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DD 50 SERVICE MANUAL

1. Caution Do not bend the reed valve stopper Otherwise it will cause its strength insufficient and rough engine running If the reed valve or its seat is damaged replace with a set Reed valve Reed valve seat Installation Install in the reverse order of removal procedures Check for leaking after installed H NE s F gt p fy V Inlet pipe E Fuel Pump Carburetor Inspection Remove the body cover a connector Warm up the engine and adjust idle speed 22554 Remove fuel hose from carburetor and then wait for 5 minutes Measure the output of fuel pump Its output time is 10 seconds Output quantity Min 20 c c If the output quantity is lower than 20 c c check fuel hose vacuum hose and fuel filter Removal Installation Remove floor plate Remove fuel inlet outlet and vacuum hoses Remove 2 bolts and fuel pump Fuel inlet V T Install the fuel pump in the reverse order of hose removal procedures 10 8 SYM 10 FUEL SYSTEM Air Cleaner Removal Installation Remove the EEC hose from the air cleaner outer case Loosen connection hose clamp Remove 2 bolts and then remove the air cleaner outer case Install in the reverse order of removal procedures Install the air cleaner outer case 10 9 10 FUEL SYSTEM SYM Notes 10 10 SYM 11 BRAKE SYSTEM Front Disc Bra
2. f you swallow it by mistake drink a lot of water or milk and take some laxative such as castor oil or vegetable oil and then go to see a doctor Keep electrolyte beyond reach of children Brake shoe Do not use an air hose or a dry brush to clean components of the brake system use a vacuum cleaner or the equivalent to avoid dust flying Caution Inhaling dust may cause disorders and cancer of the breathing system Brake fluid Caution opilling brake fluid on painted plastic or rubber parts may cause damage to the parts Place a clean towel on the above mentioned parts for protection when servicing the brake system Keep the brake fluid beyond reach of children chapter Contents SYM Service Precautions e Always use with Sanyang genuine parts and recommended oils Using non designed parts for Sanyang motorcycle may damage the motorcycle Special tools are designed for remove and install of components without damaging the parts being worked on Using wrong tools may result in parts damaged When servicing this motorcycle use only metric tools Metric bolts nuts and screws are not interchangeable with the English system using wrong tools and fasteners may damage this vehicle Clean the outside of the parts or the cover before removing it from the motorcycle Otherwise dirt and deposit accumulated on the part s surface may fall into the engine chassis or brake system
3. Caution Do not damage the steering stem Installation Install a new bottom cone race onto the steering stem Push the cone race until to mounted position Steering stem mounting nut Caution NM cone NS Do not tilt the ball bearing seats as installation Apply with grease onto the ball bearing seats and install steel balls onto the seats Top 26 balls bottom 29 balls 7 Top ball 2 bearing seat hm Bottom ball Steel balls Lubricate the top cone race seat with grease Screw the cone race in to top ball bearing seat till touching and then screw out the cane race 1 4 3 8 turns Torque value 0 25kgf m Caution Check the steering stem that should be rotated V p freely and no clearance in vertical direction Locking 1 4 3 8 turns Steering lock nut Top cone race 13 9 This chapter Contents 13 STEERING FRONT WHEEL SUSPENSION SYM Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body Torque value 1 5kgf m Install in reverse order of removal procedures Top cone race 13 10 SYM 14 REAR WHEEL SUSPENSION Maintenance Information Rear Wheel Troubleshooting Rear Shock Absorber 11 0kgf m a d a i gt Ch m X p a 8 JT E is d w a
4. Piston Apply clean brake fluid to the piston cup and then install the cup onto the piston Install the larger end of the spring onto the master cylinder The master cup s cavity should be face inside of master cylinder when installing the master cup Install the cir clip Caution Never install cup lip in the opposite direction Make sure the cir clip is seated securely in the groove Install the rubber pad into groove properly Cir dp M j 7 1 Sub cup 11 BRAKE SYSTEM Cylinder gauge Micrometer Spring 11 9 This chapter Contents 11 BRAKE SYSTEM Install the rubber pad into the groove correctly Master cylinder Place the master cylinder onto handlebar and install the bolts Install the brake lever and connect leads to brake light switch Connect brake hoses with 2 new washers TEES Hose bolt Tighten the brake hose bolt to the specified torque value Torque 3 5kgf m Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together N m Caution Improper routing may damage leads hoses Brake hose BEBE pipes g Caution Kink of brake leads hose or pipe may reduce brake performance Add specified brake fluid and bleed the system 11 10 SYM This chapter Contents SYM 11 BRAKE SYSTEM Drum Brake To use vacuum cleaner or other alternatives to av
5. SERVICE MANUAL SYM FORWARD This service manual contains the technical data of each component inspection and repair for the SANYANG DD 50 series scooter The manual is shown with illustrations and focused on Service Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the scooter DD 50 series are different from that of the photos pictures shown in this manual the actual vehicle shall prevail specifications are subject to change without notice Service Department Sanyang Indusiry Co LTD How to Use This Manual SYM This service manual describes basic information of different system parts and system inspection amp service for Sanyang DD 50 scooters In addition please refer to the manual contents in detailed for the model you serviced in inspection and adjustment The first chapter covers general information and trouble diagnosis The second chapter covers service maintenance information Th third to the tenth nine chapters covers engine and driving systems The tenth to the fourteenth is contained the parts set of assembly body The fifteenth chapter is electrical equipment The sixteenth chapter is wiring diagram Please see index of content for quick having the special parts and system information All information illustration directions and specifications included in this manual are current as at t
