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Parts manual

JNSZ800UV

1

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.

4

PARTS MANUAL ................................................................................................................................................ 161

1.MAIN FRAME AND RIGHT SEAT MOUNT ............................................................................................................. 161

2 ROLL BAR AND REARVIEW MIRROR ..................................................................................................................... 162

3 FRONT PROTECT BAR AND SMALL SPOT LIGHT .................................................................................................... 163

4 CARGO BED ......................................................................................................................................................... 164

5 ELECTRICAL WINCH ............................................................................................................................................ 165

6 ENGINE AND MUFFLER ........................................................................................................................................ 166

7 DRIVEN ............................................................................................................................................................... 168

8 FRONT/REAR DIFFERENTIAL LOCKER .................................................................................................................. 171

9 GEAR SHIFT ......................................................................................................................................................... 172

10 PEDAL AND PARK BRAKE ................................................................................................................................... 174

11 HYDRAULIC PUMP ASSEMBLY OR FOOT BRAKE ............................................................................................... 177

12 HYDRAULIC PUMP ASSEMBLY OF PARKING BRAKE .......................................................................................... 178

13 CLUTCH HYDRAULIC ASSEMBLY....................................................................................................................... 179

14 FRONT SUSPENSION ......................................................................................................................................... 180

15 REAR SUSPENSION ............................................................................................................................................. 182

16 STEERING .......................................................................................................................................................... 184

17 RADIATOR ......................................................................................................................................................... 187

18 GASOLINE AND AIR TAKING（OLD） ............................................................................................................... 190

19 GASOLINE AND AIR TAKING（NEW） .............................................................................................................. 193

20 PLASTIC PARTS .................................................................................................................................................. 196

21 ELECTRICAL APPLIANCE AND OTHER PARTS ...................................................................................................... 198

22 SEATS AND SAFETY BELTS ................................................................................................................................ 201

