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    Joyner Manuals Trooper Parts Trooper

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    #1 Kinarfi

    Kinarfi

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    Posted 06 October 2008 - 03:48 PM

    If something need editing, removed or added, PM Kinarfi
    Dealers - - - also see
    http://www.utvboard....dpost__p__16044 & http://www.utvboard....dpost__p__16045
    No Limits Powersports in Arlington Texas - Contact Jarrad (Snowman6479). (817)695-1151 http://www.joyner-atv-utv.com/
    Silver Bullet Motorsports in Yuma Arizona - Contact (silverbullet). (928) 344-2117 http://www.silverbul...otorsports.net/
    Thin Air Powersports in Spring Creek Nevada - Contacts Tim (Anylizer) or Amanda (Long Track Lady) (775)753-8223 http://www.thinairpowersports.com/
    McCoy Motorsports in Pikeville Kentucky - Contact Art (Art) (606)432-1556 http://www.tobefast....sa-c-63727.html
    Mudslingers Motorsports, Alberta, Canada, Trevor Carson (780) 576-2860 cell: (780) 984-2711 http://www.mudslinge...website_006.htm
    www.JMCmotors.us Welcome To JMC MOTORS Contact Jeff Langseth or Casey Strebe - 480.545.1693 email - [email protected] or [email protected]
    I watch for stuff to add here and EDIT this post to add stuff
    I also take suggestions for any and everyone!!

    Joyner Manuals --- http://www.jmcmotors...vehicle-manuals

     

    parts & pieces from dealer in Germany

    http://www.utvboard....-parts/?p=18349

     

    AIR FILTER K&N RU-1000, RC-4160, and another link
    If you have the new 09 filter box, w/ Fram # CA-7764
    ALTERNATOR BELT 14mmx 755mm replacement that works....Carquest #K040292
    Alternator Belt - Checkers Auto Parts KO40292 - Exact Match
    Battery, according to 2 scoops, Duralast 51-DL is the correct size.
    OIL FILTERS
    Troopers with Thread Size 20X1.5 MM can use:
    WIX 51347, 51334 --- Napa 1347, 1334, PS1334 --- Fram PH6010A, PH3593A
    Troopers with Thread Size 3/4X16 " can use:
    Fram PH4967, Napa 1394 & Wix 5194 (slightly longer than original, Wix 51396 (even longer yet).

    OIL COOLER See thread, http://www.utvboard....768-oil-cooler/

    Oil Pressure Gauge Replacement
    Zorro found some at his Local Marine Supply store
    Sending Unit -- TeleFlex Morse Part # IA15001 0-80 psi, 240-33 ohm
    Gauge -- TeleFlex Morse Part # 57903P 0-80 psi, 240-33 ohm
    Manufactured by Veethree Elec. & Marine LLC
    together cost aprox $80.00
    Says it fits the existing hole perfectly Thanks Zorro
    Plumber added this reference; http://www.spydertal...pressure-gauge/ which Crosses over to a Sierra part# 01858990
    IMHO--I would move the the sender away from the exhaust manifold.

    FUEL FILTER replacement, Fram Fuel Filter G4777

    FUEL PUMP replacement, Bosch 0 580 254 910 According to Brostar, (Thank You!!)
    Fuel Pumps 0 580 254 910 (A) $59.95
    http://www.utvboard....dpost__p__12906 - This directs you to Ebay supplier & a Hayg fuel pump for $44.99. 12-15-11

    PRE FILTER KNN-RC-4160-DK prefilter

     

    HEAD LIGHT REPLACEMENT    Sylvania H5006  replaces the whole bulb, It works sooooo much better than the original.