6. i 92 Universal holder Clutch drive belt Belt tooth This chapter Contents 7 TYPE BELT DRIVE SYSTEM KICK STARTER Install the driven pulley that has installed the belt Drive face onto drive shaft Install the clutch with universal holder and then tighten nut to specified torque value Torque value 3 8kgf m Movable Drive Face Removal Remove left crankcase cover Hold generator flywheel with universal holder and then remove drive face nut Remove drive face 7 6 Drive belt Drive shaft This chapter Contents SYM V TYPE BELT DRIVE SYSTEM KICK STARTER Removal Drive face boss Movable drive face Remove movable drive face set and drive belt from crankshaft Remove ramp plate Remove weight rollers from movable face Movable drive face Weight roller Inspection The weight roller is to press movable driven face Weight roller by means of centrifuge force Thus if weight rollers are worn out or damage the centrifuge force will be affected Check if rollers are wear out or damage Replace it if necessary Measure each roller s outer diameter Replace it if exceed the service limit Service limit 15 40 mm This chapter Contents 7 TYPE BELT DRIVE SYSTEM KICK STARTER Check if movable drive face boss is worn or damage and replace it if necessary Measure the outer diameter of drive face boss and replace it if it exceed service limi
7. 5000 rpm Resistance Measurement of Resistor at 20 Resistor 10 20 5W Green Black and Body ground 9 00 10 00 Resistor 5 90 5W Pink and Body ground 5 6 6 20 Front cover 2 Headlight connector Resistor 15 7 This chapter Contents 15 ELECTRICAL EQUIPMENT SYM Voltage Regulator Inspection Voltage regulator Check the each pins of connector on the voltage regulator Inspection Probable cause Check voltage between battery terminal red and ground Blown fuse or poor main switch green contact Check continuity between ground and frame Check charging coil white to ground if its resistance is within 0 2 1 00 Open circuit in alternator charging Check charging illumination coil yellow to ground if its coil or in illumination switch resistance is within 0 2 0 80 If wire circuit check is in normal and there is no loose in the pins of voltage regulator connector then measure the resistance among pins on the connectors of voltage regulator Voltage Regulator White Yellow Red Green A 7 White A Yellow L If the resistance values are abnormal among the pins replace the voltage regulator Caution If the probe is touched by finger then the resistance values will be incorrect It contains semi conductor in circuit so the measured resistance value will be in different if different testers are used Thus these values cannot be judged with standards
8. AC Generator Inspection Remove body cover 4 Disconnect the generator harness connector amas piers Measure the resistance on both charging coil the white to ground and illumination coil the yellow to ground Resistance Measurement 20 Charging coil white green 0 2 1 00 Illumination coil yellow green 0 1 0 80 15 8 This chapter Contents SYM 15 ELECTRICAL EQUIPMENT Ignition System Blue Yellow Black Red Black White 15 9 This chapter Contents 15 ELECTRICAL EQUIPMENT Ignition Coil Inspection e Remove body cover Measure the primary coil resistance Resistance 0 19 0 23KO B Measure the secondary coil resistance Resistance 8 2 9 3KO C D Remove the high voltage coil cap and measure its negative terminal for the secondary coil resistance Resistance 3 1 3 2KQ A D D 15 10 This chapter Contents SYM 15 ELECTRICAL EQUIPMENT Electrical System Circuit Inspection Pulse Generator Exciting Coil Remove body cover Disconnect alternator connector Resistance Measurement 20 C Pulse generator coil blue yellow ground E EET Mrs generator j 4 ato p harness connector 50 2000 NOD E une Exciting yellow ground 400 8000 y TUA CDI Electrical System Circuit Inspection Remove front cover Disconnect the CDI set connector and check its circuit to d
9. Inspect the following items on the removed oil pump e Check if O ring is damaged or softening Check if crankcase interface is damaged Check if pump body is damaged Check if pump gear is damaged Check for oil leaking Caution The oil pump can not be disassembled Oil Pump Installation Install the oil pump onto the crankcase Caution e Apply with some grease onto oil pump O ring e he connection between both oil pump and crankcase has to be installed in position security Tighten the oil pump mounting bolt security Install the oil tube Installation in the reverse order of removal Caution Inspection and adjustment following items as installed The adjustment operation of control cable Air bleeding operation of oil pump Air bleeding operation of oil tube Check each section for leaking chapter Contents 3 LUBRICATION SYSTEM Oil Pump Oil Tube Air Bleeding Caution The oil tube system has to be conducted air bleeding operation because air will clog or restraint oil flowing so that cause serious engine damage Caution After disconnect the oil tube air enters oil tube due to oil leak out without added oil There is why the oil tube and oil pump have to conduct air bleeding operation Tube Oil Pump e t has to add some oil into the oil tank e Place a piece of dry cloth around the oil pump e Disconnect the oil tube e Fill out oil
10. Polluted fuel ot OF 10 2 Lean Mixture Clogged carburetor jet Clogged hose from carburetor to canister Bend squeezed or clogged fuel lines Clogged fuel filter Malfunction of float valve Low fuel level in float chamber Clogged vent pipe Malfunction of fuel pump eo eS SYS Rich Mixture 1 Malfunction of float valve 2 Low fuel level in float chamber 3 Clogged carburetor air injector This chapter Contents SYM 10 FUEL SYSTEM Carburetor Throttle Valve ef upper part Removal Remove the body cover Remove the carburetor upper part throttle valve spring and sealed cap Remove the throttle valve cable from the throttle valve Remove needle clamp and fuel needle Inspection Throttle valve spring Sealed cap r Needle clamp Throttle valve cable a Fuel needle clip Fuel needle Carburetor upper part Washer Throttle valve Installation Place the fuel needle onto the throttle valve and clip it with needle clamp Install the sealed cap carburetor upper part and throttle valve spring Connect the throttle valve cable to the throttle valve Install the throttle valve into the carburetor Caution Align the groove inside the throttle valve with the throttle stopper screw of the carburetor body Tighten the carburetor upper part Install carburetor protector Adjust the free play of throttle valve cable 10 3 This chapter Contents 10 FUEL SYSTE
11. SYM 15 ELECTRICAL EQUIPMENT Charging System White Yellow UJ AC Generator Auto by starter Resistor 10 20 5W Resistor 5 90 30W Current Leakage Inspection Turn the main switch to OFF position and j remove the negative cable terminal from the a Battery terminal battery Connect an ammeter between the negative cable terminal and the battery negative terminal Caution Ammeter n the current leakage test set the current range at larger scale then gradually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse Do not turn the main switch to ON position during test Ammeter If the leaked current exceeds the specified value it may indicate a short circuit Allowable current leakage Less than 1mA Disconnect each cable one by one and take measurement of the current of each cable to locate the short circuit Fuse connector 15 5 This chapter Contents 15 ELECTRICAL EQUIPMENT Charging Voltage Inspection Caution Before conducting the inspection be sure that the battery is fully charged If undercharged the current changes dramatically Use a fully charged battery having a voltage larger than 13 0 V While starting the engine the starter motor draws large amount of current from the battery After the engine is warmed up replace original battery with a fully charged b