132

PARTS MANUAL

1. ENGINE

1. COOLING SYSTEM

No Part number Name Quantity

1 Q1400612 HEXAGON HEAD BOLT 4

2 372-1307014 WATER PUMP PULLEY 1

3 Q1840840 HEXAGON FLANGE BOLT 1

4 Q1840855 BOLT（M8X55） 1


6 372-1307010 WATER PUMP SET 1

7 372-1307015 ‘O’ RING 1

8 372-1307041 WATER PUMP WASHER 1

9 372-1307018 SEAL STRIP 2 1

10 Q1840825 BOLT 3

11 372-1307019 SEAL STRIP 3 1

12 372-1307012 SEAL STRIP 1 1

13 50-'O' 'O' RUBBER RING 1

14 372-1306016 SEAT - THERMOSTAT OUTER 1

15 372-1306020 THERMOSTAT ASSY 1

16 372-1306001 SEAT - THERMOSTAT 1


18 372-1306012 SEAT - THERMOSTAT INNER 1

19 372-1306018 SEAT - THERMOSTAT 1

1

11 10

9

8 7

6

5

4

3

2

17

16-

15

14

19

18

13 12

133

2. CYLINDER BLOCK


1 372-1002010 CYLINDER BLOCK ASSY 1

2 372-1002037 POSITION PIN 6

3 372-1002046 CRANKCASE VENTILATION PIPE 1

4 372-1002044 CYLINDER HEAD SEAL PLUG 2


6 372-1002060 KNOCK SENSOR 1

7 372-1002036 POSITION PIN 2

8 372-1002070 OIL PRESSURE SWITCH 1

9 372-1000410 ENGINE ASSY 1

10 11G10GB308 BALL - STEEL 1

11 372-1002023 BOLT - MAIN BEARING CAP 8

12 372-1002045 CAP - OIL CONTROL 1

13 372-1012021 CONNECTOR - OIL FLITER 1

14 372-1014110BA PIPE - CRANKCASE VENTILATION 1

15 372-1014130BA PIPE(3) - CRANKCASE VENTILATION 1

1

2

3

4

5 6

7

15

8

11

12

9

14

13

10

134

3. CRANKSHAFT


1 372-1005031 PULLEY BOLT 1

2 372-1005040 TORSION SHOCK ABSORBER ASSY 1

3 372-1005018 CRANKSHAFT TIMING GEAR 1

4 372-1005017 TOOTHED BELT BAFFLE 1

5 372-1005015 CRANKSHAFT FRONT OIL SEAL 1

6 372-1005033 NEEDLE BEARING 1

7 372-1005032 WOODRUFF KEY 1

8 372-1005010 CRANKSHAFT ASSY 1

9 372-1005016 STOPPER PLATE 2

10 S11-1601101 COVER SET BOLT 4

11 372-1DF1005010 BEARING - CRANKSHAFT 4

12 372-1005036 PIN - DOWEL 1

13 372-1005030 REAR OIL SEAL 1

14 372-1005021 REAR OIL SEAL BRACKET 1


16 372-1005050 FLYWHEEL ASSY 1

17 372-1005054 LOCK-FLY WHEEL BOLT 6

18 S11QZ-QZWZCGQ CRANKSHAFT POSITION SENSOR 1

19 S11-1601020 COVER SET 1

20 S11-1601030 DRIVEN DISK ASSY 1

1

2 3 4 5

7 8

9

13 14 15

16

17

18

12 6

20

10

19 11

135

4. EXHAUST MANIFOLD


1 372-1008033 EXHAUST MANIFOLD WASHER 1

2 SQR7080PQQG-PQQG EXHAUST MANIFOLD 1

3 Q1200825F3 STUD 4

4 Q33008 HEXAGON NUT 6

5 372-1008044 HEAT INSULATOR 1


7 S11-1205110 OXYGEN SENSOR 1

8 Q1200835F3 STUD 1

9 S11-3724863 OXYGEN SENSOR BRACKET 1

1

2

3

4

5

6

7

9 8

136

5. INTAKE SYSTEM



2 372-1107011CA BODY - THROTTLE 1

3 372-1107012 THROTTLE BODY WASHER 1


5 372-1008043 ACCELERATOR PULLING WIRE BRACKET 1

6 S11-1109411 INTAKE TEMPERATUREAND PRESSURE SENSOR 1


8 372-1008013 MANIFOLD - AIR INTAKE 1


10 S11-1112030 OIL RAIL 1

11 S11-1112010 INJECTOR ASSY 3

12 Q1200835F3 STUD 2

13 Q1200828F3 STUD 4

14 372-1008021 INTAKE MANIFOLD WASHER 1

15 Q1200840F3 STUD 1

7

9

29

6

10

11

12

13

14

31

16 17 19

18

21 23

25

15

28

8

5

4 26

3 2

1

20

22

27

30

137

5. INTAKE SYSTEM


16 372-1008041 INTAKE MANIFOLD FRONT BRACKET 1

17 372-1008042 INTAKE MANIFOLD REAR BRACKET 1

18 372-1014150 FIXING CLAMP 1


10 372-1014120 CRANKCASE VENTILATION PIPE (2) 1

21 372-1014140 OIL-GAS SEPARATOR ASSY 1





27 372-1008082EA BRACKET - INLET MANIFOLD 1

28 372-1014140AB SEPARATOR - TEMPERATURE SELFCONTROL 1

29 372-1107051 SENSOR - THROTTLE POSITION 1

30 S11-1008020FA BRAKET - THROTTLE 1

31 S11-1109416BA HOSE- PVC VALVE TO AIR INTAKE PIPE 1

7

9

29

6

10

11

12

13

14

31 16 17 19

18

21 23

25

15

28

8

5

4

3 2

1

20

22

27

30

138

6. LUBRICATING DEVICE


1 372-1012010 OIL FILTER ASSY 1

2 372-1009130 OIL DIP STICK ASSY 1

3 372-1009120 OIL DIP STICK PIPE ASSY 1

4 372-1011055 SEAL STRIP 1

5 372-1011021 OIL PUMP WASHER 1

6 372-1011030 OIL PUMP ASSY 1

7 Q1840825 BOLT 1

8 Q1840855 BOLT（M8X55） 2


10 372-1010017 OIL STRAINER WASHER 0

11 Q1200616 STUD 2

12 Q33006 HEXAGON NUT 2

13 372-1010010 OIL STRAINER ASSY 1



1

2

3 4

5

6

7

8

9

10

11

12

13

14

15

139

7. CYLINDER HEAD


1 372-1003074 SPARK PLUG SLEEVE 3


3 372-1003051 CYLINDER HEAD BOLT 8

4 372-1003052 CYLINDER HEAD BOLT WASHER 8

5 S11-3808013 WATER TEMP SENSOR 1

6 S11-1003069 CAMSHAFT POSITION SENSOR 1


8 372-1003023 GUIDE - VALVE 12

9 372-1003022 EXHAUST VALVE SEAT INSERT 6

10 372-1003021 INTAKE VALVE SEAT INSERT 6

11 372-1003040 GASKET - CYLINDER HEAD 1

12 372-1003202 FRONT TRUNNION 1


14 372-1003067 BLOCK COVER 1

15 372-1003066 CAMSHAFT OIL SEAL 1

16 372-1003010 HEAD ASSY - CYLINDER 1

1

19 2

3

4

5

6 7

20 22

24

10 9

11

12 13

14

15

16

21

23

17

18

8

140

7. CYLINDER HEAD


17 372-1003063 CAMSHAFT BEARING CAP POSITION COVER 8

18 S11-3808010 WATER TEMP. SENSOR SET 0

19-1 372-1003201 HANGER - REAR ENGINE 0

19-2 372-1003201BA HANGER - REAR ENGINE 1

20 372-1003001 HEAD ASSY - CYLINDE 1

21 372-1003024 PLUG - BOWL SHAPE 1

22 372-1003028 PLUG 1

23 372-1003038 STUD 1

24 372-1003076 BUSH - WATER PROOF 1

1

19-1

19-2 2

3

4

5

6 7

20 22

24

10 9

11

12 13

14

15

16

21

23

17

18

8

141

8. COVER-VALVE CHAMBER


1 372-1003090 OILING PORT COVER ASSY 1

2 Q2540616 SCREW 6

3 372-1003075 ENGINE TRIMING COVER ASSY 1

4 372-1003030 COVER ASSY - ROCKER 1

5 372-1003036 CYLINDER HEAD COVER GASKET 1


1

3

2

4

5