     

    SPARK PLUGS NGK Iridium BKR5EIX-11, NGK 2387, NGK BKR7ES-11, Bosh 3311, Denso Iridium plug 5310 IK22

    CV Boot Kit There appears to be a difference between inner and outer boots, I used a NAPA CVB6862340 for my outer rear, fit good but not tightly on the CV end, I held it on with Tyraps
    Autozone part # 03606. Comes with bands and grease for $11.99, quick/split boot. K2181 95 Geo Metro $15.99
    NAPA #686-2149 fits for the Troopers inner CV. It's a speck tight but only about 1/16".(Lenny)
    Napa 686-2181 CV Boot from a 95 Geo Metro.
    http://www.norrecind...tart=1&cat=1394 or
    Norrec Industries then Application, then UTV, then look up joyner, they have them all
    Polaris CV Boot Kit # 2203438, (PR-8061)
    Also see CV boot for driveline? - UTV BOARD - Side X Side and UTV Forum

    Valves shims are 25mm, Joyner shims start at 2.18 and increase in increments of .02 up to 2.80, The Honda shims come out of CB450s and GL1100s, start at 2.30 and increase in increments of .05
    http://www.mawonline...gle/P137630.HTM
    http://stores.ebay.c...&_sid=120606839

    Master Electrical Switch Key
    http://www.jegs.com/...oductId=1231908
    http://www.pegasusau....asp?RecID=1467
    Make your own, it's easy, I did, just in case mine breaks.

    At the suggestion of one of our members, here's some info on the gas gauge sending unit.
    3 ohms is full, 13 ohms is 3/4, 23 ohms is 1/2, 63 ohm is 1/2, 110 ohms is empty.
    Electrical readings are: F=0.75v-98ma, 3/4=1.91v-82ma, 1/2=2.7v-71ma, 1/4=3.3v-62ma, 0=4.1v-52ma, E=5.0v-39ma
    0 is top of red zone, E is bottom of red zone.


    Manuals and Information


    Trooper T2 weights, 380lb. on each front wheel, 480 lb. on left rear, 520 on right rear TOTAL = 1760 pounds

    down load this and save it!!!!
    Torque Values Select Your type of bolt at the top. http://www.engineers...bles/torque.htm
    My Snorkel Made from a Sears ShopVac 7' Hose and the Extension Wand,
    Pressing Technology - RIDGID Professional Tools
    Pressing Technology - RIDGID Professional Tools


    Oil Drain QuickOilDrainValve.com QuickOilDrainValve.com - the best way to change oil
    Fram Sure Drain #SD3

    Paint as recommended by Brostar: http://www.zynolyte..../rustmaster.asp

    Supplier of parts in General

    http://www.cxracing.com/default.aspx
    http://www.jegs.com/
    http://www.summitracing.com/
    Pegasus Auto Racing Supplies - Home Page
    TireRack.com
    McMaster-Carr
    Discount Hydraulic Hose.com

    Tie Rod Dust Boot, Checker Auto#13566

    Rod End / Heim Joint Seals , http://pitstopusa.co...-end-seals.html, thanks rocmoc
    Ball Joint Rod Ends AKA Heim Joints
    16 x2.0mm threat, 16mm ID, 21 mm thick,
    I got mine at McMaster-Carr 4483T36
    PTFE/Kevlar Insert, M16 x 2.0 x 40.mm shank, 21,966 lb static radial load capacity, 23°, $25.60 ea. or $204.80 for 8
    http://www.vxb.com/p...s/PROD/Kit12360
    http://www.vxb.com/p...s/PROD/Kit12960

    14 Inch Tires That fit our Stock Wheels Note that the stock lug bolt pattern is 4 X 115
    STEEL WHEELS http://www.utvboard....dpost__p__10804
    JC Whitney for all Auto parts - Car, Truck, Jeep, Motorcycle & RV Parts
    Interco Tires SSR-24R - INTERCO SSR Series Tire - Quadratec
    Interco Tires SAM-12 - INTERCO Super Swamper TSL Tire - Quadratec
    TSL Radial | Interco Tire
    Maxxis Bighorn 2.0 AT26 X 11R 14
    General Grabber AT2 27x8.50 R14 95Q 6PR OWL $90.10 http://ssl.delti.com.../GRABBERAT2.jpg
    National Chaparral A/P 27x8.50 R14 95Q 6PR OWL $113.80 http://ssl.delti.com...ChaparralAP.jpg
    Kumho Road Venture MT-834 27x8.50 R14 95Q 6PR OWL $110.30
    Mastercraft COURSER A/T 27x8.50 R14 95Q 6PR OWL $87.00 http://ssl.delti.com...t/COURSERAT.jpg
    Cooper Discoverer LT 27x8.50 R14 95Q 6PR OWL $99.60 http://ssl.delti.com...iscovererlt.jpg
    Laramie Performer RV 27x8.50 R14 95Q 6PR OWL $100.70 http://ssl.delti.com...PerformerRV.jpg
    ITP MUD LITE XTR 27-9-14 $87.99
    ITP TERRACROSS R/T 26-9-14 $144.99