12. 05 Measure the OD of piston at the 7 mm from the bottom of the piston Service limit 38 935 mm Calculate the clearance between piston and cylinder Service limit 0 100 mm Measure the ID of piston pin hole Service limit 12 030 Measure the OD of piston pin Service limit 11 970 mm 5 6 The ID of piston pin hole 2 E gt SYM The OD of piston pin This chapter Contents SYM 5 CYLINDER HEAD CYLINDER PISTON Piston Ring Inspection Measure the end gap of each piston ring Service limit 0 40 mm A Caution With the piston push each piston ring into cylinder correctly Connecting Rod Inspection Install bearing and piston pin onto connecting rod small end and then check its clearance Measure the ID of connecting rod small end Service limit 17 025mm Piston Cylinder Installation Install the expanding ring into the groove of 2 ring Align the ring end with the lock pin in the ring groove Install the top ring and the 2 ring onto the ring groove respective A Caution c fid The top ring and the 27 ring can not be L changeable each other 1T top ring 2T 2 ring Push the rings into ring groove and then check rings mating condition If ring could not be push in the ring groove it means that ring groove is dirty or wrong ring groove installation A Caution All rings should be installed with the marks facing up All rings should be replace
13. 1 Remove body cover 2 Disconnect oil gauge wire and connect a jump wire among connector and then turn the main switch to ON position Indicator light up Malfunction of oil gauge Indicator not light up Poor wire connection 3 Disconnect oil gauge connector and check voltage between wire and ground No voltage Voltage Open circuit between e Malfunction of oil oil gauge and gauge Poor connection of oil gauge indicator Blown bulb Removal Installation Remove oil tank Remove oil level switch from the oil tank Install the oil level switch in reverse order of removal procedures Main switch Fuse Indicator RM Oil level switch Main switch Indicator Oil level switch 15 14 This chapter Contents SYM Fuel Unit Removal Installation Remove 4 bolts and floor panel Disconnect fuel unit connector Remove the fuel unit plastic cap Turn the snap ring in CCW direction and then remove the fuel unit Caution Do not bend the float arm Install in reverse order of removal procedures Remark Aligning the slot of fuel unit with the ring of oil tank as installation and then turn the snap ring in CW direction until matching to the arrow Inspection 1 Connect the fuel unit connector Turn the main switch ON Move the float in up and down and make sure that the fuel indicator can be reached to F Full and E Empty position
14. 12 This chapter Contents SYM 15 ELECTRICAL EQUIPMENT Starter Motor Removal Disassembly Remove body cover Remove bolt and oil pump control cable Disconnect starter motor harness connector Remove 2 bolts for separation starter motor and gasket Remove 2 bolts for disassembly the starter motor Armature Motor housing Spring Carbon bracket Front bracket Armature Inspection Check the armature for discoloration or other damage It may be short circuit if dark surface on the shifter found Caution Do not clean the shifter surface with sandpaper Check continuity 1 both the shifter surface and shaft 2 among the shifter surfaces t can be in continuity among the shifter surfaces but both the shifter surface and the shaft can not be in continuity Starter Motor Re Assembly Installation Re assemble and install the starter motor in reverse order of removal procedures 15 13 This chapter Contents 15 ELECTRICAL EQUIPMENT Oil Level Switch Troubleshooting lf the oil level in oil tank is in specified level but the oil level indicator still goes on 1 Remove body cover 2 Disconnect oil gauge wire and turn the main switch to ON position Indicator light up Short circuit between Malfunction of oil indicator and oil gauge gauge Indicator not light up e lf there is no oil in oil tank or low oil level but the oil level indicator still not goes on
15. 18 0mm Allowable limit replace it if below 16 5mm Driving belt width This chapter Contents 2 SERVICE MAINTENANCE INFORMATION SYM Periodical Maintenance Schedule Maintenance 300KM Every Every Every Every kilometer 1000 3000KM 6000KM 12000KM Check item Maintenance New 1 month month 6 month 1 year interval t 1 10 S R ___ erg toe B Engmeoifitercleanng a 4 Oil pump linkage operation ees S Trepessue l 6 Battery inspection 8 Steering handle check f Cushion operation check ft ff fp 10 Every screw tightening check Fit Gear of eheck orleaing Ib 1 12 Sparkplugcheckorchange 1 13 Gear oil cnange Replacement for every 5000km 14 Frame lubrication p amp Exhaustpipe 1 16 Carburetor EP 18 Ignition timing 1 1 1 goldespedchek _ _____ 22 Throttle operation 1 41 1 25 Carbon cleaning for cylinder X head cylinder piston head and exhaust system Have your scooter checked adjusted periodically by your SYM Authorized Dealer to maintain the scooter at the optimum condition Code Inspection cleaning and adjustment R Repl
16. Check if carburetor is pre compression clogged Remove spark plug No foul or discoloration Fouled and discoloration 1 Remove dirt 2 Incorrect spark plug heat range Check if engine over heat Piston and cylinder worn out Lean mixture Poor fuel quality Too much carbon deposited in combustion chamber B odi Continually drive in 5 Ignition timing too advanced acceleration or high speed 1 Too much carbon deposited in combustion chamber Lean mixture Poor fuel quality 4 Lean mixture 1 12 This chapter Contents SYM 1 GENERAL INFORMATION C Engine runs sluggish especially in low speed and idling Check and adjustment Probable causes Fault condition Check ignition timing using ignition lamp Adjust the air screw of carburetor 1 Incorrect ignition timing malfunction of CDI or AC generator Rich mixture loosen the screw Lean mixture tighten the screw Air sucked through carburetor gasket leads 6 Malfunction of main switch 1 Poor heat insulation gasket 3 Poor intake gasket Remove spark plug install 4 Poor carburetor O ring spark plug into spark plug cap and perform spark test against engine ground 1 Spark plug fouled 2 Malfunction of CDI 3 Malfunction of AC generator Good spark o Poor 4 Malfunction of ignition coil 5 Open or short circuit in spark plug D Engine runs sluggish High speed CHECK AND ADJUSTMENT FAULT C