6

142

9. OIL PAN


1 372-1009010 OIL PAN ASSY 1


3 372-1009017 SEAL WASHER-OIL DRAIN THREADED PLUG 1

4 372-1009014 MAGNET PLUG 1

1 1

2 1

3 1

4 1

143

10. VALVE MECHANISM


1 372-1007030 TENSIONING PULLEY ASSY 1



4 372-1007040 TIMING GEAR COVER ASSY 1



7 Q43140 SHIELD-SHAFT SPRING RING 1

8 372-1006032 SADDLE FLIP WASHER 1

9 372-1006031 DRIVE RING 1

10 372-1006041 GEAR ( SUB ) - INTAKE CAMSHAFT 1

11 372-1006030 GEAR (MAIN ) - INTAKE CAMSHAFT 1

1 2

3 4

5

6

35 36

29 33

28

27

26

25

24

21

23

22

20

32

19 18 17

16 15 14

13

12

7 8 9 10 11

31

30

144

10. VALVE MECHANISM


12 372-1006020 CAMSHAFT ASSY - INTAKE 1

13 372-1006071 HEXAGON FLANGE BOLT 1

14 372-1006066 TIMING BELT SPROCKET 1

15 372-1006064 LOCK-CLUTCH HUB NUT 1

16 Q2180620 INNER HEXGON HEAD BOLT 4

12 372-1006020 CAMSHAFT ASSY - INTAKE 1

13 372-1006071 HEXAGON FLANGE BOLT 1

14 372-1006066 TIMING BELT SPROCKET 1

15 372-1006064 LOCK-CLUTCH HUB NUT 1

16 Q2180620 INNER HEXGON HEAD BOLT 4

17 372-1006063 COUPLING FLANGE 1

18 372-1006062 EXHAUST CAMSHAFT GEAR 1

19 372-1006060 CAMSHAFT ASSY - EXHAUST 1

20 372-1007017 ADJUSTMENT WASHER 12

21 372-1007018 VALVE LIFTER 12

22 372-1007019 VALVE LOCK BLOCK 24

23 372-1007021 EDDY SLEEVE 12

24 372-1007014BA UPPER VALVE SPRING SEAT 12

25 372-1007013 VALVE SPRING 12

26 372-1007020 VALVE SEAL 12

27 372-1007016 LOWER VALVE SPRING SEAT 12

28 372-1007012 EXHAUST VALVE 6

29 372-1007081 TOOTHED TIMING BELT 1

30 372-1007011 INLET VALVE 1

31 372-1006042 PIN - GEAR 1

32 372-1006067 PIN - STOPPER 1

33 372-1007014 SEAT - VALVE SPRING UPPER 1

34 Q673B155 CLAMP 1

35 472-1007042 LOWER TIMING GEAR COVER 1

36 480-1011062 BOLT 1

145

11. IGNITION DEVICE


1 S11-3705100 IGNITION COIL 3

2 Q2320525 SCREW AND WASHER UNIT 6

3 S11-3705001 IGNITION COIL BRACKET 1

4 S11-3707100 SPARK PLUG ASSY 3


6 S11-3707040 HI.TENSION CORD NO.3 1

7 S11-3707030 HI.TENSION CORD NO.2 1

8 S800.04.01.05.00-R2 HI.TENSION CORD NO.1 1

9 S11-3724183 CLIP 0

1

2

3

4

6

8

5

7

9

3

146

12. PISTON AND CONNECTING ROD DEVICE


1 372-1DE1004030 RING ASSY - PISTON 1

2 372-1004031 PISTON PIN 3

3 372-1004021 PISTON 3

4 372-1004110 CONNECTING ROD ASSY 3

5 372-1DF1004110 BEARING - CONNECTING ROD 6

1 1

3 1

4 1

5 1

2 1

147

13. OTHER ACCESSORY 1


1 S11-3724180CA Engine Harness 1

2 S11-3605010BA-1 372 ECU 1

3 SV1100.05.02.01.00 Shift Bracket 1

4 S11-1206211 carbon can PCV 1

5 S11-3708110BA Starter assembly 1

6 S11-1700103 lower Steel cushion 1

7 S11-1200011CA Single Exhaust Gasket 1

8 Q1841245 Hex socket head bolt M12*45 1

9 Q218B1245 Bolt 12*45 1

10 Q1841240 Bolt 12*50 2

11 372-1002030 Upper steel cushion 1

12 S11-3708111 locating dowel 2

13 Q1840845 Bolt 8*45 2

14 Q1840850 Bolt 8*50 1

15 S11-3802020 Electric odometer sensor assy. 1

1

3

4

5 7 6

4

2

3

12 8

9

10

11

13

14

15

148

14. OTHER ACCESSORY 2


1 S11-3701110BB Alternator 1

2 S11-3701211BA Alternator bracket 1

3 S11-1001415BA Rear bracket 1

4 S11-3701315 V-ribbed belt 1

1

4

2

3

149

2. 5T07D1 TRANSMISSION

1 CASE&ACCESSORY

Ref Part No. Part Description Qty Comments

1 QR512－1701101 Clutch case 1

2 4T08A1－1701111 Transmission case 1

3 5T07－1701020 Side cover 1

4 5T07－1702010 Declutch bearing 1

5 5T07－1702020A Declutch fork 1

6 5T07－1702004 Clutch fork 2 sleeve 1

7 5T07－1702030 Clutch fork seal 2

8 5T07－1702001 Clutch fork 1 sleeve 1

9 QR512－1701103 Double－screw rod 2

10 5787－M8x40 Flange bolt M8x40 12

150

1 CASE&ACCESSORY


11 5T07－1701001 Locating pin 2

12 5T07－1701002 Oil plug screw 1

13 5T07－1701003 Screw plug washer 2

14 5T07－3729010 Back－up light switch 1

15 5T07－1701058A Double－screw rod 1

16 5T07－1701009 Bearing stop plate 1

17 5T07－1701004 Oil－stop plate 1

18 5787－AM6X12 Flange bolt M6x12 2

19 7246－W6 Flat washer 6 4

20 5T07－1701400 Oil groove 1

21 S800.04.01.02.01－R2 Clutch rocker 1

22 5787－AM8X35 Flange bolt M8x35 1

23 6177.1－8 Flange nut M8 1

24 5T07－1701603 Side cover bolt 8

25 QR512－1602113 Declutch release spring 1

26 S800.04.01.02.00－R2 5T07D1 Transmission assy. 1

151

2 COUNTERSHAFT


1 QR512－1701401 Output shaft 1

2 QR512－1701410 First gear assy. 1

3 QR512－1701420 Second gear assy. 1

4 QR512－1701441 Third gear 1

5 QR512－1701461 Fourth gear 1

6 5T07－1701610 Front bearing of output shaft 1

7 5T07－1701240 Needle bearing of 1ST

&2ND

gear 2

8 QR512－1701439 Synchronizer out ring of 1ST

&2ND

gear 2

9 QR512－1701406 Synchronizer middle ring of 1ST

&2ND

gear 2

10 QR512－1701435 Synchronizer inner ring of 1ST

&2ND

gear 2

11 QR512－1701430 Synchronizer of 1ST

&2ND

gear 1

152

2 COUNTERSHAFT


12 QR512－1701433 Synchronizer spring of 1ST

&2ND

gear 2

13 QR512－1701434 Synchronizer gear－hub of 1ST

&2ND

gear 1

14 QR512－1701431 Synchronizer gear-sleeve of 1ST

&2ND

gear 1

15 QR512－1701432 Synchronizer gear block of 1ST

&2ND

gear 3

16 5T07－1701205 Synchronizer retainer of 1ST

&2ND

gear 1

17 5T07－1701202 Spacer of 3RD

&4TH

gear 1

18 5T07－1701250 Rear bearing of output shaft 1

19 QR512－1701187 Adjusting washer of rear bearing Demand

20 4T08A－1701402 Countershaft sleeve 1

21 MQC4－1701219 Countershaft nut 1

22 4T08A1－1701400 Countershaft assy. 1

