Joyner Renegade R2 User manual

Owner’s Manual
Repair 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.
It does not confirm to federal motor vehicle safety standards, and operation on
public streets, roads, or highways is illegal.
16
Renegade
R2，R4

2/ 278
INTRODUCTION
Thank you for choosing JOYNER JNSZ800UV. 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.

3/ 278
CONTENTS
OWNER’S MANUAL.......................................................................................................................................... 8
1 WARRANTY POLICY.......................................................................................................................... 8
Liability Release of Joyner Recreational Vehicle .......................................................................... 9
Team Joyner USA Limited Manufacturer’s Defect Warranty ..................................................... 10
Parts Order Form and Warranty Claim Form............................................................................... 12
Service Record Form....................................................................................................................... 13
Preventative Maintenance and Service Log ................................................................................ 14
2 LOCATION OF THE WARNING AND SPECIFICATION LABELS ............................................. 19
3 SAFETY INFORMATION.................................................................................................................. 21
4 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
5 IS YOUR VEHICLE READY TO DRIVE?....................................................................................... 25
Pre-drive Inspection......................................................................................................................... 25
6 OPERATION INSTRUCTION .......................................................................................................... 27
Main electrical kill switch................................................................................................................. 27
Ignition switch ................................................................................................................................... 27
Gauges .............................................................................................................................................. 28
Control switches............................................................................................................................... 29
Indicator lights .................................................................................................................................. 30
Differential-locker holder ................................................................................................................. 31
Accelerator, Brake, Clutch pedal ................................................................................................... 31
Parking brake lever.......................................................................................................................... 33
Gear shift lever ................................................................................................................................. 34
Fuel tank............................................................................................................................................ 35
Seats and seat belts ........................................................................................................................ 35
Kartgo bed......................................................................................................................................... 37
Start engine....................................................................................................................................... 38
Stop engine....................................................................................................................................... 38
Passenger ......................................................................................................................................... 38
Break-in ............................................................................................................................................. 38

4/ 278
Starting and operating instructions................................................................................................ 39
7 MAINTENANCE AND ADJUSTMENT ............................................................................................ 40
Air cleaner ......................................................................................................................................... 40
Engine Lubrication ........................................................................................................................... 40
Transmission lubrication ................................................................................................................. 41
Differential lubrication...................................................................................................................... 41
Engine coolant.................................................................................................................................. 42
Idle Speed ......................................................................................................................................... 43
Spark plug inspection ...................................................................................................................... 43
Wedge belt figure............................................................................................................................. 44
Shift cable adjustment..................................................................................................................... 45
Pedal adjustment ............................................................................................................................. 45
Parking brake adjustment............................................................................................................... 45
Differential lock cable adjustment.................................................................................................. 46
Spot light adjustment....................................................................................................................... 47
Oil filter change ................................................................................................................................ 47
Fuel pressure adjuster adjustment................................................................................................ 48
Front Wheel Replacement.............................................................................................................. 48
Rear Wheel Replacement............................................................................................................... 49
Clutch replacement.......................................................................................................................... 49
Front Wheel Alignment.................................................................................................................... 50
Fuses and relays.............................................................................................................................. 51
Bulb replacement ............................................................................................................................. 52
Shock adjustment ............................................................................................................................ 53
Principle diagram of wiring ................................................................................................................ 54
No.1 harness wiring diagram of R2 and R4 (old)............................................................................... 55
No.2 harness wiring diagram of R2 and R4 (old)............................................................................... 56
No.1 harness wiring diagram of R2 and R4 (new) ............................................................................. 57
No.2 harness wiring diagram of R2 and R4 (new) ............................................................................. 58
8 SPECIFICATIONS............................................................................................................................. 59
REPAIR MANUAL............................................................................................................................................ 61
1 ENGINE MECHANICAL SYSTEMS ............................................................................................... 61
2 ELECTRIC INJECTION SYSTEM................................................................................................. 105
PARTS MANUAL ........................................................................................................................................... 146
1 ENGINE ............................................................................................................................................... 146
1.1 Cooling system ........................................................................................................................ 146

5/ 278
1.2 Cylinder block .......................................................................................................................... 147
1.3 Crankshaft ................................................................................................................................ 148
1.4 Exhaust manifold..................................................................................................................... 149
1.5 Intake system........................................................................................................................... 150
1.6 Lubricating device ................................................................................................................... 151
1.7 Cylinder head........................................................................................................................... 152
1.8 Cover-valve chamber.............................................................................................................. 153
1.9 Oil pan....................................................................................................................................... 154
1.10 Valve mechanism .................................................................................................................. 155
1.11 Ignition device ........................................................................................................................ 157
1.12 Piston and connecting rod device....................................................................................... 158
1.13 Other accessory 1................................................................................................................. 159
1.14 Other accessory 2................................................................................................................. 160
2 5T07D1 TRANSMISSION .............................................................................................................. 161
2.1 Case & accessory ................................................................................................................... 161
2.2 Countershaft............................................................................................................................. 163
2.3 Input shaft assy........................................................................................................................ 165
2.4 Shift fork & shift-fork shaft...................................................................................................... 168
2.5 Shift control mechanism......................................................................................................... 170
2.6 Driven gear assy...................................................................................................................... 172
3 SELF MADE PARTS .......................................................................................................................... 173
3.1 Main frame and right seat mount of R2................................................................................ 173
3.2 Main frame and right seat mount of R4................................................................................ 174
3.3 Roll bar of R2 ........................................................................................................................... 175
3.4 Roll bar of R4 ........................................................................................................................... 176
3.5 Front bumper of R2 and R4 ................................................................................................... 177
3.6 Cargo bed of R2 and R4 ........................................................................................................ 178
3.7 Engine and muffler of R2 and R4.......................................................................................... 179
3.8 Driven of R2 ............................................................................................................................. 181
3.9 Driven of R4 ............................................................................................................................. 184
3.10 Front/rear differential locker of R2（old）......................................................................... 187
3.11 Front/rear differential locker of R2（new）....................................................................... 188
3.12 Front/rear differential locker of R4（old）......................................................................... 189
3.13 Front/rear differential locker of R4（new）....................................................................... 190
3.14 Gear shift of R2 ..................................................................................................................... 191
3.15 Gear shift of R4 ..................................................................................................................... 193