    15 inch Wheels [Be sure to get the correct lug nuts, 12X1.5
    Vision Wheel Inc Vision Wheel
    ITP has one now also, getting info. ITP TIRES - The World's #1 ATV Aftermarket Tire & Wheel Source :: Holeshot

    Non Trooper Info
    u joints for joyner renegade are Spicer 5-1501X and Precision 391. They are American work great. graybeard9

    Attached Files





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    #2 Kinarfi

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    Posted 27 December 2010 - 11:42 PM

    How to change the Rear Wheel Bearings - By Rocmoc.

    You will need -

    Two rear wheel bearings, I got mine from snowman at No Limits Powersports, http://www.joyner-atv-utv.com/ but also available from Silver Bullet Motorsports, http://silverbulletmotorsports.net/ & http://www.jmcmotors.us/ Roller bearings
    Two seals (metric sizing), part specs TC 45 65 8 purchased from Motion Industries, http://www.motionind...LocationsMI.jsp NOTE: Page 198 of the 2009 manual, page 183 of the 2008 manual,
    says I need #3(03.06.13871-FB45×65× 13871-FB65X42X8 Seal FB65X42X8) and #32 (03.06.13871-FB45×65× 13871- FB65X45X8 Seal FB65X45X8) seals, but I know that the # 3 seals actually needs to be 62X42X8
    Large socket set to break the nut loosen the axle holding the hub on. I have a 3/4" set and worked great.
    C-clip removal tool, I have one but was easier using an old screwdriver trick.
    Seal puller, I have a bodyman's dent removal tool with an adapter that works. This saves the old seal but you could use a screwdriver and kill the seal.


    Remove the wheel/tire.
    Remove the cotter key.
    Remove large nut, someone needs sit in the Trooper applying the brakes to keep the axle from turning.
    Remove the brake calipers, 2 bolts per caliper & two calipers per wheel in the rear for a total of 4 bolts.
    Slide the hub & rotor off the end of the axle.
    Remove the 2 bolts holding the backing hub/bearing housing to the swingarm. One on top, one on bottom.
    Remove the bearing housing.
    Wipe, clean so you can see what you are doing.
    Remove the seal. The seal is in front of the C-clip & bearing.
    Wipe, clean so you can see what you are doing.
    Remove the C-clip, can be a pain if you have never done it before.
    Slide the bearing out.
    CLEAN!

    That is as far as I am on one side. Waiting for the seals. Why there are seals is beyond me. The bearing is sealed so it is just extra protection. There was grease in the area between the seal & bearing. Cheap insurance so I will put it back the way I found it. I can tell the bearing has spun a very very small amount. The fit between the housing & the bearing is still very very good. Lenny's tip to locite the outside of the bearing in place to the housing is important! But will make it more difficult to remove the bearing the next time it requires replacement.

    Yes, my original bearing had wear & slop. IMHO not that bad but did need replacement. The bearing isn't as bad as the design of the housing is. Taper roller bearings should have been the real design but what the heck lasted 4 years.


    If you see anything that needs correction, please post it as a reply. I'll take note, fix, and delete your post.

