X11-12),BR-2 on the 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 S650.03.02.01.00A wheel(27*11-12),BL 1
No. Erp code Part name Description Q'ty
10.Check vehicle

1. Before starting the engine check engine oil,gearbox oil and all plugs have
good connection. check the level of coolant at the filler neck of inlet to radiator
after leaving the cap off at this stage. check pressure in the tire; front tire: 15PSI;
rear tire: 15PSI check all bolts and nuts 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 filler neck, top up as it drops. install
radiator cap and test drive gently for 2-3 minutes allow engine to cool,top up
coolant in radiator ,refit cap.
WARNING:when the enige is at high temprature, never open radiator cap.
If you do that,the high temprature coolant will spray out and could
cause serious burns.
DEALER PRE-DELIVERY INSPECTION
_______Jumping the vehicle can cause serious damage to the drive train (axle, transmission,
suspension).
_______Injury or death can result from jumping vehicle. Do Not Jump.
_______I understand that the roll bars are cosmetic and a roll over could cause death or serious
injury. The seller is not liable for death or injury.
_______I have inspected all machines for any cosmetic damage and found it/them to be satisfactory.
I further understand that cosmetic damage is NOT covered by any factory warranties and unless
noted here are deemed accepted by me.
_______Sand dunning or desert riding is dangerous. Death or injury could occur. The seller is not
liable for injury or death.
_______I understand all sales are final and that there is no right of rescission, no option for return or
exchange for any vehicle purchased, and that the titled and registered machines were effectively
purchased when I signed the title application.
_______I understand the warranty is 90 day manufacture defect only with the following not covered:
axles, electrical batteries, light bulbs, clutches, turbo cartridges, carburetor cleaning, piston rings that
are scorched from one revving, rims/tires, bearings.
_______I understand that although some lending institutions do not require insurance, state law
DOES require liability insurance and a driver’s license. I also understand that none of the products
offered by the dealer constitutes insurance and a separate policy would have to be purchases from
an outside source to protect my purchase and fulfill state requirements.
_______I have been shown the VIN number for each machine and they match this form and all
paperwork received.
_______I understand that I have only 72 hours to notify the seller of any issues to the paperwork or
the vehicle.
_______Off Road use only. Driving on paved roads can cause axle or transmission damage. Both
tires turn equally, this is not a limited slip differential. Injury or death can occur form operating a non
DOT vehicle on public roads.
_______Turbo systems, system lessen life of engine, over revving the engine to increase boost of
turbo can cause engine damage. 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 essence of this contract. Sellers acceptance of partial
payments shall not in any manner modify the terms of this contract and such acceptance shall not be
construed as a waiver of any subsequent defaults on Buyer’s part nor shall it waive the “time is of the
essence” provision.
y NOTICE. Any notice required to be given to Buyer shall be deemed reasonable notification if
(Ⅰ)mailed by ordinary mail, postage prepaid, to Buyer’s mailing address as shown on this
contract or to Buyer’s most recent address as shown by a “notice of change of address” on file with
Seller, whether or not such notice is actually received by buyer, or(Ⅱ) if given in any other manner
which results in Buyer’s actual receipt of such notice.
y BAD CHECK. If Buyer pays Seller with a check that is dishonored or unpaid for any reason, Seller
may at Seller’s sole option, terminate this contract and retake the vehicle, or make claims against
Buyer on the check. In addition, Seller will charge Buyer a $25 returned check charge plus any actual
charges assessed by Seller’s financial institution resulting from such returned check.
y ATTORNEYS FEES. If it is necessary for Seller to take legal action to enforce any of seller’s
rights under this contract, Buyer agrees to pay to the extent permitted by law, the seller‘s reasonable
attorneys fees and court costs.
y GENERAL. This contract is governed by applicable federal law and the laws of the State of
Arizona. Any provisions found to be invalidate the remainder hereof, Waiver of any default shall not
constitute waiver of any subsequent default. All words used herein shall be construed to be of such
gender and number as the circumstances require. The contract shall be binding upon Buyer’s heirs,
personal representatives, successors and assigns and shall inure to the benefit of Seller’s
successors and assigns. This contract constitutes the entire agreement between the parties with
respect to the subject matter herein, and may not be altered or amended unless made in writing and
duty executed by Seller.