153

3 INPUT SHAFT ASSY


1 QR512－1701201 Input shaft 1

2 5T07－1701080 Input shaft seal 1

3 4T08－1701130 Bearing 6204/YA/P63 1

4 QR512－1701240 3TH

gear assy. 1

5 5T07－1701150 Needle bearing of 3RD

&4TH

gear 2

6 QR512－1701257 Synchronizer ring of 3TH

&4TH＆5

TH gear 1

7 QR512－1701250 Synchronizer assy. of 3TH

&4TH 1

8 QR512－1701252 Synchronizer gear－hub of 3TH

&4TH

gear 1

9 QR512－1701251 Synchronizer gear-sleeve of 3TH

&4TH

gear 1

10 QR512－1701254 Synchronizer spring of 3TH

&4TH＆5

TH gear 1

11 QR512－1701253 Synchronizer gear block of 3TH

&4TH

gear 3

154

3 INPUT SHAFT ASSY


12 5T07－1701103 Synchronizer retainer of 3TH

&4TH

gear 1

13 QR512－1701258 Synchronizer waveform washer ring 1

14 QR512－1701260 4TH

gear assy. 1

15 5T07－1701110 Back bearing of input shaft 1

16 QR512－1701285 Spacer of 5TH

gear 1

17 QR512－1701200 Input shaft assy. 1

18 QR512－1701287 Adjusting washer of rear bearing Demand

19 QR512－1701280 5TH

gear assy. 1


&4TH＆5

TH gear 1

21 QR512－1701258 Synchronizer waveform washer ring 1

22 QR512－1701290 Synchronizer assy. of 5TH

gear 1

155

3 INPUT SHAFT ASSY


23 QR512－1701254 Synchronizer spring of 5TH

gear 2

24 QR512－1701293 Synchronizer gear block of 5TH

gear 1

25 QR512－1701292 Synchronizer gear－hub of 5TH

gear 1

26 QR512－1701291 Synchronizer gear－sleeve of 5TH

gear 1


gear 1

28 QR512－1701298 Nut of 5TH

gear synchronizer 1

29 QR512－1701710 Reverse gear 1

30 5T07－1701053 Ring of reverse gear 1

31 5T07－1701061A Shaft of reverse gear 1

32 5T07－1701052 Washer of reverse gear shaft 1

33 5T07－1701057A Bolt of reverse gear shaft 1

156

4 SHIFT FORK&SHIFT－FORK SHAFT


1 QR512－1702311 Shift fork of 1ST

&2ND

gear 1

2 5T07－1702041A Shift fork of 3RD

&4TH

gear 1

3 308－7.9375 Steel ball 7.9375 6

4 5T07－1702042A Shift fork of 5TH

gear 1

5 5T07－1702061A Shift fork of 3RD

&4TH

gear 1

6 4T08A－1702042A Stop block 1

7 QR512－1702231 PIN 4.5x20 1

8 QR512－1702411 Shift－fork shaft of 1ST

&2ND

gear 1

9 5T07－1702067 Shift－fork shaft spring 3

10 QR512－1701421 Shift－fork shaft of 3RD

&4TH

gear 1

157

4 SHIFT FORK&SHIFT－FORK SHAFT


11 QR512－1702431 Shift－fork shaft of 5TH

gear 1

12 QR512－1702441 Shift－fork shaft of reverse gear 1

13 5T07－1702234 Shift－fork shaft screw plug 3

14 5T07－1702233 Washer of screw plug 3

15 QR512－1702341 Shift fork pin of reverse gear 1

16 5T07－1702068 Shift block spring 1

17 5T07－1702050A Shift arm 1


19 5T07－1702232A Bolt of shift arm 2

158

5 SHIFT CONTROL MACHINSM


1 5T07－1702100A Shift－select shaft assy. 1

2 5T07－1702101A Shift－selecting shift 1

3 QR512－1702214 Snap ring of shift interlock 3

4 5T07－1702102 Release－sprig seat of 1ST

&2ND

gear 1

159


5 5T07－1702103 Release sprig of 1ST

&2ND

gear 1

6 5T07－1702104 Spring－stop plate 2

7 5T07－1702107A Stop plate of shift interlock 1

8 5T07－1702105A Shift－select arm. 1

9 QR512－1702113 Spring pin 3.5x28 1

10 5T07－1702106 Pin of shift－select arm 1

11 5T07－1702114A Release spring of 5TH

& reverse gear 1

12 5T07－1702112

Release － spring seat of 5TH

&

reverse gear 1

13 879.1－P3x22 Pin 3x22 1

14 5T07－1702108A Seat of reverse gear spring 1

15 5T07－1702109A Limiting spring reverse gear 1

16 QR512－1702111A Limiting cam of reverse gear 1

17 879.1－5x22 Pin 5x22 1

18 QR512－1702070 Guide case assy. of shift－select shaft 1

19 QR512－1702071 Guide case of shift－select shaft 1

20 5T07－1702072 Stop plate of release spring 1

21 5787－Mx12 Flange bolt M6x12 2

22 QR512－1702227

SHIFT － SELECT SHAFT OIL

SEAL 1

23 5T07－1702062

Anti－ dust cover of shift－ select

shaft 1

24 5T07－1702073 Limiting bolt of reverse gear 1

25 QR512－1702229 Washer of limiting bolt 1

26 119－P6x12 Pin B 6x12 2

27 5787－M8x20 BOLT AM 8x20 4

28 5T07－1702065A Limiting bolt of shift 1

29 QR512－1702229 Washer of limiting bolt 1


31 5T07－1702063 Shift pushing block 1

32 5T07－1702062 Anti－dust cover 1

33 6170－M8 Nut M8 1

34 93－SW8 Spring washer 8 1

35 5T07－1702046 Big washer of shift arm 1

36 5T07－1702045 Small washer of shift arm 1

37 S800.05.02.04.00－R2 Gear changing arm 1

38 SV1100.05.02.02.03 Cuprum bush 1

39 5T07－1702047 Anti－dust washer of shift arm 1

40 S800.05.02.05.00－R2 Choosing gear arm mount 1


42 879.1－P5x28 PIN 5x28 1

43 S800.05.02.06.00－R2 Gear cable mount 1

160

6 DRIVEN GEAR ASSY


1 5T07D1--1701600 Driven gear assy. 1

2 5T07-1701310 Front bearing of differential 1

3 QR512-1701604 Driving gear of odometer 1

4 4T08A-1701602 Front bearing of output shaft 1

5 4T08A-1701601 Output shaft 1

6 4T08A-1701603 Connecting disc 1

7 QR512-1701611 Driven gear of speed reducer 1

8 4T08A-1701605 Rear bearing of output shaft 1

9 5T07-1701320 Rearing bearing of differential 1

10 5T07-1701309 Flange bolt 8

11 MQC4-2303016 Retaining ring 2

12 5T07-1701090 Right seal of differential 1

13 5T07-1701010 Left seal of differential 1

14 QR512-1701605 Right seal adjusting washer of differential Demand

161

PARTS MANUAL

1 MAIN FRAME AND RIGHT SEAT MOUNT


1 S800.01.01.00.00－R2 Main frame 1

2 6177.1－M10x1.25 Flange nut M10x1.25 3

3 S800.01.05.00.00－R2 Right seat mount 1

4 5787－M10x1.25x20 Flange bolt M10x1.25x20 3

5 70.1－M10x1.25x25 Hex bolt M10x1.25x25 4

