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
Owner’s manual ............................................................................................................................................ 7
Warranty policy .......................................................................................................................................7
Parts order form, warranty claim form................................................................................................11
Service record form..............................................................................................................................12
Preventative maintenance and service log ........................................................................................13
Location of warning labels and specification labels.........................................................................18
Safety information.................................................................................................................................22
Are you ready to drive?........................................................................................................................24
Protective apparel ............................................................................................................................ 24
Helmets and ayes protection.......................................................................................................... 24
Drive training..................................................................................................................................... 25
Age recommendation ...................................................................................................................... 25
No alcohol or drugs.......................................................................................................................... 25
Is your vehicle ready to drive? ............................................................................................................26
Pre-drive Inspection..............................................................................................................................26
Operation instructionMain switch.......................................................................................................28
Battery switch ................................................................................................................................... 28
Gauges .............................................................................................................................................. 29
Switches ............................................................................................................................................ 29
Steering wheel.................................................................................................................................. 31
Pedal.................................................................................................................................................. 32
Parking brake lever.......................................................................................................................... 32
Drive select lever.............................................................................................................................. 33
Differential control handle ............................................................................................................... 33
Fuel tank............................................................................................................................................ 34
Seats and safety belts..................................................................................................................... 34
Safari bed.......................................................................................................................................... 36
Start engine....................................................................................................................................... 36
Stop engine ....................................................................................................................................... 37
Passenger ......................................................................................................................................... 37
Break-in ............................................................................................................................................. 37
Starting and operating instructions................................................................................................ 38
Specifications........................................................................................................................................39
Maintenance and adjustment...................................................................................................................... 42
Air Cleaner.............................................................................................................................................42
Engine Lubrication................................................................................................................................42
Transmission lubrication......................................................................................................................43
Differential lubrication..........................................................................................................................44
Engine Coolant......................................................................................................................................44
Idle Speed ..............................................................................................................................................46
Spark plug inspection...........................................................................................................................46

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Wedge belt figure..................................................................................................................................48
Shift cable adjustment..........................................................................................................................48
Parking brake cable adjustment..........................................................................................................49
Steering lubrication...............................................................................................................................50
Throttle cable adjustment ....................................................................................................................51
Differential lock cable adjustment.......................................................................................................51
Spot light adjustment............................................................................................................................52
Oil filter change.....................................................................................................................................53
Fuel pressure adjustment ....................................................................................................................53
Front Wheel Replacement....................................................................................................................54
Rear Wheel Replacement.....................................................................................................................54
Clutch replacement...............................................................................................................................55
Front Wheel Alignment.........................................................................................................................58
Fuse and relay.......................................................................................................................................58
Bulb replacement..................................................................................................................................60
Shock adjustment .................................................................................................................................62
Chassis wiring diagram........................................................................................................................64
Engine wiring diagram..........................................................................................................................65
Engine disassembly, installation and repair ......................................................................................66
Timing Belt ........................................................................................................................................ 66
Camshaft ........................................................................................................................................... 73
Cylinder head.................................................................................................................................... 82
Water pump....................................................................................................................................... 89
Oil pump ............................................................................................................................................ 90
Crankshaft connecting rod mechanism ........................................................................................ 98
Electric injection system................................................................................................................ 109
PARTS MANUAL ...................................................................................................................................... 149
1. ENGINE.............................................................................................................................................149
1. COOLING SYSTEM.................................................................................................................. 149
2. CYLINDER BLOCK................................................................................................................... 150
3. CRANKSHAFT........................................................................................................................... 151
4. EXHAUST MANIFOLD ............................................................................................................. 152
5. INTAKE SYSTEM ...................................................................................................................... 153
5. INTAKE SYSTEM ...................................................................................................................... 154
6. LUBRICATING DEVICE ........................................................................................................... 155
7. CYLINDER HEAD ..................................................................................................................... 156
7. CYLINDER HEAD ..................................................................................................................... 157
8. COVER-VALVE CHAMBER..................................................................................................... 158
9. OIL PAN ...................................................................................................................................... 159
10. VALVE MECHANISM.............................................................................................................. 160
10. VALVE MECHANISM.............................................................................................................. 161
10. VALVE MECHANISM.............................................................................................................. 162
11. IGNITION DEVICE .................................................................................................................. 163

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12. PISTON AND CONNECTING ROD DEVICE...................................................................... 164
13. OTHER ACCESSORY 1......................................................................................................... 165
14. OTHER ACCESSORY 2......................................................................................................... 166
2.5T07D1 TRANSMISSION..................................................................................................................167
1 CASE&ACCESSORY ................................................................................................................ 167
1 CASE&ACCESSORY ................................................................................................................ 168
2 COUNTERSHAFT ...................................................................................................................... 169
2 COUNTERSHAFT ...................................................................................................................... 170
3 INPUT SHAFT ASSY ................................................................................................................. 171
3 INPUT SHAFT ASSY ................................................................................................................. 172
3 INPUT SHAFT ASSY ................................................................................................................. 173
4 SHIFT FORK&SHIFT-FORK SHAFT....................................................................................... 174
4 SHIFT FORK&SHIFT－FORK SHAFT.................................................................................... 175
5 SHIFT CONTROL MACHINSM ................................................................................................ 176
6 DRIVEN GEAR ASSY................................................................................................................ 178
3. CHASSIS ..........................................................................................................................................179
1.Frame assembly ......................................................................................................................... 179
2.Engine mount assy..................................................................................................................... 181
3.Muffler........................................................................................................................................... 182
4.Gear-shift mechanism................................................................................................................ 183
4.Gear-shift mechanism................................................................................................................ 184
5.Steering assembly ...................................................................................................................... 185
5.Steering assembly ...................................................................................................................... 186
5. Steering assembly..................................................................................................................... 187
6. Throttle, parking brake, brake.................................................................................................. 188
6. Throttle, parking brake, brake.................................................................................................. 190
6. Brake (TR1100.07.01.01.00B, TR1100.07.01.01.00B-T4).................................................. 192
6. Parking ........................................................................................................................................ 193
6. Clutch (TR1100.07.04.01.00, TR1100.07.04.01.00-T4) ...................................................... 194
7. Front and rear suspension assembly ..................................................................................... 195
7.Front and rear suspension assembly ...................................................................................... 196
8.Driven system.............................................................................................................................. 197
8. Driven system ............................................................................................................................ 199
9. Front/Rear differential locking.................................................................................................. 201
10.Fuel tank and gasoline pump ................................................................................................. 202
10.Fuel tank and gasoline pump ................................................................................................. 204
11.Radiator assembly.................................................................................................................... 206
11.Radiator assembly.................................................................................................................... 207
12.Roll bar and Rearview mirror.................................................................................................. 208
12.Roll bar and Rearview mirror.................................................................................................. 209
13. Cargo bed................................................................................................................................. 212
14. Electrical winch ........................................................................................................................ 213
15. Plastic parts.............................................................................................................................. 214
15. Plastic parts.............................................................................................................................. 215

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16. Seats and safety belts ............................................................................................................ 218
17.Other parts................................................................................................................................. 220
17.Other parts................................................................................................................................. 221
DEALER PRE-DELIVERY INSPECTION.............................................................................................222

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Owner’s manual
Warranty policy

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9

10

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Parts order form, warranty claim form

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Service record form

13
Preventative maintenance and service log

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15

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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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