y CASH DEPOSIT. If Buyer fails or refuses to accept delivery of any Vehicle or product or fails to
comply with this contract, Seller may keep any cash deposit as liquidated damages, to the extent not
prohibited by law. The deposit may also be used reimburse Seller for any expenses and losses Seller
incurs or suffers as a result of Buyer’s failure or refusal to accept deliver of the Vehicle or product or
to comply with this contract. Such expenses and losses may include Seller s reasonable attorney’s
fees.
y NON-DELIVERY. Seller is not liable for failure to deliver or for delay in delivering the Vehicle or
other product where such failure or delay is due, in whole or in part, to any cause beyond Seller’s
control or without Seller’s fault or negligence,
y RISK OF LOSS, INSURANCE. The risk of loss to the Vehicle or any other items covered by this
invoice passes to Buyer upon delivery of the Vehicle or other goods to Buyer at the address set forth
on this invoice for shipment to Buyer or such other place of receipt designated by Buyer. Buyer is
responsible for maintaining its own theft and liability insurance coverage for the Vehicle.
y AGE. Buyer represents and warrants to Seller that Buyer is over the age of majority and is fully
competent to enter into this contract. Buyer acknowledges that Seller is relying on this representation
in entering into and performing this contract.
ADDITIONAL TERMS AND CONDITIONS OF SALE
1) PROMISE TO PAY. By signing this contract, Buyer agrees to pay Seller the “TOTAL DUE”.
2) TIME OF ESSENCE. Time is of the essence of this contract, Seller’s acceptance of partial
payments shall not in any manner modify the terms of this contract and such acceptance shall not be
construed as a waiver of any subsequent defaults on Buyer’s part nor shall it waive the “time is of
the essence” provision.
3) NOTICE. Any notice required to be given to Buyer shall be deemed reasonable notification if (Ⅰ)
mailed by ordinary mail, postage prepaid, to Buyer’s mailing address as shown on this contract or to
Buyer’s most recent address as shown by a “notice of change of address” on file with Seller, whether
or not such notice is actually received by Buyer, or (Ⅱ) if given in any other manner which results in
Buyer’s actual receipt of such notice.
4) BAD CHECK. If Buyer pays Seller with a check that is dishonored or unpaid for any reason, Seller
may at Seller’s sole option, terminate this contract and retake the vehicle, or make claims against
Buyer on the check. In addition, Seller will charge Buyer a $25 returned check charge plus 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 under this contract. Buyer agrees to pay to the extent permitted by law, the seller’s reasonable
attorney’s fees and court costs.
6) GENERAL. This contract is governed by applicable federal law and the laws of the State of
Arizona. Any provisions found to be invalid shall not invalidate the remainder hereof. Waiver of any
default shall not constitute waiver of any subsequent default. All words used herein shall be
construed to be of such gender and number as the circumstances require. The contract shall be
binding upon Buyer’s heirs, personal representatives, successors and assigns and shall inure to the
benefit of Seller‘s successors and assigns. This contract constitutes the entire agreement between
the parties with respect to the subject matter herein, and may not be altered or amended unless
made in writing and duly executed by Seller.
7) CASH DEPOSIT. If Buyer fails or refuses to accept delivery of any Vehicle or product or fails to
comply with this contract, Seller may keep any cash deposit as liquidated damages, to the extent not
prohibited by law. The deposit may also be used to reimburse Seller for any expenses and losses
Seller incurs or suffers as a result of Buyer’s failure or refusal to accept delivery of the Vehicle or
product or to comply with this contract. Such expenses and losses may include Seller’s reasonable
and loses Seller incurs or suffers as a result of Buyer’s failure or refusal to accept delivery of the
Vehicle or product or to comply with this contract .Such expenses and losses may include Seller’s
reasonable attorney’s fees.
8) NON-DELIVERY. Seller is not liable for failure to deliver or for delay in delivering the vehicle or
other product where such failure or delay is due. In whole or in part, to any cause beyond Seller’s
control or without Seller’s fault or negligence.
9) RISK OF LOSS: INSURANCE. The risk of loss to the vehicle or any other items covered by this
invoice passes to Buyer upon delivery of the vehicle or other goods to Buyer at the address set forth
on this invoice for shipment to Buyer or such other place of receipt designated by Buyer. Buyer is
responsible for maintaining its own theft and liability insurance coverage for the vehicle.
AGE. Buyer represents and warrants to Seller that Buyer is over the age of majority and is fully
competent to enter into contact. Buyer acknowledges that Seller is relying on this representation in
entering into performing this contract.