17. DRIVE SYSTEM KICK STARTER Install snap clip and mounting plate onto lock pin Snap clip Replacement of Driven Pulley Bearing Remove inner bearing A Caution Outer bearing f the inner bearing equipped with oil seal on side in the driven pulley then remove the oil seal firstly e If the pulley equipped with ball bearing it has to remove snap clip and then the bearing Inner ball bearing Remove snap clip and then push bearing forward to other side of inner bearing j Inher needle bearing Place new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified grease Specified grease Outer bearing Sealing end Install new inner bearing A Caution Inner bearing Sealing end Its sealing end should be forwarded to outside as bearing installation e Install needle bearing with hydraulic presser Install ball bearing by means of hydraulic presser or driver Install snap clip into the groove of drive face Align oil seal lip with bearing and then install the new oil seal if necessary 7 13 This chapter Contents 7 TYPE BELT DRIVE SYSTEM KICK STARTER Installation of Clutch Driven Pulley Oil seal Assembly Install new oil seal and O ring onto sliding pulley Apply with specified grease to lubricate the inside of sliding pulley Install sliding pulley onto driven pulley Oil seal Install guide pin and guide pi
18. if necessary e Measure the driving belt width Allowable limit 16 5mm Ignition Timing Caution e C D l ignition timing can not be adjusted If the ignition timing is incorrect check the C D I device and the alternator and replace damaged components Check ignition timing with standard instrument Hemowve the right side cooling fan cover Check ignition timing with the timing light When engine speed setting to 1800 rpm and if the mark aligns with F mark then it means that the ignition timing is correct Throttle Valve Operation Check if each steering positions are operated in smooth and handle bar if its operation is smooth as the throttle valve wide opening or fully closed Check throttle cable and replace it if deteriorated twisted or damaged Lubricate the cable if operation is not smooth Measure throttle valve handle free play Free play 2 6 mm 1 8 1 4 in Loosen the mounting nut and turn the free play adjustment nut of the throttle valve handle for adjustment Replace the cable if it can not be adjusted 2 12 SYM p Belt width This chapter Contents SYM 2 SERVICE MAINTENANCE INFORMATION Carburetor Idle Speed Adjustment Caution e Inspection amp adjustment for idle soeed have to be performed after all parts in engine had been adjusted in specification e Idle speed check and adjustment have to be done after engine is being warn up around operates engine from
19. nuts to specified torque Torque value 0 5kgf m Brake arm big indent Wear indicator plate Brake arm Use a brake cleaner to clean brake hub and replace the two brake shoes if brake linings are contaminated Caution Brake efficiency will be reduced if brake linings is contaminated by oil or grease Install spring onto the brake shoes Install the brake shoes to the brake panel one after one and make sure the shoe springs are in correct position Install the wheel 11 12 SYM 12 BODY COVER Body Overview Front Under Spoiler Maintenance Information Front Inner Box Side Covers Floor Panel Luggage Box Front Fender Body Cover Steering Handle Cover Front Cover Under Cover Body Overview 050 FTO5W Handle rear cover Luggage box Handle front cover 5 gt Handle front cover 050 Front cover stripe Front inner upper cover Front cover _ Left side cover Tail light Front inner under cover Front under spoiler Rear fender Front fender Under cover 12 1 12 BODY COVER SYM Body Overview FTO5T 05 Handle front cover FTO5V Handle rear cover Luggage box Front inner Battery cover upper cover Handle front cover FTOST Front cover stripe Front cover Frame number cover Front inner under cover Front under spoiler Floor panel Re
20. of rear brake drum 95 0 95 5 Thickness of front brake lining Thickness of rear brake lining Torque values Brake hose bolt 3 5kgf m Bolt for brake caliper 3 3kgf m Bolts for the lining guide pin 1 8kgf m Bolts for the lining guide pin cap 1 0kgf m Air bleed valve 0 55kgf m Bolts for the brake disc 4 5kgf m Nuts for the wheel rim 2 5kgf m Nuts for the front wheel 6 0kgf m Nuts for the rear wheel 11 0kgf m Bolt for rear brake arm 0 55kgf m 11 4 This chapter Contents SYM 11 BRAKE SYSTEM Troubleshooting Disc Brake Soft brake lever Hard operation of brake Tight brake 1 Air inside the hydraulic lever 1 Dirty brake lining disc system 1 Blocked brake system 2 Poor wheel alignment 2 Hydraulic system leaking 2 Poor brake caliper 3 Deformed or warped brake 3 Worn master piston 3 Blocked brake pipe disc S O ARG 4 Seized worn master ee caper cylinder piston Brake noise 5 Bent brake lever 1 Dirty lining e 2 Deformed brake disc 3 Poor brake caliper 9 Warp bent brake disc preven retaliation 10 Bent brake lever 1 Dirty brake lining disc 2 Poor wheel alignment 3 Clogged brake hose WIE 4 Deformed or warped brake disc 5 Restricted brake hose and fittings Drum Brake Poor brake performance Tight operation or low Brake noise 1 Improper brake adjustment return speed of brake 1 Worn brake lining 2 Worn brake lining 2 Worn dr
21. on the scooter Please refer to Chapter 15 for the relative alternator inspection Torque value Flywheel 3 8kgf m Tool General tool Rotor puller Universal holder Coil resistance value for the A C alternator Earth SYM 6 ALTERNATOR Alternator Removal Remove the body cover Remove two bolts and then take out cooling fan Remove four bolts and then take out the cooling fan Hold flywheel with universal holder Support the flywheel and the remove the 10 mm nut on the flywheel 10mm flanged nut 7 Remove the flywheel with rotor puller Rotor puller This chapter Contents 6 ALTERNATOR SYM Disconnect alternator wire connector and pulse generator connector Wire harness connector Remove the pulse generator and alternator four 4 bolts and then take out the alternator assembly Caution Care to be taken for not damaging the alternator coil Alternator Installation Install the alternator assembly Connect the alternator connector Caution Connect the alternator wire harness properly and then clip the harness with clipper T Install the woodruff key onto the crankshaft J 10mm flanged nut groove Caution Clean dirt and metal pieces inside the flywheel Make sure that there is no foreign material inside the flywheel Install the flywheel Tighten the flywheel 10 mm nut Torque value 3 8kgf m Install
22. rear sides by two hands and then lift up the box to remove it 2 Installation e Install in reverse order of removal procedures Oil tank cap 12 5 This chapter Contents 12 BODY COVER Body Cover 1 Removal Remove 3 bolts from rear carrier and then remove rear carrier Remove the luggage box Remove 4 screws from the two side cover and then remove the side cover 4 screws from the both sides 12 6 SYM 12 BODY COVER Remove 1 screw from the front side Remove the body cover 2 Installation e Install in reverse order of removal procedures 12 7 This chapter Contents 12 BODY COVER Front Cover 1 Removal Remove 2 screws from the inner cover and front cover Remove 1 screw from the front cover Push the front guard up and then remove it 2 Installation e Install in reverse order of removal procedures 12 8 This chapter Contents SYM 12 BODY COVER Front under Spoiler Removal Remove the front cover and right left side cover Remove 4 screws from the front inner box e Remove 2 screws from the front upper part of the front spoiler and the front inner Remove front wheel bolt and wheel e Remove 2 screws from the lower part of the front spoiler e Remove the front spoiler 2 Installation Install in reverse order of removal procedures 12 9 This