6 825－M10 Cable buckle M10 8

7 S800.01.02.06.00－R2 Upper Engine roll bar 1

8 6177.1－M10 Flange nut M10 8

9 S800.01.06.00.01－R2 Lower engine board 1

10 6187.1－M6 Self locking nut M6 8

11 JD0900008－FW6 Flat rubber washer 6 8


162

2 ROLL BAR AND REARVIEW MIRROR


1 70.1－M10x1.25x25 Hex bolt M10x1.25x25 16

2 6177.1－M5 Flange nut M5 8

3 S800.10.04.00.01-R2 “U” clamp 39 4

4 923－M8 Nut M8 2

5 95－FW8 Flat washer 8 2



8 S800.09.01.06.00－R2 Right bracket of rearview mirror 1

9 S800.09.01.04.00－R2 Rearview mirror 2

10 S800.01.02.02.00－R2 Right roll bar 1

11 S800.01.02.03.00－R2 Front upper roll bar 1

12 S800.01.02.04.00－R2 Rear upper roll bar 1

13 S800.01.02.05.00－R2 Lower roll bar 1

14 S800.01.02.01.00－R2 Left roll bar 1

15 S800.09.01.05.00－R2 Left bracket of rearview mirror 1

163

3 FRONT PROTECT BUMPER AND SMALL SPORT LIGHT


1 6170－M12 Nut M12 3



4 S650.01.03.00.01 Decorative cover 2

5 S800.10.10.01.00-R2 New front metal bumper 1

6 S800.06.03.04.00－R2 Small sport light 3



9 6170－M14x1.5x35 Bolt M14x1.5x35 2

10 S800.01.03.00.00－R2 Old front metal bumper 1 Option

164

4 CARGO BED


1 S800.01.04.00.00－R2 Cargo bed 1

2 6177.1－M10x1.25 Flange nut M10x1.25 2

3 S650.02.03.02.00 Rubber 2

4 882－PP 8x30 Pivot pin 8x30 4

5 S800.02.03.01.00－R2 Air shock 2


7 91－CP3.2x30 Cotter pin 3.2x30 6

8 882－PP10x70 Pivot pin 10x70 2


10 S650.09.01.07.00 Release lever 2

11 6177.1－M6 Flange nut M6 8


13 825－M10 Cable buckle M10 6 Both side

14 6177.1－M10 Flange nut M10 6

165

5 ELECTRICAL WINCH


1 S800.01.01.00.00－R2 Main frame 1

2 882 －PP10x70 Pivot pin 10x70 2

3 95 －FW10 Flat washer 10 2

4 91－CPØ3.2x30 Cotter pin Ø3.2x30 6

5 6187.1－ M6 Self－lock nut M6 8

6 S650.06.12.00.03 Wire cable guide 1

7 S650.01.05.00.00 Mount of electrical winch 1


9 S650.06.12.00.01 Electrical winch 1

166

6 ENGINE AND MUFFLER

167

6 ENGINE AND MUFFLER


1 6177.1－M10x1.25 Flange nut M10x1.25 18

2 D650.04.01.00.01 Engine rubber bumper 8



5 95－W10（11x20x2） Washer 10（11x20x2） 13

6 S800.04.01.04.00－R2 Engine mount, right 1

7 MV800.06.04.00.01 Oil pressure sensor 1

8 SV800.04.07.00.02 Connecting pipe 1

9 S800.04.01.01.00－R2 SQR372 Engine 1

10 6177.1－M5 Flange bolt M5 2

11 S800.04.01.00.01－R2 Ignition coil mount 1




15 95－W8 Washer 8 1

16 SV1100.04.01.04.00 Engine mount , rear 1

17 S800.04.01.03.00－R2 Engine mount , front 1


19 6177.1－M10 Flange bolt M10 1


21 S800.07.04.04.00－R2 Hydraulic clutch mount 1


23 S800.04.01.02.01－R2 Hydraulic clutch arm 1

24 6177.1－M8 Flange nut M8 3

25 D650.04.04.00.08－2 U clamp screw rod 1

26 D650.04.04.00.08－1 U clamp mount 1

27 S800.04.04.01.00－R2 Sport muffler 1

28 6187.1－M8 Self－locking nut M8 6

29 DS250.11.01.00.02 Rubber 2



32 S800.04.04.03.00－R2 Exhaust muffler mount 2


34 S11－1200011CA Seal washer 2

35 S800.04.04.02.00－R2 Exhaust pipe 1


37 SV1100.04.04.04.00 Seal washer 1

38 S800.04.04.04.00－R2 Catalyst package 1

168

7 DRIVEN


1 5787－ M10x35 Flange bolt M10x35 4

2 S650.03.01.00.04A Front left stub axle 1

3 D650.03.01.00.06 Seal 40x58x7x5 2

4 S800.03.01.02.00－R2 Front propellers shaft 2

169

7 DRIVEN


5 91－CP4x40 Cotter pin 4x40 1

6 JGC1801－K M18x1.5 Nut M18x1.5 2

7 PT SZW1002 Bell type housing 1

8 KHC1802 Circlip 1

9 SH07680 Seal retainer, bigger 2

10 BT1045 Boot 1

11 SH07350 Seal retainer, smaller 2

12 PTSZ－9056 Core shaft 1

13 BT－2075 Boot 2

14 KHZ0011 Circlip 1

15 KHC1854 Bigger circlip 1

16 PTSZW5024 Bell type housing 1


18 S800.03.01.00.03－R2 Small circlip 2

19 S800.03.01.01.00－R2 Front differential 1

20 6177.1－M12x1.25 Flange nut M12x1.25 8

21 S650.03.01.00.05A Front right stub axle 1

22 S650.06.10.00.00 Electric locker for 2WD to 4WD 1


24 818－ M6x16 Cross head screw M6x16 2

25 91－CP Ø3.2x30 Cotter pin Ø3.2x30 2

26 882 －PP8x60 Pivot pin 8x60 2

27 S800.03.03.01.00－R2 Front inboard slip driveshaft 1

28 2303016 Steel cable baffle ring 2

29 S800.04.01.02.00－R2 5T07D1 Transmission 1 5T07D1

30 D650.03.01.00.05 Front hub bearing 30x55x30x25 2

31 893.2－C55 Internal circlip 55 2

32 D650.03.01.00.04 Seal 40x55x6 2


34 D650.03.02.00.05 Brake disc 4

35 S650.03.01.00.01 Hub bolt M12x1.5 16

36 S650.03.01.00.03A Front hub 2

37 S650.03.01.01.00A Wheel 25x8－12,FL 1 38、39

38 S650.03.01.01.02A Front tire 2

39 S650.03.01.01.01 Front wheel rim 12x6 2

170

7 DRIVEN


40 S650.03.01.00.02 Hub nut M12x1.5 16

41 S650.03.01.04.00A Wheel 25x8－12,FR 1

42 S650.03.02.04.00A Wheel 27x11－12,RR 1

43 S650.03.02.01.02A Rear tire 2

44 S650.03.02.01.01 Rear wheel rim 12x8 2

45 TR1100.03.01.00.03 Rear hub 2

46 13871－FB45x65x8 Seal FB 45x65x8 2

47 893.2－C65 Internal circlip 65 2

48 Peer 35x65x35 Bear 35x65x35 2

49 S800.03.03.02.00－R2 Rear inboard slip driveshaft 1

50 S650.03.02.01.00A Wheel 27x11－12,RL 1

51 13871－FB42x62x8 Seal FB 42x62x8 2

52 S650.02.01.00.03 Seal 8

53 S650.03.02.00.01 Bush 8

54 S650.03.02.00.02 Spacer 4


56 S800.03.01.02.00－R2 Rear propellers shaft 2

57 JGC2024－K Nut M24x1.5 1


59 KHC2026 Smaller circlip 1

60 SH07780 Bigger seal retainer 2

61 BT－1055 Boot 1

62 SH07350 Smaller seal retainer 2

63 PTSZ－9055 Core shaft 2

64 BT－1063 Inner boot 1

65 KHZ0017 Circlip 1

66 KHC1836 Circlip 1


