Joyner TROOPER T2 User manual

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Owner’s Manual
Parts manual
READ THIS MANUAL CAREFULLY
IT CONTAINS IMPORTANT SAFETY INFORMATION.
MINIMUM
RECOMMENDED
OPERATOR AGE:
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for off-road use only.
USA only;
It does not confirm to federal motor vehicle safety standards, and operation on public streets, roads,
or highways is illegal.
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TROOPER
T2，T4

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INTRODUCTION
Thank you for choosing JOYNER TROOPER. 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.

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CONTENTS
Warranty policy .......................................................................................................................................6
Parts order form, warranty claim form................................................................................................10
Service record form ..............................................................................................................................11
Preventative maintenance and service log.........................................................................................12
Location of warning labels and specification labels.........................................................................17
Safety information.................................................................................................................................21
Are you ready to drive?........................................................................................................................23
Protective apparel ............................................................................................................................23
Helmets and ayes protection ..........................................................................................................23
Drive training .....................................................................................................................................24
Age recommendation.......................................................................................................................24
No alcohol or drugs..........................................................................................................................24
Is your vehicle ready to drive? ............................................................................................................25
Pre-drive Inspection..............................................................................................................................25
Operation instruction............................................................................................................................27
Main switch........................................................................................................................................27
Battery switch....................................................................................................................................27
Gauges...............................................................................................................................................28
Switches.............................................................................................................................................28
Steering wheel ..................................................................................................................................30
Pedal ..................................................................................................................................................31
Parking brake lever ..........................................................................................................................31
Drive select lever..............................................................................................................................32
Differential control handle ...............................................................................................................32
Fuel tank ............................................................................................................................................33
Seats and safety belts .....................................................................................................................33
Safari bed ..........................................................................................................................................35
Start engine .......................................................................................................................................36
Stop engine .......................................................................................................................................36
Passenger .........................................................................................................................................37
Break-in..............................................................................................................................................37
Starting and operating instructions ................................................................................................37
Specifications........................................................................................................................................38
Maintenance and adjustment...................................................................................................................... 41
Air Cleaner.............................................................................................................................................41
Engine Lubrication................................................................................................................................41
Transmission lubrication......................................................................................................................42
Differential lubrication..........................................................................................................................43
Engine Coolant......................................................................................................................................43
Idle Speed ..............................................................................................................................................45
Spark plug inspection...........................................................................................................................45
Wedge belt figure..................................................................................................................................47

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Shift cable adjustment..........................................................................................................................47
Parking brake cable adjustment..........................................................................................................48
Steering lubrication...............................................................................................................................49
Throttle cable adjustment ....................................................................................................................49
Differential lock cable adjustment.......................................................................................................49
Parking adjustment ..........................................................................................................................49
Gear shift adjustment.......................................................................................................................50
Front Wheel Replacement....................................................................................................................50
Rear Wheel Replacement .....................................................................................................................50
Clutch replacement...............................................................................................................................51
Front Wheel Alignment.........................................................................................................................54
Battery....................................................................................................................................................54
Fuse replacement..................................................................................................................................54
Bulb replacement..................................................................................................................................54
Shock adjustment .................................................................................................................................54
Repair manual............................................................................................................................................. 55
Chassis wiring diagram........................................................................................................................55
Engine wiring diagram..........................................................................................................................56
Chassis disassembly, installation and repairment............................................................................56
Front suspension..............................................................................................................................56
Rear suspension...............................................................................................................................56
Driven system ...................................................................................................................................56
Coolant system .................................................................................................................................56
Fuel system.......................................................................................................................................56
Steering box ......................................................................................................................................56
Shift.....................................................................................................................................................56
Brake ..................................................................................................................................................56
Parking brake....................................................................................................................................56
clutch ..................................................................................................................................................56
Engine disassembly, installation and repair ......................................................................................57
Timing Belt.........................................................................................................................................57
Camshaft ...........................................................................................................................................64
Cylinder head....................................................................................................................................73
Water pump.......................................................................................................................................79
Oil pump.............................................................................................................................................80
Crankshaft connecting rod mechanism.........................................................................................88
Electric injection system..................................................................................................................99
PARTS MANUAL ......................................................................................................................................139
1. ENGINE.............................................................................................................................................139
1. COOLING SYSTEM ..................................................................................................................139
2. CYLINDER BLOCK ...................................................................................................................140
3. CRANKSHAFT ...........................................................................................................................141
4. EXHAUST MANIFOLD..............................................................................................................142

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5. INTAKE SYSTEM ......................................................................................................................143
5. INTAKE SYSTEM ......................................................................................................................144
6. LUBRICATING DEVICE............................................................................................................145
7. CYLINDER HEAD......................................................................................................................146
7. CYLINDER HEAD......................................................................................................................147
8. COVER-VALVE CHAMBER .....................................................................................................148
9. OIL PAN.......................................................................................................................................149
10. VALVE MECHANISM ..............................................................................................................150
10. VALVE MECHANISM ..............................................................................................................151
10. VALVE MECHANISM ..............................................................................................................152
11. IGNITION DEVICE...................................................................................................................153
12. PISTON AND CONNECTING ROD DEVICE ......................................................................154
13. OTHER ACCESSORY 1.........................................................................................................155
14. OTHER ACCESSORY 2.........................................................................................................156
5T07D1 TRANSMISSION.....................................................................................................................157
1 CASE&ACCESSORY.................................................................................................................157
1 CASE&ACCESSORY.................................................................................................................158
2 COUNTERSHAFT ......................................................................................................................159
2 COUNTERSHAFT ......................................................................................................................160
3 INPUT SHAFT ASSY..................................................................................................................161
3 INPUT SHAFT ASSY..................................................................................................................162
3 INPUT SHAFT ASSY..................................................................................................................163
4 SHIFT FORK&SHIFT-FORK SHAFT .......................................................................................164
4 SHIFT FORK&SHIFT－FORK SHAFT ....................................................................................165
5 SHIFT CONTROL MACHINSM.................................................................................................166
6 DRIVEN GEAR ASSY ................................................................................................................168
CHASSIS ..............................................................................................................................................169
18 HYDRAULIC PUMP ASSEMBLY OF FOOT BRAKE ..........................................................199
19 HYDRAULIC PUMP ASSEMBLY OF PARKING BRAKE....................................................200
20 CLUTCH HYDRAULIC ASSEMBLY.......................................................................................201
DEALER PRE-DELIVERY INSPECTION.............................................................................................202

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Warranty policy

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Parts order form, warranty claim form

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Service record form

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Preventative maintenance and service log

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Location of warning labels and specification labels
Read and understand all of the labels on your vehicle. They contain important information for
safe and proper operation of your vehicle.
Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a
replacement label is available from your Joyner dealer.

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