23. resistor to make sure that the auto by starter is in normal Engine is running If the resistor is in open circuit then current will not flow into the PTC Thus the auto by starter is not operated However if the resistor is in short circuit current higher than specification will flow into the PTC Then it will cause the fuel rich circuit close rapidly and difficult to start the scooter Resistance value 10 20 Automatic By Starter Removal Installation Remove the cover of the auto by starter Remove screw and mounting plate Remove the auto by starter from carburetor Install in the reverse order of removal procedures 10 5 10 FUEL SYSTEM SYM Float Float Valve Jet Removal Remove the float from carburetor body Remove the float pin and then remove float and float valve Check the valve seat for worn out or damage Check float for bend and if fuel inside the float Before removing both the throttle valve stopper and air screws record their original turns for close to their original set up position as installation X Caution damaging the valve seat Remove main jet needle jet seat and idle jet and H X A clean them and each component with 77 m M s D circuit compressed air slants xir inlet for idle speed Install the idle jet the needle jet seat and main jet n Then install the throttle valve stopper and air screws to their origi
24. seal has to be replaced with new one after assembled the crankcase Limit mm Lateral clearance of the big end of the connecting rod 0 60 Radial clearance of the big end of the connecting rod 0 04 Crankshaft run out point A 0 10 Crankshaft run out point B 0 10 Special Tools Crankcase disassemble tool SYM 1120100 G5 Outer bearing puller SYM 6204010 R Crank shaft puller SYM 1130000 R R Crank shaft install bush SYM 1 130020 L Crank shaft puller SYM 1130000 L L Crank shaft install bush SYM 1130010 20 32 6 Oil seal driver SYM 9120200 Bearing driver 6204 SYM 91 10400 Troubleshooting Engine noise 1 Worn bearing of connecting rod bog end 2 Bend connecting rod 3 Worn crankshaft bearing This chapter Contents 9 CRANKCASE CRANKSHAFT SYM Crankcase Disassembly Remove the crankcase bolts Install the crankcase puller onto the right crankcase with two 2 bolts 6mm as the diagram shown Disassemble the right crankcase Crankshaft Removal As the diagram show with 3 special bolts to install the crankcase puller onto the left crankcase Remove the crankcase Caution Do not use iron hammer to knock out the crankshaft Remove crankshaft bearing with outer bearing puller Remove the right and left side oil seals Caution Replace the oil seal with new one as removing the crankshaft n F Spec al bolts Shaft protection
25. the removed parts in reverse order of removal procedures otart engine and check its ignition timing 6 4 SYM 7 V TYPE BELT DRIVE SYSTEM KICK STARTER Maintenance Information 7 2 757 75 2517 7 57 0 T 7 5 Trouble 7 2 Movable Driven Pulley 7 6 Left Crankcase Cover 7 3 Clutch Driven Pulley 7 10 Reassembly of Kick Starter 7 4 Installation of the Left Crankcase Cover TO 7 4 This chapter Contents 7 V TYPE BELT DRIVE SYSTEM KICK STARTER SYM Maintenance Information Precautions in Operation The surfaces of drive belt and driven pulley must be free of grease Specification Standard value mm ID of movable driving pulley 20 035 20 085 OD of movable driving pulley boss 20 010 20 025 19 98 OD of weight roller 15 92 16 08 o 15400 ID of clutch outer 107 0 107 2 107 5 OD of driven pulley 33 965 33 985 3394 ID of movable driven pulley 34 000 34 025 3406 ID Inner Diameter OD Outer diameter Torque Values Special Service Tools Movable drive face 3 8kgf m Clutch spring compressor Driven pulley 5 5kgf m Bearing driver Clutch outer 3 8kgf m Clutch nut wrench 39x41 mm Bearing driver accessory 39x41 mm Universal holder Driver Trouble Shooting Engine ca
26. to cause a damage Wash and clean parts with high ignition point solvent and blow dry with compressed air Pay special attention to O rings or oil seals because most cleaning agents have an adverse effect on them e Never bend or twist a control cable to prevent stiff control and premature worn out 1 GENERAL INFORMATION Rubber parts may become deteriorated when old and prone to be damaged by solvent and oil Check these parts before installation to make sure that they are in good condition replace if necessary When loosening a component which has different sized fasteners operate with a diagonal pattern and work from inside out Loosen the small fasteners first If the bigger ones are loosen first small fasteners may receive too much stress otore complex components such as transmission parts in the proper assemble order and tie them together with a wire for ease of installation later Note the reassemble position of the important components before disassembling them to ensure they will be reassembled in correct dimensions depth distance or position Components not to be reused should be replaced when disassembled including gaskets metal seal rings O rings oil seals snap rings and split pins Caution In addition to damaging paint finish brake oil can also damage the structural integration of plastic or rubber parts 1 3 chapter Contents 1 GENERAL INFORMATION SYM e
27. wheel axle into the wheel and the install the wheel axle nut Tighten the nut to specified torque Torque value 6 0kgf m Connect the speedometer cable to the speedometer gear Shaft nut p 7 Speedometer cable 13 7 This chapter Contents 13 STEERING FRONT WHEEL SUSPENSION SYM Front Shock Absorber Hose clamp Removal e Front cover Front under spoiler Front fender e Front wheel Disc Brake a amy f Cableclamp Remove the caliper mounting bolts and the pi d E xu caliper Take out the hose from hose clamp Remove the hose clamp mounting bolt and the clamp Drum Brake Hemove the cable clamp mounting bolt and the clamp Remove the front shock absorber upper bolt and the shock absorber Installation Align the cover flange with upper level of the shock absorber clamp and then tighten bolts Torque value 2 7kgf m Install the removed components in reverse order of removal procedures 13 8 This chapter Contents SYM 13 STEERING FRONT WHEEL SUSPENSION Front Fork Steering stem Removal mounting nut Handle Front wheel Front shock absorber Remove the steering stem mounting nut Remove top cone race and front fork Caution M A d Place the steel ball onto a parts container to ey E prevent from missing ae Slightly tap the top and bottom ball bearing seats with a plastic hammer to remove the seats Remove bottom cone race body with a punch