68 S800.03.02.01.00－R2 Rear differential 1

69 S800.03.02.00.02－R2 Big circlip 2

171

8 FRONT/REAR DIFFERENTIAL LOCKER




3 S800.03.01.07.00－R2 Release lever mount 2


5 JD1082101 Rubber cover 2

6 S800.03.01.06.00－R2 Release lever 2

7 REV－35 Spring 2

8 REV－36 Spacer 2

9 70.1－M8x45 Hex bolt M8x45 2

10 REV－33 Spring 2

11 S800.03.02.05.00－R2 Rear cable 1


13 S800.03.01.00.02－R2 Cable bracket 2

14 S800.03.01.05.00－R2 Front cable 1

172

9 GEAR SHIFT

173

9 GEAR SHIFT


1 S800.05.02.07.00－R2 Gear shift assembly 1 2、3、4

2 S800.05.02.07.01－R2 5 speed gear shift indicator 1

3 S650.05.02.01.02 Ripple rubber 1

4 S650.05.02.01.03 Gear shift lever 1


6 818－M6x25 Cross head screw M6x25 4

7 91－CP2.5x25 Cotter pin 2.5x25 1



10 S800.05.02.02.00－R2 Changing gear cable 1

11 S800.05.02.01.00－R2 Choosing gear cable 1

12 S800.05.02.06.00－R2 Gear cable mount 1




16 879.5－ SP5x28 Spring pin 5x28 1

17 5T07－1702047 Rubber seal 1

18 S800.05.02.05.00－R2 Choosing gear arm mount 1



21 SV1100.05.02.02.03 Cuprum bearing 1

22 S800.04.01.02.00－R2 5T07D1 transmission 1

23 5T07－1702063 Nylon 1


25 5T07－1702045 Small washer 1

26 5T07－1702046 Big washer 1


28 6170－M8 Nut M8 1

29 5T07－1702064 Rubber 1

174

10 PEDAL AND PARKING BRAKE

175




2 S800.07.04.01.00A－R2 Clutch hydraulic pump assy. 1


4 6177.1－ M6 Flange nut M6 8


6 S800.07.01.01.00－R2 Hydraulic pump assembly of foot brake 1

7 D650.07.01.00.04 Master cylinder rod 2

8 6172.1－ M8 Thin nut M8 2

9 S800.07.01.00.02－R2 Foot braking bump mount 3

10 70.1－ M6x50 Hex bolt M6x50 4


12 91－CP3.2x25 Cotter pin 3.2x25 4

13 6177.1－ M10x1.25 Flange nut M10x1.25 4

14 S800.01.07.00.00－R2 Steering mounting 1

15 5787－ M10x1.25x50 Flange bolt M10x1.25x50 4

16 S800.07.01.00.01－R2 Pedal spring 3

17 S800.07.03.02.00－R2 Upper throttle pedal 1

18 S800.07.03.03.00－R2 Lower throttle pedal 1

19 D650.07.01.00.05 Pedal rubber cover 1


21 882－PP10x80 Pivot pin 10x80 1

22 S800.07.03.01.00－R2 Throttle cable 1


24 91－CP2.5x25 Cotter pin 2.5x25 5

25 S800.07.01.02.00－R2 Upper braking pedal 1

176



26 S800.07.01.02.00－R2 Lower braking pedal 1


28 882－PP10x105 Pivot pin 10x105 2


30 S800.07.04.03.00－R2 Lower clutch pedal 1

31 S800.07.04.02.00－R2 Upper clutch pedal 1

32 70.1－M6x80x28 Hex bolt M6x80x28 1

33 882－PP 6x40 Pivot pin 6x40 3

34 D1600.07.01.00.01 Short push rod holder 3

35 D650.07.02.01.00 Brake parking lever 1

36 6187.1－M8 Self lock nut M8 9

37 882－PP 8x25 Pivot pin 8x25 1

38 S800.07.02.00.02－R2 Parking brake connection 1

39 S800.07.02.00.02－R2 Steel bush 1

40 S800.07.02.02.00－R2 Parking cable 1

41 882 －PP10x105 Pivot pin 10x105 1

42 S800.07.02.03.00－R2 Parking arm 1


44 S800.07.02.04.00－R2 Hydraulic pump assembly of

parking brake 1


46 S800.07.04.04.00－R2 Hand hydraulic mounting 1

177

11 HYDRAULIC PUMP ASSEMBLY OF FOOT BRAKE


1 ZJ602.04-00/22 Master cylinder assy. 1

2 ZJ509.05-00R Right caliper assy. 2

3 S800.07.01.01.01-R2 Outlet hose No.1 of “T”connection 2

4 S800.07.01.01.02-R2 Outlet hose No.1 of master cylinder 1

5 ZJ609.F02-01 “T” connection 2

6 S800.07.01.01.03-R2 Outlet hose No.2 of master cylinder 1

7 ZJ509.05-00L Left caliper assy. 2

8 S800.07.01.01.04-R2 Outlet hose No.2 of “T”connection 1

9 S800.07.01.01.05-R2 Cuprum hose 2

10 S800.07.01.01.06-R2 Inlet hose No.1 of rear caliper 1

11 S800.07.01.01.07-R2 Inlet hose No.2 of rear caliper 1

12 ZJ509.03-04 Hydraulic brake pad 4 Two pieces of each one

13 ZJGS.01-02 Hose bolt M10x1.25 12

14 ZJGS.01-01 Seal washer 24

15 S800.07.01.01.00-R2 Hydraulic pump assembly of

foot brake

1 1~14

178

12 HYDRAULIC PUMP ASSEMBLY OF PARKING BRAKE


1 ZJ610.04-00/14 Master cylinder assy. 1

2 S800.07.02.04.01-R2 Outlet hose of master cylinder 1

3 S800.07.02.04.02-R2 Right outlet hose of “T”connection 1

4 ZJ509.05-00R Right caliper assy. 1

5 ZJ609.F02-01 “T” connection 1

6 S800.07.02.04.03-R2 Left outlet hose of “T”connection 1

7 ZJ509.05-00L Left caliper assy. 1

8 ZJ509.03-04 Hydraulic brake pad 2 Two pieces of each one



11 S800.07.02.04.00-R2 Hydraulic pump assembly of

parking brake 1 1~10

179

13 CLUTCH HYDRAULIC ASSEMBLY


1 ZJ610.04-00/19 Master cylinder assy. of clutch 1

2 S800.07.04.01.01A-R2 Outlet hose of Master cylinder 1

3 ZJ610.05-00/22 Lower cylinder of clutch 1

4 ZJ610.05-05 Ripple boot 1



7 S800.07.04.01.00A-R2 Clutch hydraulic pump assembly 1 1~6

180

14 FRONT SUSPENSION



2 S650.02.01.00.03 Seal Ø54 16

3 S650.02.01.00.01 Bear 16

4 S650.02.01.00.02 Spacer 8

5 1152－M8x1 Blowhole M8x1 8

6 6177.1－M12x1.5 Flange nut M12x1.5 12

7 S800.02.01.03.00－R2 Upper suspension arm , FL 1


9 894.2－C34 External circlip 34 4

10 S650.02.01.01.00 Ball joint 4


12 S800.02.01.01.00A－R2 Lower suspension arm , FL 1

181

14 FRONT SUSPENSION


13 S650.09.01.09.03－COC U clamp Ø32 10

14 S800.02.01.00.01－R2 Half shaft protect board ,FL 1


16 S800.02.01.04.00－R2 Upper suspension arm, FR 1

17 S800.02.01.02.00A－R2 Lower Suspension arm, FR 1

18 S800.02.01.00.02－R2 Half shaft protect board ,FR 1

19 S800.02.01.05.00－R2 Front shock 2

182

15 REAR SUSPENSION


1 6177.1－M12x1.5 Flange nut M12x1.5 12

2 S650.02.01.00.03 Seal 54 24

3 S650.02.01.00.01 Bear 16