    #3 Kinarfi

    Kinarfi

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    Posted 22 January 2011 - 02:17 PM

    Major work jobs by owners, this is just a link to the topics
    This is Rocmoc's engine pull -- http://www.utvboard....ndpost__p__4179
    This is Kinarfi's engine pull ----- http://www.utvboard....ndpost__p__8847

    #4 Kinarfi

    Kinarfi

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    Posted 09 March 2011 - 11:00 AM

    get your joyner manual here http://www.jmcmotors...vehicle-manuals

    #5 huunz

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    Posted 11 September 2011 - 11:30 AM

    650 Sand Spiders (two cylinder models) with Thread Size 3/4X16 " can use:
    STP S3614


    Oil filter for the 650 Sand Spider - STP S3614 will fit without hitting the frame rail. The crossover in the Fram brand is too long, so although a PH 3614 looks as though it should fit, it won't clear the frame.

    You may have to loosen the motor mount nuts (14 mm wrench) to jimmy the engine up high enough to install the filter. I had to take the nuts clear off to jimmy the engine high enough to get the Fram filter in there, but then the end of the filter contacted the frame.

    You can see how close it gets in the picture, and this is the STP filter.

    The filter has a 3/4" thread, not the more common (for imports) 20 mm thread.

    Attached Files



    #6 Merchant Mariner

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    Posted 19 April 2012 - 12:04 PM

    some additional info I cam across. Some of it is redundant to what we already have here, but thought I would put it out here.

    Passenger diff seal, Car Quest part # 3655 size 51.9mm O.D. x 35mm I.D. Fits 1100, 800 EFI

    Front wheel bearings - NSK 6205Z-2ZR-C3 and 6206Z-2ZR-C3, SKF or FAG 6205-2RSR and 6206-2RSR
    Conversion to tapered roller bearings is possible with some hub modification - 30205A and 30206A

    Rear wheel bearings - Peer FWD 305532, 6006 2RS and 3006 2RS
    Conversion to tapered roller bearings is possible with some modification - 32006X

    Front a-arm ball joint - GE25ES 2RS

    Oil filter - Mann W67/81, China SPC932, Bosch O 004

    Brake pads - EBC FA482TT -
    tried to find these, but unable to get through an american vendor. ordered sets of FA473V to try out. Will follow up with full post when I get them in and try them out

    Tachometer w/ temperature gauge - Koso GP-Style (55mm, 0-9,000 RPM)

    Arctic Cat quads use the same hubs as the 650 Joyner so the brakes will also work from Arctic Cat. Others have found Wilwood brakes that fit the 650. These parts do not fit the 800cc and larger buggies

    The Geo Metro and Suzuki Swift 3-cylinder 1-liter engine will fit the 800cc chassis with minimum modification

    inner cv boots off a 1998 Geo Metro. They only cost $10 each instead of the $20 to $30 at a off road shop and available at any auto store! Fits 1100, other models not too sure


    source: http://www.joynerfor...-Need-your-help!

    Want to add, I have not verified this. Thats up to anyone who may need a listed item. But if anyone does verify via use of any of the listed items, please let us know!

    #7 bigdan120

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    Posted 04 August 2012 - 09:12 AM

    If you need a reverse switch use this one 96 Geo Metro reverse switch 1.0 Same threads same gasket same lengh...Ordered it from Rockauto...12.00 bucks with shipping. Anyways it takes care of 2 things it is a sealed unit with wires attached no dirt in it and I soldered the wires togather on mine so 1 less plug to worry about. Works well.....Hope this helps someone out there....
    2009 Joyner T2 96 KX500

    #8 bigdan120

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    Posted 10 August 2012 - 03:28 PM

    Replacement Headlights I used are Sylvania H5006 High/Low. I would imaging the number is the same for any manufacturer. The Headlight sockets to change it over are Dorman 9003 High Temps.....

    Edit by Kinarfi, I just soldered leads to the lugs and used my own connectors, but the H5006 Lamps fit good.