28. wheel axle nut is not tightened The ball and the top cone of the steering improperly shaft are damaged 3 Bend wheel rim 4 Insufficient tire pressure Side worn or poor tire 5 bearing play of the wheel axle 15 too The Steering Handle Is Tilted large 1 Uneven arrangement of the front shock absorbers Soft Shock Absorber 2 The front fork is bent 1 Weak front shock absorber spring 3 front wheel axle is bent Noise In Front Shock Absorber 1 Shock absorber outer tube noise 2 The joint of the shock absorber gets loose 13 2 This chapter Contents SYM 13 STEERING FRONT WHEEL SUSPENSION Steering Handle Removal Remove handle cover front cover and inner box Remove throttle grip after mounting screw removed Remove master cylinder disc brake after 2 bolts removed Remove rear brake lever bracket after mounting bolt removed Remove handle mounting bolt and nut and then remove the handle Installation Install handle and align with bolt hole Install bolt and nut and then tighten it Torque value 4 5kgf m Apply with grease onto throttle cable and the sliding surface of handle Align the lock pin of the handle outer tube with the hole on the handle and then install the handle Tighten the bolt Caution Align the lock pin with the hole on the handle and also install brake lever seat Then tighten the lever with clamp and bolt Master cylinde Rear brake lever
29. 0 10 42J 1 8 00 10 42J 1 75 2 0 Tire pressure cold kg cm Check if the tire tread and wall rubber for crack or damage and replace if necessary Check if foreign materials such as nail metal pieces and stones stuck on tire The thread depth can be checked by visual inspection or by a depth gauge tread bend too much replace the tire lf tire wear exceeds limitation replace the tire and check it for un even wear X Caution Wear indicator A is distributed on average UN Wear indicator along the wall rubber for check Battery Open the seat Loosen two screws of battery cap and then remove the cap Check if the battery terminals loosen Remove the battery if its terminals are corroded obviously Battery Removal 1 Remove the Negative battery cable at first 2 Then remove the Positive battery cable 3 Remove the battery Clean the rust with steel brush Install the battery in reverse order of removal and apply with grease onto two terminals Caution The electrolyte is contained sulfuric acid so be careful not to let it touch to eyes skin or clothes If touched by accident flush them with clean water immediately However if the electrolyte sprays to eyes medical care should be done quickly 2 6 chapter Contents SYM 2 SERVICE MAINTENANCE INFORMATION Rear Brake Free Play Drum Brake Type Measure the free play of t
30. 3kgf m Install the removed parts in the reverse order of removal procedures Inspect following item after installation Compression pressure test Check for engine noise 5 4 This chapter Contents SYM 5 CYLINDER HEAD CYLINDER PISTON Cylinder Piston Cylinder Removal Be careful to pull the cylinder up and prevent piston from damage A Caution Do not have pry out operation between cylinder and crankcase Or let radiation fan be knocked seriously Piston Removal Place a clean rag onto crankshaft to cover the piston Remove piston pin clip one piece and then push piston pin out the piston A Caution Do not damage or scratch the piston Do not apply with lateral force to connecting rod Do not let piston pin snap ring falling into crankcase Piston Ring Removal A Caution Pry out the opening end of each piston ring and then remove the ring from piston Check if cylinder and piston are worn or damaged and then clean carbon deposit on exhaust opening area as the diagram shown A Caution Do not scratch both the cylinder and the piston This chapter Contents 5 CYLINDER HEAD CYLINDER PISTON Use a straight edge and a feeler gauge to measure the cylinder head for warp Service limit 0 10 mm In X and Y direction measure the cylinder for worn out as the three levels shown in the figure With the max value to decide cylinder wear out condition Service limit 39
31. LUBRICATION SYSTEM ENGINE REMOVAL CYLINDER HEAD CYLINDER PISTON ALTERNATOR V TYPE BELT DRIVING SYSTEM KICK STARTER FINAL DRIVING MECHANISM CRANKCASE CRANKSHAFT FUEL SYSTEM BRAKE SYSTEM BODY COVER STEERING FRONT WHEEL SUSPENSION REAR WHEEL SUSPENSION ELECTRICAL EQUIPMENT ELECTRICAL DIAGRAM E EOM BUM EE 9 og EUM EM NUR MODEL ILLUSTRATION SYM FTOSV Light Starter switch Front turn signal Helmet hook High amp Low beam Turn signal Horn switch Battery Fuses C D I Fuel tank cap Eng Oil tank cap Head light Tail light Rear turn signal Storage box Air cleaner Frame number SYM MODEL ILLUSTRATION SYM 1 GENERAL INFORMATION Symbols and Marks 1 1 Torque 1 6 General Safety 1 2 Cables and Harness Routing 1 8 Service Precautions 1 3 Troubleshooting 1 11 Specifications Lubrication Points 1 15 Symbols and Marks oymbols and marks are used in this manual to indicate what and where the special service are needed in case supplemental information is procedures needed for these symbols and marks explanations will be added to the text instead of using the symbols
32. M Carburetor Remove Remove the body cover Disconnect the auto by starter connector Auto by starter Loosen draining screw and then drain out fuel Carburetor inside the carburetor A Ap upper part Loosen carburetor upper part and remove un carburetor upper part Remove fuel and oil hoses from carburetor Remove carburetor mounting bolt and carburetor Auto By Starter Inspection FEIA Connect resistor meter to the terminals of auto by starter and then measure its resistance If the resistance value exceeds specification too much it means that the PTC in the auto by starter is malfunction Then replace the auto by starter Resistance value Max 100 at cold engine Caution If the resistance value exceeds the standard a little bit the auto by starter may still in normal However it is necessary to check other relative components for damage 10 4 This chapter Contents SYM 10 FUEL SYSTEM Remove carburetor and allow it to cool off for 30 minutes Connect fuel rich circuit with a hose and pump compressed air to the hose Air should flow into fuel rich circuit Replace the auto by starter if the circuit clogged Connect battery to starter s connectors and wait for several minutes Pump compressed air into the fuel rich circuit Air should not flow into the circuit If air flow through the circuit then replace the Nhe starter a Battery Check
33. MENSION WEIGHT e 5 O PERFORMANCE ENGINE Cylinder ION og C O 1 5 This chapter Contents 1 GENERAL INFORMATION SYM Torque values Standard Torque Values for Reference The torque values listed in below table are for more important tighten torque values Please see above standard values for not listed in the table Engine Crankcase bolts 1 6 This chapter Contents SYM 1 GENERAL INFORMATION Frame Thread Dia Torque Value Item Remarks mm Kgf m Mounting screws for exhaust pipe connection Brake hose bolts wm res Brake cushion guide bolts eme pa o 1 4 s a AA l Le ___ 4 ____ ___ _ ce 1 4 25 ____ 1 7 This chapter Contents 1 GENERAL INFORMATION SYM Cables and Harness Routing Note the following when routing cables and wire harnesses X A loose wire cable or harness may cause safety hazard After clamping check each wire to make sure it is secured Do not squeeze wires against the weld or its clamp SN Secure wires and wire harnesses to the frame with respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses Route harnesses so that they neither pu
