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 Post subject: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Viper
PostPosted: Sat Sep 03, 2016 10:56 am 
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Joined: Fri Jun 14, 2013 9:13 am
Posts: 251
Location: SoCal
All,

Got a new project and will need some assistance with. Picked up a Joyner 800cc Sand Viper this week. Old motor gone and a 1999 2000cc Ford Zetec S/R sitting in the engine cradle.

First step is to get it mounted, so I bought all the motor mounts and trans mount to being the measurements. I got a Mig welder but looking into getting a AC/DC Tig for this project.

Engine is pretty dirty and I was looking for an engine number to verify the engine. Only thing I can see if the Ford VCT stamped on the valve cover. Looked below the oil filler and followed it down to where the engine mounts to the bell housing but I can see nothing. Any thoughts where else to look?

The whole harness (somewhat) is there, including the ECU. Has a nice AGM battery. Gave it a charge and all the lights, dash and even Kenwood stereo work.

Harness to ecu pigtail doesn't seem to match up as I am now trying to solder and heat shrink the cut wires back. Will need to know what wires are needed for the computer (ecu) for the engine to operate.

Here is what I think I will need, I know there will be more as I move along the project.

1) left and right CV axles, joyners are still there and will bring to the local driveshaft shaft to have them mated and balanced.

2) cherry picker to remove and place engine, etc.

3) tig welder to make the engine mount holders. radiator and gas tank mounts, etc.

4) seats redone or repaired. probably will take those to Tijuana.

5) lots of time and patience :wink:

Going to post my spendings here so far. If I can keep editing my first post, I'll keep updating here. Tools I'll keep out of the tally.

Buggy: $500

All new Mounts: $42

Motor mount poly inserts: $24

Escort Radiator: $51

Motorcraft Radiator cap: $13

16" Radiator fan push/pull: $28

Oil Dipstick: $13

Metal for custom motor mounts: $35

Chilton used manual: $8

Hydraulic Clutch Kit: $140

Spray Paints (ongoing): $25

Fasteners (ongoing): $20

Roof Rack, Light Bar and Nerf Bars: $140

Marine Stereo Enclosure: $32

Header and Downpipe: $140

Clutch Throwout and Pilot Bearings: $40


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_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF


Last edited by MPDano on Fri Oct 07, 2016 10:54 am, edited 4 times in total.
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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Sat Sep 03, 2016 11:54 am 
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Joined: Fri Jun 14, 2013 9:13 am
Posts: 251
Location: SoCal
Brought home 9/1/2016


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_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF
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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Sat Sep 03, 2016 11:55 am 
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Joined: Fri Jun 14, 2013 9:13 am
Posts: 251
Location: SoCal
working on the wiring harness nightmare.


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_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF
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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Sat Sep 03, 2016 11:00 pm 
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Joined: Fri Jun 14, 2013 9:13 am
Posts: 251
Location: SoCal
Found some numbers. One has to be the engine number, what is the numbers above it? For sure a 2 liter, but is it a zx2 s/r that the po said it was.


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_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF
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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Sun Sep 04, 2016 6:15 am 
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Joined: Sun Nov 16, 2008 7:25 pm
Posts: 5100
Location: De Soto MO
If that is the split port engine you may want to pull the head and have a good shop go thru it. They are notorious for dropping intake seats. And well you know what can happen when that does happen. Good head shops will pop the old seats out and install good ones. If that is the twin cam motor you are probably good to go. Good luck with you build.

_________________
09 250SV Joyner Polaris 500 (SOLD)
here-we-go-again-joyner-polaris-500-swap-t46499.html
HH GTS150 stk 250SS wheels
Polaris Dark side ride


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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Sun Sep 04, 2016 9:40 am 
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Joined: Fri Jun 14, 2013 9:13 am
Posts: 251
Location: SoCal
Papa Rich wrote:
If that is the split port engine you may want to pull the head and have a good shop go thru it. They are notorious for dropping intake seats. And well you know what can happen when that does happen. Good head shops will pop the old seats out and install good ones. If that is the twin cam motor you are probably good to go. Good luck with you build.


Yes, it's a twin cam engine. As soon as I have the engine mounted, I am going to pull it out and go thru it. Are you saying that if it's "not" a twin cam engine, they drop the intake valve seats?

_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF


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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Sun Sep 04, 2016 9:43 am 
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Joined: Fri Jun 14, 2013 9:13 am
Posts: 251
Location: SoCal
Twin Cam


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_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF
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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Sun Sep 04, 2016 10:48 am 
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Joined: Sun Nov 16, 2008 7:25 pm
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Location: De Soto MO
Yah the single cam motors are bad for dropping seats.

_________________
09 250SV Joyner Polaris 500 (SOLD)
here-we-go-again-joyner-polaris-500-swap-t46499.html
HH GTS150 stk 250SS wheels
Polaris Dark side ride


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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Sun Sep 04, 2016 11:16 am 
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Joined: Fri Jun 14, 2013 9:13 am
Posts: 251
Location: SoCal
thanks Papa Rich, one less thing to worry about. any way to tell what engine this is for sure by the markings I posted?

