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Parts, Pieces, and Information for our Troopers & Joyners

19 posts in this topic

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
Joyner USA In Phoenix Arizona - Contact Brandon Deruiter Office (480) 882-9612  Email [email protected]   Web site Joyner-usa.com

I also take suggestions for any and everyone!!

parts & pieces from dealer in Germany


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.
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!!)
http://www.ebay.com/itm/Hayg-OEM-Inline-Fuel-Pump-0-580-254-910-0580254910-New-/230568738342#vi-content (updated 05-2015)

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

Master Electrical Switch Key
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,

Oil Drain QuickOilDrainValve.com


the best way to change oil, IMHO Kinarfi
Fram Sure Drain #SD3

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

Supplier of parts in General

Pegasus Auto Racing Supplies - Home Page
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

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

Differential Bolts

40 28 to Full 25 96144A227 8.33

1100 Trooper T2 ECU Wiring Diagram.pdf

Diff Ring Bolt.png

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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.


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.

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Major work jobs by owners, this is just a link to the topics

This is Rocmoc's engine pull -- http://www.utvboard.com/topic/1192-pulling-engine-trans/page__view__findpost__p__4179

This is Kinarfi's engine pull ----- http://www.utvboard.com/topic/2076-kinarfis-engine-rebuild/page__view__findpost__p__8847

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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.


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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!

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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....

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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.

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Current Dealer list:

Go Karts USA

2121 North California Blvd

Walnut Creek, CA 94596




7209 Arlington Ave. #A

Riverside, CA 92503



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



Audio 2000

4742 East Speedway Boulevard

Tucson, AZ 85712(520) 624-2000 ‎tucsoncaraudio.net

Beavers Construction


Shop address:

1038 state hy 99 n

Ada, ok 74820

NFR Auto Sales and ATV

10 Shaft Rd

Hazelton, PA 18201


Lems Auto Sales

2337 Hoey Church Road

Shelby, NC 28152



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The below are Service ONLY Dealers:

Four brothers ATV


4903 RT 66

Apollo, PA 15613

Bulldog Motorsports

48163 Taylor Rd

Roger, Ohio 44455



313 Shawnee Ave

Big stone gap, VA 24219


SYC Powersports

468 Christian College Rd,

Senatobia, MS 38668

662-301-1563 Tom


No limit Powersport

2925 East Division Street,

Arlington, TX

(817) 695-1151


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


2811 S Avenue 2 1/2 E

Yuma, AZ

Berts Mega Mall

1151 North Azusa Avenue

Covina, CA 91722

Emrock ATV


320 S Rock Blvd,

Reno, NV

Thin Air Powrsports


1169 Solar W Dr

Spring Creek, NV


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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.

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Idle Air Control (IAC) for the Chery 1100:


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.

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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.

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OK for the 09 Trooper T2 front CV's

Outer Front NAPA 686-2149

Inner Front NAPA 686-2151

1 person likes this

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We recently received our Wheel Bearing Shims and have tested them, they work very well. Also, we now have billet steering racks available for the Trooper. If your interested please feel free to contact me.

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Airtex E2000 fuel pump works and is very quite and only $60 on amazon

Sent from my SM-G900V using Tapatalk

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