5 S650.02.01.00.02 Spacer 8

6 1152－M8x1 Blowhole M8x1 8

7 S800.02.02.02.00－R2 Upper suspension arm , RL 1

8 S800.02.02.03.00－R2 Lower suspension arm , RL 1

9 S800.02.02.04.00－R2 Lower suspension arm , RR 1

10 S800.02.02.05.00－R2 Upper suspension arm , RR 1

11 6177.1－M12x1.25 Flange nut M12x1.25 4


183

15 REAR SUSPENSION


13 S650.03.02.00.01 Bear of rear shaft carrier 8

14 S650.03.02.00.04 Rear shaft carrier 2

15 S650.03.02.00.02 Spacer 4


17 S800.02.02.01.00－R2 Rear shock 2


19 S650.09.01.09.03－COC U clamp 32 10

20 S800.02.02.00.01－R2 Half shaft protect board ,RL 1


22 S800.02.02.00.02－R2 Half shaft protect board ,RR 1

184

16 STEERING

185

16 STEERING


1 2673－ M4x5 Hex screw M4x5 2

2 DI250.03.01.00.01 Plastic cover 1

3 DI250.03.01.00.02 Rubber cover 1

4 D250.03.00.00.02 Rubber washer 1

5 815－ M6x25 Cross sunk screw M6x25 6

6 D250.03.01.00.00 Steering wheel 1

7 6787.1－ M6 Self locking M6 6

8 S800.05.01.01.00－R2 Steering column assembly 1 9－15

9 S800.05.01.01.01－R2 Steering wheel shaft 1

10 S650.05.01.00.01 Rubber cover 1

11 893.1－CØ28 Internal circlip Ø28 1

12 276－B61902 Ball bearing 61902 1

13 S800.05.01.01.02－R2 Steering column housing 1

14 276－B61803 Ball bearing 61803 1

15 893.1－CØ15 External circlip Ø15 1

16 6177.1－M10x1.25 Flange bolt M10x1.25 6


18 S800.01.08.00.00－R2 Steering mount 1

19 5782－ M8x25 Bolt M8x25 2


21 S800.05.01.02.00－R2 Steering universal rod 1



24 D650.05.01.00.03 Thick rubber cover 1

25 D650.05.01.00.05 Small iron cushion 1

186

16 STEERING


26 D650.05.01.00.02 Mounting rack 2

27 D650.05.01.00.04 Thin rubber cover 1

28 D650.05.01.00.06 Big iron cushion 1

29 S650.05.01.03.05A Steering assy. 1 30－36

30 6176－M14x1.25 Nut M14x1.25 2


32 S650.05.01.03.05.01 Connection 2

33 S650.05.01.03.05.02 Ripple boot 2

34 S650.05.01.03.05.03 Spacer 2

35 S650.05.01.03.05.04 Steering box 1

36 S650.05.01.03.05.05A Steering shaft 1

37 6771.1－M14x1.25 Flange bolt M14x1.25 2

38 6170－ M14x1.5 Nut M14x1.5 2

39 S650.05.01.03.01 Joint ball 2

40 9457－ M14x1.5 Slotted nut M14x1.5 2

41 91－CP3.2x25 Cotter pin 3.2x25 2

42 S800.05.01.03.01－R2 Steering roll 2

43 6170－M14x1.5－L Nut M14x1.5－L 2

44 POA14－L Joint bear POA M14x1.5－L 2

45 S650.05.01.03.04 Joint bear spacer 4

187

17 RADIATOR

188

17 RADIATOR


1 D250.09.902 Overflow bottle cover 1

2 D250.09.903 Overflow bottle 1



5 D650.04.03.00.04 Hoop (10~16) 7

6 S800.04.02.00.09－R2 No.1“T”hose 1

7 DS150.05.02.00.02 “T”connection 1

8 S800.04.02.00.10－R2 No.2 “T”hose 1

9 S800.04.02.00.11－R2 No.3 “T”hose 1


11 D650.04.02.00.03 Hoop (25－38) 13

12 S800.04.02.00.07－R2 Inlet cup hose 1

13 S800.04.02.04.00－R2 Aluminum radiator assay 1

14 SV1100.04.07.00.01 Hose clip(19－25) 4

15 D250.09.904 Inlet cup cover 1

16 93－W8 Washer 8 1


18 CF250T－420001 Plastic inlet cup 1

19 S650.04.02.02.06 Plug 1

20 818－M6x20 Cross head screw M6x20 12

21 JD0900008 Rubber flange washer 6 12

22 S800.04.02.02.00－R2 Radiator right mount 1


24 S650.04.02.11.00 Inlet cup cover 1

25 S650.04.02.10.00 Cuprum inlet cup 1

189

17 RADIATOR


26 S800.04.02.00.04－R2 No.1 engine water outlet hose 1

27 D650.04.02.03.00 Temperature detect switch(TDS) 1

28 S800.04.02.00.08－R2 Water hose connection 2

29 S800.04.02.00.12－R2 Cuprum inlet cup hose 1

30 S650.04.02.02.00 “T”connection 2



33 6177.1－M8 Flange nut M8 6

34 S800.04.02.05.00－R2 Water hose bracket 3

35 S800.04.02.03.00－R2 Lower radiator mount 1

36 S800.04.02.01.00－R2 Left radiator mount 1

37 S800.04.02.00.01－R2 No.1 engine water inlet hose 1



40 D1600.04.02.00.06 Hose clip (16－25) 2

41 S800.04.02.00.14－R2 Small cycle water hose 1

42 D1600.04.02.02.00 Radiator fan 1


190

18 GASOLINE AND AIR TAKING (OLD)



1 6177.1－M10 Flange nut M10 4

51

191

2 S800.04.03.01.00－R2 Fuel tank strap 2

3 S650.04.03.01.02 Fuel tank rubber strap 2

4 S800.04.03.00.03－R2 No.1 connector hose 1

5 S650.04.03.01.00 Fuel tank assy. 1 3、6、7

6 S650.04.03.01.03 Fuel tank cap 1

7 S650.04.03.01.02 Fuel level sensor unit 1

8 D650.04.03.00.04 Hoop (10－16) 16

9 S800.04.03.00.01－R2 Fuel tank outlet hose 1




13 D650.04.03.00.10 Fuel filter clip 3


15 D650.04.03.00.05 Fuel filter 1

16 S800.04.03.00.04－R2 Fuel filter outlet hose 1

17 D1600.04.02.00.06 Hose clip (16－25) 1

18 D1600.04.03.02.00 Fuel bump 1

19 S800.04.03.00.05－R2 Fuel bump outlet hose 1

20 D1600.04.03.03.00 Fuel press adjuster 1

21 5782－M4X12 Bolt M4X12 2


23 95－W4 washer 4 2

24 S800.04.03.00.02－R2 Gasoline returning hose 1

25 S800.04.03.00.07－R2 Fuel press adjuster out hose 1



26 D1600.04.03.00.03 Express connector (7.95) 1

27 S800.04.01.01.00－R2 CHERY 372 engine 1

192

28 SV800.04.05.00.02 Rubber sleeve 1

29 S800.04.05.00.05－R2 Hose clip (46－70) 2

30 S650.04.05.00.01 Flexible intake hose 1

31 S800.04.05.00.04－R2 Gas－recycle hose 1

32 S800.04.05.00.06－R2 No.1 PCV hose 1

33 S11－1109110 Air filter 1


35 95－W8 washer 8(Ф24xФ8.5x2) 2

36 S800.04.05.02.00－R2 Air filter bracket 1

37 JD1910002 Metal spacer 2

38 JD1910003 Rubber spacer 2


40 S800.04.05.00.03－R2 Board 1

41 6170－M8 Nut M8 4


43 S11－1206211 Pressure Control Valve (PCV) 1

44 S800.04.05.00.07－R2 No.2 PCV hose 1


46 D800.04.03.00.01 Connector 1