I was told on a zx2 forum that it's not an s/r engine but wanted to verify for sure.

_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF


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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Mon Sep 05, 2016 9:12 pm 
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Joined: Fri Jun 14, 2013 9:13 am
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Location: SoCal
Pulled the engine and pressure washed today


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_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF
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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Tue Sep 06, 2016 4:26 pm 
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Joined: Fri Jun 14, 2013 9:13 am
Posts: 251
Location: SoCal
Adding this image for the a/c p/s delete

Pulley 5 and 8 need to be swapped, pulley 2 removed altogether


Attachments:
AC-PS Delete.png
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_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF
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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Tue Sep 06, 2016 9:28 pm 
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Joined: Fri Jun 14, 2013 9:13 am
Posts: 251
Location: SoCal
New engine/tranny mounts came in today. Put them in their respected place so I know where they go.


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_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF
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 Profile  
 
 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Wed Sep 07, 2016 9:50 pm 
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Buggy Enthusiast

Joined: Fri Jun 14, 2013 9:13 am
Posts: 251
Location: SoCal
Picked up a Roof Rack, Lightbar and some Nerf bars today


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_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF
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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Thu Sep 15, 2016 9:52 am 
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Joined: Fri Jun 14, 2013 9:13 am
Posts: 251
Location: SoCal
Removed everything from the engine compartment. Grinded down all the previous owner torch slag from removing old mounts. Next is to drop the engine back in and start fabbing up the new motor/trans mounts.


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_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF
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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Thu Sep 15, 2016 6:20 pm 
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Location: Prattville, AL
nice project, we have alot of the joyner parts we bought from jmc
www.mpsracing.net

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American sportworks, Renli, Kymco, Landmaster , Hyosung,
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http://www.mpsracing.net
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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Thu Sep 15, 2016 8:20 pm 
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BIGE wrote:
nice project, we have alot of the joyner parts we bought from jmc
http://www.mpsracing.net


Nice. Will be hitting you up when that time comes 8)

_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF


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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Thu Sep 15, 2016 9:31 pm 
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Joined: Fri Jun 14, 2013 9:13 am
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Engine positioned exactly where I want it. Had to clear the transmission pan and pulleys on the opposite side. Next to fabricate the mounts with cardboard as templates.


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_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF
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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Fri Sep 16, 2016 7:57 am 
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Joined: Sun Nov 16, 2008 7:25 pm
Posts: 5100
Location: De Soto MO
MPDano wrote:
thanks Papa Rich, one less thing to worry about. any way to tell what engine this is for sure by the markings I posted?

I was told on a zx2 forum that it's not an s/r engine but wanted to verify for sure.


No I can't answer that question sorry. I am wondering if that is a later model Focus engine. I know the later model 07 thru 11 have a different style engine. I actually have one of those here in an 08 that I bought new and my son bought from me and was totaled about a month ago. Great running engine with a 5sp manual tranny. Not sure how much it got damaged in the accident. The car was hit from the side. Ton of miles but still didn't use any oil or have any leaks, it was a great car hated to see it get wasted.

_________________
09 250SV Joyner Polaris 500 (SOLD)
here-we-go-again-joyner-polaris-500-swap-t46499.html
HH GTS150 stk 250SS wheels
Polaris Dark side ride


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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Fri Sep 16, 2016 9:05 am 
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Joined: Fri Jun 14, 2013 9:13 am
Posts: 251
Location: SoCal
Papa Rich wrote:
MPDano wrote:
thanks Papa Rich, one less thing to worry about. any way to tell what engine this is for sure by the markings I posted?

I was told on a zx2 forum that it's not an s/r engine but wanted to verify for sure.


No I can't answer that question sorry. I am wondering if that is a later model Focus engine. I know the later model 07 thru 11 have a different style engine. I actually have one of those here in an 08 that I bought new and my son bought from me and was totaled about a month ago. Great running engine with a 5sp manual tranny. Not sure how much it got damaged in the accident. The car was hit from the side. Ton of miles but still didn't use any oil or have any leaks, it was a great car hated to see it get wasted.


I believe they were also used in the contour model. I just saw on craigslist a 2000 escort with the exact engine as well.

_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF


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 Post subject: Re: MPDano NEW Joyner Project - 2005 800cc to 2000cc Sand Vi
PostPosted: Sat Sep 17, 2016 2:07 pm 
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Joined: Fri Jun 14, 2013 9:13 am
Posts: 251
Location: SoCal
3/16" of metal goodness.


Attachments:
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_________________
2006 Joyner Viper 250cc
2005 Joyner Sand Viper 800cc to 2000cc - In Progress
1978 Honda Odyssey 250cc - In Pieces
1985 Honda ATC 250SX
2007 E-Ton Rover 90cc (Red)
2007 E-Ton Rover 90cc (Blue)
2002 KTM 250SX
2006 KTM 250SXF
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