34. ONDITION PROBABLE CAUSES Check ignition timing 2 Malfunction of AC generator Check for fuel supplying system in automatic fuel cup Check if carburetor clogged 1 Insufficient fuel in fuel tank Fuel filter clogged Restricted fuel tank vent 1 13 This chapter Contents 1 GENERAL INFORMATION SYM E CLUTCH DRIVING AND DRIVING PULLEY FAULT CONDITION PROBABLE CAUSES 1 Driving belt worn out or deformation 2 Driving disk damaged 3 Driving pulley spring broken Engine can be started but motorcycle can be driving 4 Clutch ling broken 5 Driving slide shaft gear groove broken 6 Transmission gear damage 7T Transmission gear worn out or burned Engine running and misfire as 1 Clutch ling spring broken motorcycle initial forward moving or jumping sudden rear wheel 2 Clutch outer cover stuck with clutch balance weights rotating as engine in running 3 Connection parts in clutch and shaft worn out or burned 1 Driving belt worn out or deformation Poor initial driving Poor climbing 2 Balance weight roller worn out performance 3 Driving sliding gear shaft worn out 4 Driving disk spring deformation 5 Driving sliding gear shaft worn out 6 Greased in driving belt and sliding gear 1 14 This chapter Contents SYM 1 GENERAL INFORMATION Lubrication Points 7 Throttle cable Front amp rear brake lever pivot Engine suspension bushing Seat lock S Steering shaft bear
35. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out Close the drain valve and add specified brake fluid into the brake master cylinder Recommended brake fluid WELLRUN DOT 3 brake fluid Caution To reuse the spent brake fluid will effect brake performance 11 6 SYM Cap 8 X Cap plate Pu lau jin m UE M a Em E L i m am i d Diaphragm Upper leve Air bubble gt Connect one end of transparent hose to the drain valve and put the other end into a container Open the drain valve around 1 4 turns and at the same time hold the brake lever until the there is no air bubble in the drain hose and also feeling resistance on the brake lever Close the drain valve when finishing the brake system refilling fluid procedure and operate the brake lever to check whether air bubble is in brake system or not If brake is still soft please bleed the system as described below This chapter Contents SYM Disc Brake Air Bleed 1 Tightly hold the brake lever and open the drain valve around 1 4 turns and then close the valve Caution Do not release the brake lever before the drain valve is closed Always check the brake fluid level when carrying out the air bleeding procedure to avoid air enter into the system 2 Slowly release the brake
36. TENANCE INFORMATION Fuel Filter Remove the luggage box Remove the fuel line from the fuel filter Replace the fuel filter with new one Install the fuel filter The arrow indicates the fuel flowing direction Check the fuel line for leaking Engine Oil Line Remove the body cover Check the engine oil line and replace damaged parts Remove the filling pipe from the oil pump and drain oil into a cleaning container Loosen the clamp under the engine oil tank and then remove the oil pipe Bleed the air inside the oil pump and oil pipe if air found Install the body cover Oil pump LU omy 2 4 in hs This chapter Contents SYM 2 SERVICE MAINTENANCE INFORMATION Oil Pump Control Cable Caution To adjust the oil pump control cable after adjusted the throttle grip play Remove the body cover Wide open the throttle valve and check if the calibration point aligns on the oil pump lever with the mark of pump T the adjustment nut of the oil pump control aul 7 ed Turn the adjustment nut and align with the point then tighten the nut This chapter Contents 2 SERVICE MAINTENANCE INFORMATION Tire Caution Tire pressure should be checked when cold Check tire for cracks damage nail or other object stuck in tread Recommended tire and tire pressure Front Rear 3 0
37. The length of bolts and screws for assemblies The ends of rubber hoses for fuel vacuum or cover plates or boxes is different from one coolant should be pushed as far as they can go another be sure they are correctly installed In to their connections so that there is enough case of confusion Insert the bolt into the hole to room below the enlarged ends for tightening the compare its length with other bolts if its length clamps out side the hole is the same with other bolts it is a correct bolt Bolts for the same assembly should have the same length e Rubber and plastic boots should be properly reinstalled to the original correct positions as designed e Tighten assemblies with different dimension fasteners as follows Tighten all the fasteners with fingers then tighten the big ones with special tool first diagonally from inside toward outside important components should be tightened 2 to 3 times with appropriate increments to avoid warp unless otherwise indicated Bolts and fasteners should be kept clean and dry Do not apply oil to the threads e When oil seal is installed fill the groove with e he tool should be pressed against two inner grease install the oil seal with the name of the and outer bearing races when removing a ball manufacturer facing outside check the shaft on bearing Damage may result if the tool is which the oil seal is to be installed for pressed against only one race either inner race smoo
38. acement C Cleaning replaced if necessary L Lubrication The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first Remarks 1 Clean or replace the air cleaner element more often for pro long engine life span when the scooter is operated on dusty roads or in the Heavily polluted environment 2 Maintenance should be performed more often if the scooter is frequently operated in high speed and after the scooter has accumulated a higher mileage Reference 2 2 This chapter Contents SYM 2 SERVICE MAINTENANCE INFORMATION Air Cleaner e Remove the mounting screw from the air cleaner cover e Remove the air cleaner cover Remove the air cleaner element Clean the element with non flammable or high flash point solvent and then squeeze it for dry Caution Never use gasoline or acid organized solvent to clean the element ooap the element into cleaning engine oil and then squeeze it out Install the element onto the element seat and then install the air cleaner Limit to use SAE 20 class engine oil otherwise SYM is no responsible for the warranty Recommended engine oil MAX 2 serial oils Squeeze oil out Fuel Lines Remove the body cover Check fuel lines and replace damaged lines if found Install the body cover Squeeze out remaining oil Fuel line This chapter Contents 2 SERVICE MAIN