48 D650.04.06.00.02 Sheet metal 1

49 D650.04.06.00.01 mount 1

50 D650.04.06.01.00A Fuel vapor canister 1

51 R1 800.01.01.01.01A Air filter element 1

193

19 GASOLINE AND AIR TAKING (NEW)

194



1 6177.1－M10 Flange nut M10 4

2 S800.04.03.01.00－R2 Fuel tank strap 2

3 S650.04.03.01.02 Fuel tank rubber strap 2


5 S650.04.03.01.00A Aluminum fuel tank 1

6 SR2000.04.03.00.03A Aluminum tank cover 1

7 SR2000.04.03.00.00 Fuel level sensor unit 1

8 D650.04.03.00.04 Hoop (10－16) 16

9 S800.04.03.00.01A－R2 Fuel tank outlet hose 1




13 D650.04.03.00.10 Fuel filter clip 2


15 D650.04.03.00.05 Fuel filter 1

16 S800.04.03.00.04A－R2 Fuel filter outlet hose 1

17 D1600.04.02.00.06 Hose clip (16－25) 1

18 D1600.04.03.02.00 Fuel bump 1

19 S800.04.03.00.05A－R2 Fuel bump outlet hose 1

20 D1600.04.03.03.00 Fuel press adjuster 1

21 5782－M4X12 Bolt M4X12 7


23 95－W4 Washer 4 2

24 S800.04.03.00.02－R2 Gasoline returning hose 1

25 S800.04.03.00.07－R2 Fuel press adjuster out hose 1

195



26 D1600.04.03.00.03 Express connector (7.95) 1

27 S800.04.01.01.00－R2 CHERY 372 engine 1

28 SV800.04.05.00.02 Rubber sleeve 1

29 S800.04.05.00.05－R2 Hose clip (46－70) 2

30 S650.04.05.00.01 Flexible intake hose 1

31 S800.04.05.00.04－R2 Gas－recycle hose 1

32 S800.04.05.00.06－R2 No.1 PCV hose 1

33 S11－1109110 Air filter 1


35 95－W8(Ф24xФ8.5x2) washer 8(Ф24xФ8.5x2) 2


37 JD1910002 Metal spacer 2

38 JD1910003 Rubber spacer 2


40 S800.04.05.00.03－R2 Board 1

41 6170－M8 Nut M8 4


43 S11－1206211 Pressure Control Valve (PCV) 1

44 S800.04.05.00.07－R2 No.2 PCV hose 1


46 D800.04.03.00.01 Connector 1


48 D650.04.06.00.02 Sheet metal 1

49 D650.04.06.00.01 mount 1

50 D650.04.06.01.00A Fuel vapor canister 1

196

20 PLASTIC PARTS

197

20 PLASTIC PARTS

Ref Part No Part Description Qty Comments

1 818－M6x35 Screw M6x35 4

2 JD0900008 Rubber washer 6 100

3 S800.08.00.00.01－R2 Hood vent 1

4 S800.08.01.00.00－R2 Hood 1

5 818－M6x20 Screw M6x20 87


7 818－M6x25 Screw M6x25 9

8 S800.08.02.00.00－R2 Dash 1


10 S800.08.00.00.04－R2 Fire wall 1

11 S800.08.00.00.16－R2 Left foot panel 1

12 S800.08.00.00.06－R2 Counsel 1

13 S800.08.00.00.15－R2 Right rear fender 1

14 S800.08.00.00.14－R2 Left rear fender 1

15 S800.08.00.00.12－R2 Left inner fender 1

16 S800.08.00.00.13－R2 Rear inner fender 1

17 S800.08.00.00.09－R2 Left side panel 1

18 S800.08.00.00.07－R2 Vent cover 1

19 S800.08.00.00.11－R2 Right side panel 1

20 S800.08.00.00.08－R2 Left seat panel 1

21 S800.08.00.00.10－R2 Right seat panel 1

22 S800.08.00.00.05－R2 Tunnel 1

23 S800.08.00.00.17－R2 Right foot panel 1

24 S800.08.00.00.03－R2 Front bumper 1

25 S800.08.00.00.02－R2 Fog rill 1

198

21 ELECTRICAL APPLIANCE AND OTHER PARTS

199



1 S800.06.03.01.00－R2 Front turning light 2

2 S650.06.02.00.00 Headlight 2 3~6

3 S650.06.02.01.00 Headlight bulb 2

4 S650.06.02.03.00 Spring 2


6 948－M5x50 Bolt M5x50 2

7 S800.06.03.03.00－R2 Side turning light 2


9 S650.04.02.02.04 Inlet cup bracket 2



12 S800.06.03.02.00－R2 Fog light 2


14 D650.06.00.09.00 Horn 1


16 6170－M8 Nut M8 2


18 DN250.10.07.00.00 Total power switch 1

19 6177.1－M5 Flange nut M5 4

20 D1600.01.02.00.06 Speedometer bracket 1

21 S800.06.05.01.00－R2 Speedometer 1

22 D1600.06.05.00.00 Tachometer 1

23 DS250.10.00.00.05 Horn button 1

24 S650.06.08.00.00 Ignition switch 1

25 S800.06.04.03.00－R2 Combination switch 1


27 S800.09.01.07.00－R2 Battery bracket 1

28 D1600.06.02.00.03 Battery rubber cover 1

29 D1600.06.02.00.00 Battery 1

30 S800.08.00.00.18－R2 Plastic battery box 1

200



31 S650.06.00.14.00 Tail light 2

32 N650.06.04.00.01 Fuel level gauge bracket 1

33 6177.1－M4 Flange nut M4 8

34 D1600.06.09.00.00 Voltmeter 1

35 MV800.06.03.00.00 Coolant temperature indicator 1

36 D1600.06.07.00.00 Oil pressure gauge 1

37 N650.06.04.00.00 Fuel level gauge 1

38 S800.06.04.01.00－R2 Combination button 1

39 S650.06.07.00.00A Three switch assembly 1


41 S650.06.12.00.05 Electric winch relay 1

42 6177.1－M8 Flange nut M8 4

43 S650.06.14.02.00 Express connection－peg(Red) 2

44 S650.06.14.01.00 Express connection－peg(Red) 1

45 S650.06.12.00.01 Electric winch 1

46 S650.06.12.00.03 Wire cable guide 1

47 S650.06.14.01.00 Express connection－peg(Black) 1

48 S650.06.14.02.00 Express connection－peg(Black) 2

49 SV800.01.02.00.04 ECU plastic cover 1

50 SV800.01.02.00.02 ECU bracket 1

51 S800.09.01.00.05－R2 Wire bracket 1

52 S800.06.01.01.00A－R2 Harness wiring 1

53 SR2000.06.00.04.01A Wire (battery “+” to power switch) 1

54 S800.06.00.04.03A－R2 Wire (power switch to starter) 1

55 SR2000.06.00.04.02A Wire (battery “－” to frame) 1

56 SR2000.06.00.04.04A Wire (frame to transmission) 1

57 S800.06.00.05.02A－R2 Rear electric winch wire 1

201

22 SEATS AND SAFETY BELTS


1 6177.1－M10x1.25 Flange nut M10x1.25 8

2 91－CP3.2x25 Cotter pin 3.2x25 4

3 882－PP 7x80 Pivot pin 7x80 4

4 S800.09.01.02.00－R2 Left seat mount 1

5 70.1－M8x20 Hex bolt M8x20 8

6 S800.09.01.01.01－R2 Track without release lever 1

7 S800.09.01.01.03－R2 Seat 2

8 S800.09.01.01.02－R2 Track with release lever 1

9 TR1100.08.01.18.00 Safety belt 2

10 S800.09.01.03.00－R2 Right seat mount 1

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