6/ 278
3.16 Pedal and parking brake of R2............................................................................................ 195
3.17 Hydraulic pump assembly of foot brake of R2.................................................................. 197
3.18 Hydraulic pump assembly of parking brake of R2 and R4.............................................. 198
3.19 Clutch hydraulic assembly of R2 ........................................................................................ 199
3.20 Pedal and parking brake of R4............................................................................................ 200
3.21 Hydraulic pump assembly of foot brake of R4.................................................................. 202
3.22 Clutch hydraulic assembly of R4 ........................................................................................ 203
3.23 Front suspension of R2 and R4 .......................................................................................... 204
3.24 Rear suspension of R2 and R4........................................................................................... 205
3.25 Steering of R2 and R4.......................................................................................................... 206
3.26 Radiator of R2 (old)............................................................................................................... 208
3.27 Radiator of R2 (new)............................................................................................................. 210
3.28 Radiator of R4 (old)............................................................................................................... 212
3.29 Radiator of R4 (new)............................................................................................................. 214
3.30 Gasoline and air taking of R2 and R4 (old)....................................................................... 216
3.31 Gasoline and air taking of R2 and R4 (new)..................................................................... 218
3.32 Plastic parts of R2（old）.................................................................................................... 220
3.33 Plastic parts of R2（new）.................................................................................................. 222
3.34 Plastic parts of R4（old）.................................................................................................... 224
3.35 Plastic parts of R4（new）.................................................................................................. 226
3.36 Electrical appliance and other parts of R2（old）........................................................... 228
3.37 Electrical appliance and other parts of R2（new）......................................................... 230
3.38 Electrical appliance and other parts of R4（old）........................................................... 232
3.39 Electrical appliance and other parts of R4（new）......................................................... 234
3.40 Seats and seat belts of R2................................................................................................... 236
3.41 Seats and seat belts of R4................................................................................................... 237
4 OPTIONS............................................................................................................................................. 238
4.1 Sport light bar kit of R2 and R4............................................................................................. 238
4.2 Roof rack kit of R2................................................................................................................... 239
4.3 Gun rack kit of R2.................................................................................................................... 240
4.4 Canvas enclosure kit of R2.................................................................................................... 241
4.5 Enclosure with canvas door kit of R2 ................................................................................... 242
4.6 Vehicle cover and shock coat kit of R2 ................................................................................ 244
4.7 Heater kit of R2 and R4.......................................................................................................... 245
4.8 Rain wiper kit of R2 and R4 ................................................................................................... 246
4.9 Stake bed kit of R2 and R4.................................................................................................... 247

7/ 278
4.10 New front metal bumper kit of R2 and R4 ......................................................................... 248
4.11 Canvas windshield kit of R2 and R4................................................................................... 249
4.12 Simple windshield kit of R2 and R4.................................................................................... 250
4.13 Safari bed kit of R2 and R4 ................................................................................................. 251
4.14 Enclosure with plastic door kit of R2 .................................................................................. 253
4.15 Electrical winch kit of R2 and R4 ........................................................................................ 261
4.16 New air intake kit of R2 and R4 .......................................................................................... 262
4.17 Aluminum-plated plastic parts kit of R2 and R4................................................................ 263
4.18 27’-14’ wheel kit of R2 and R4 ............................................................................................ 264
4.19 Tools and bag kit of C2、C4、R2 and R4......................................................................... 265
4.20 Polished aluminum side mirror kit of C2、C4、R2 and R4............................................ 266
4.21 Oxidative aluminum side mirror of C2、C4、R2 and R4................................................ 267
4.22 Roof rack kit of R4................................................................................................................. 268
4.23 Gun rack kit of R4 ................................................................................................................. 269
4.24 Canvas enclosure kit of R4.................................................................................................. 270
4.25 Enclosure with canvas door kit of R4................................................................................. 271
4.26 Vehicle cover and shock coat kit of R4.............................................................................. 273
4.27 Tow adapter kit of C2、C4、R2、R4、T2 and T4........................................................... 274
DEALER PRE-DELIVERY INSPECTION................................................................................................... 275

8/ 278
OWNER’S MANUAL
1 WARRANTY POLICY

9/ 278
Liability Release of Joyner Recreational Vehicle

10 / 278
Team Joyner USA Limited Manufacturer’s Defect Warranty

11 / 278

12 / 278
Parts Order Form and Warranty Claim Form

13 / 278
Service Record Form

14 / 278
Preventative Maintenance and Service Log

15 / 278

16 / 278

17 / 278

18 / 278

19 / 278
2 LOCATION OF THE WARNING 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 change any labels’ position and remove them from your vehicle. If a label becomes difficult to
read or comes off, a replacement label is available from your Joyner dealer.

20 / 278
See the next form (Pic 1.15) and it will tell you the JOYNER’s parts No. and the quantity of each label
for your Renegade R2 or R4.