    2009 Joyner T2 96 KX500

    #9 BuggieDude

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    Posted 24 September 2012 - 05:00 PM

    Current Dealer list:
    Go Karts USA
    2121 North California Blvd
    Walnut Creek, CA 94596
    925-906-0330
    www.gokartsusa.com

    Supersportz
    7209 Arlington Ave. #A
    Riverside, CA 92503
    951-662-3828
    www.supersportz.com

    Advantage motorsport
    885 West Wickenburg Way
    Wickenburg, AZ 85390
    (928) 684-2522

    PBO Auto Sales
    3842 East Roeser Road
    Phoenix, AZ 85040
    (602) 828-1885

    Fun Share RV
    2583 Highway 6 and 50,
    Grand Junction, CO 81501
    970-241-2702
    www.funshares.com

    Audio 2000

    4742 East Speedway Boulevard
    Tucson, AZ 85712(520) 624-2000 ‎tucsoncaraudio.net

    Beavers Construction
    580-320-3053
    Shop address:
    1038 state hy 99 n
    Ada, ok 74820


    NFR Auto Sales and ATV
    10 Shaft Rd
    Hazelton, PA 18201
    570-459-2272


    Lems Auto Sales
    2337 Hoey Church Road
    Shelby, NC 28152
    704-484-3451
    www.lemsautosales.com
    Niles

    #10 BuggieDude

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    Posted 24 September 2012 - 05:03 PM

    The below are Service ONLY Dealers:

    Four brothers ATV
    724-727-7830
    4903 RT 66
    Apollo, PA 15613

    Bulldog Motorsports
    48163 Taylor Rd
    Roger, Ohio 44455
    330-227-9188

    Mudslinger
    313 Shawnee Ave
    Big stone gap, VA 24219
    276-393-2860

    SYC Powersports
    468 Christian College Rd,
    Senatobia, MS 38668
    662-301-1563 Tom
    www.sycpowersports.com

    No limit Powersport
    2925 East Division Street,
    Arlington, TX
    (817) 695-1151
    www.joyner-atv-utv.com

    Oasis marine
    3382 E Holladay
    Tucson, AZ 85706
    (520) 293-4041

    Woody's Performance
    405 W Main St
    Tonto National Forest
    Payson, AZ

    Unleashed Motorsport
    781 Air Park Way
    Cottonwood, AZ 86326

    Silver Bullet
    928-344-2117
    2811 S Avenue 2 1/2 E
    Yuma, AZ

    Berts Mega Mall
    1151 North Azusa Avenue
    Covina, CA 91722

    Emrock ATV
    775-856-3398
    320 S Rock Blvd,
    Reno, NV

    Thin Air Powrsports
    775-753-8223
    1169 Solar W Dr
    Spring Creek, NV
    http://www.thinair-usa.com/
    Niles

    #11 jandbcluff

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    Posted 29 November 2012 - 02:43 PM

    For the Electric Locker Actuator on the Trooper 1100, you can use the 4x4 box from an 08 Artic cat prowler 650, part # 0502-579. All you would have to do is unscrew the side of the body and clip the joyner pigtail to the circuit board.

    #12 2scoops

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    Posted 08 April 2013 - 09:20 PM

    Idle Air Control (IAC) for the Chery 1100:

    Freewai.com

     

    A: D5148 round head for DA465 1.1L, some SQR372 0.8L, siemens system

     

    I chose the "excellent" type, but you can also select the genuine part. It was $17 plus $30 shipping. It was this or $209 for a throttle body from one of the stateside vendors. They don't sell the components separately. Freewai was an excellent company to deal with and it arrived in 5 days.  
     



    #13 bigdan120

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    Posted 17 April 2013 - 02:17 PM

    For the starter solenoid you can use a 96 Geo Tracker.. Replaced my solenoid with one. Bolted right up...  1.6 GEO motor ..Make sure you check it out before buying for the starter motor part. I do not know if it spins CW or CCW plus I did not count the teeth on bendix. The solenoid is 78.00 at Advance..      25.00 For used starter at junk yard.


    2009 Joyner T2 96 KX500

    #14 bigdan120

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    Posted 19 August 2013 - 11:13 AM

    OK for the 09 Trooper T2 front CV's

     

    Outer Front   NAPA 686-2149

    Inner Front    NAPA 686-2151


    2009 Joyner T2 96 KX500





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