39. adi a NS 3 3kgf m 14 1 This chapter Contents 14 REAR WHEEL SUSPENSION Maintenance Information Specification Rear wheel rim run out pw 2 0 0 08 in Torque Value Rear shock absorber upper mounting bolt 4 0kgf m Rear shock absorber lower mounting bolt 2 7kgf m Rear wheel nut 11 0kgf m Rear wheel hub 2 5kgf m Exhaust muffler nut 1 2kgf m Exhaust muffler bolt 3 3kgf m Troubleshooting Rear wheel wobbling 1 Bend wheel rim 2 Poor tire 3 Loosen wheel shaft Shock absorber too soft 1 Insufficient shock absorber spring force Poor brake performance Poor brake adjustment Contaminated brake lining Worn brake lining cam Worn brake cam lever Worn brake drum Improper installation of brake arm gear set Sa eS 14 2 This chapter Contents SYM Rear Wheel Remove Remove exhaust pipe nut 2 connection nuts Remove exhaust muffler bolt 2 bolts then remove the muffler Remove rear wheel shaft nut and then remove the rear wheel Inspection As the diagram shown measure wheel rim wobbling with a dial gauge Service limit Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in Brake Hub Replacement Remove 4 nuts of cover and wheel rim and then remove the wheel hub Install the wheel hub and tighten the nuts Tighten torque 2 5kgf m 14 REAR WHEEL SUSPENSION Hub nut Shaft nut Connection nuts 14 3 This chapter Contents 14 REAR WHEEL SUSPENSION Inst
40. aining bolt Tighten torque 1 3 kgf m Caution Check if oil seal and washer is in good condition Replacement Quantity 0 09 L 90 cc Recommended oil King Bramax HYPOID GEAR OIL 140 Spark Plug Recommended plug NGK BR8HSA e Remove the luggage box Remove the spark plug cap Clean any dirt on the spark plug seat Remove the spark plug Visually inspect the spark plug electrodes for wear The center electrode should have square edges and side electrode should have Center electrode constant thickness Replace the spark plug if there is apparent wear or if the insulator is cracked and or chipped If the spark plug deposits can be removed by sandpaper the spark plug can be reused Measure the spark plug gap with feeler gauge Spark plug gap 0 6 0 7mm 0 024 0 028in Adjust the gap by careful bending the side electrode e Install the spark plug by screwing it with hands after installed the spark plug washer so that can prevent the plug from out of thread Then tighten the spark plug with a spark plug wrench e Install the spark plug cap Side electrode 2 11 This chapter Contents 2 SERVICE MAINTENANCE INFORMATION Control Cable Lubrication Remove the throttle control and the brake cables periodically and lubricate the moving parts of the Tooth face cables thoroughly Driver Belt e Remove left crankcase cover e Check if the belt is crack or worn out Replace the belt
41. all in reverse order of removal procedures Caution Push the front connection part of rear handle cover at first when removing front cover so that the buckles are out of the cover Never push it forcefully to cause buckles broken or cover damaged 12 12 This chapter Contents SYM 12 BODY COVER Under Cover 1 Removal e Remove the right and left side cover Remove 2 bolts from the under cover e Remove under cover 2 bolts 2 Installation Install in reverse order of removal procedures 12 13 12 BODY COVER Note 12 14 SYM 13 STEERING FRONT WHEEL SUSPENSION Maintenance Information Front Wheel Troubleshooting Front Shock Absorber Steering Handle Front Fork 3 3kgf m 2 7 kgf m 6 0kgf m 13 1 SE This chapter Contents 13 STEERING FRONT WHEEL SUSPENSION SYM Maintenance Information Specification Shaft bending oom 0 2 0 01 in ma Rim wobbling su Torque Value oteering handle nut 45kgf m Front brake caliper bolt S3kgf m Front wheel axle 6 0kgf m Steering stem mounting nut 1 5kgf m Front shock absorber mounting nut 2 7kgf m race 0 25kgf m Special Tools Inner bearing puller Bearing driver Troubleshooting Hard To Steer The Front Wheel Wobbling 1 steering shaft bolt is too tight 1 The rim is bent 2 steering shaft bearing are damaged 2 The
42. allation Shaft nut Install the rear wheel and tighten the nut Tighten torque 11 0kgf m Install exhaust pipe amp muffler Tighten torque bolt 3 3kgf m Tighten torque nut 1 2kgf m Rear Shock Absorber Removal Remove body cover Remove air cleaner Remove rear shock absorber upper amp lower bolts Remove rear shock absorber Installation Install the rear shock absorber Tighten the upper amp lower mounting bolts to specified torque Torque value Upper mounting bolt 4 0kgf m Lower mounting bolt 2 7kgf m Press down the tail of the scooter for several times to check shock absorber operation Installation all components in reverse order of removal procedures Install air cleaner 14 4 15 ELECTRICAL EQUIPMENT Starting System Oil Level Switch Fuel Unit Switch Horn Bulb Replacement Reg Rec Comp Resistor Comp Horn _ CDI Unit Main Switch A Start Headlight Switch Winker Relay Horn Winker Dimmer Switch Fuel Unit AC Generator Spark Plug Start Relay Fuse Box Battery Oil Level Switch 15 1 This chapter Contents 15 ELECTRICAL EQUIPMENT SYM Maintenance Information Precautions in Operation e When remove the battery the disconnection sequence of cable terminals shall be strictly observed First disconnect the negative cable terminal next the positive cable terminal e The model of the spark plug and the tight
43. ar fender Under cover 12 2 SYM 12 BODY COVER Maintenance Information Body covers disassemble sequence Handlebar Rear Cover Front Spoiler Front Fender Front Inner Cover Luggage Box Seat Handlebar Front Cover Left Right Side Cover Body Cover Rear Fender Left Right Side Cover Floor Panel e careful not to damage various covers in disassembly or re assembly operation Never injure hooks molded on the body covers in disassembly or re assembly operation e Align the buckles on the guards with slot on the covers e Make sure that each hook is properly installed during the assembly Never compact forcefully or hammer the guard and the covers during assembly 12 3 This chapter Contents 12 BODY COVER Side Covers 1 Removal Remove 2 screws front middle from two side covers Slide the side cover backward so that their hooks are out of slots Take out the side cover end part and then remove the cover 2 Installation e Install in reverse order of removal procedures Caution The tail of each cover is held with buckles and slot never pull them with force or it would crack the buckles 12 4 SYM 12 BODY COVER Luggage Box 1 Removal Lift up seat cushion e Remove luggage box mounting screws 1 screw e Remove luggage box bolts 4 bolts e Remove oil tank cap and oil guide rubber e Hold the luggage box in both front and
44. arts Headlight Front winker light Remove front cover Remove front winker light lens Replace front winker light bulb Install the all removed parts Tail light Brake light Rear winker light Remove 2 screws and then remove outer cover Remove 2 screws and then remove inner cover Replace tail light or winker light bulb Install the all removed parts Inner cover Screws 15 18 SYM 16 ELECTRICAL DIAGRAM Wvaovid 121410919 OS 16 1 16 ELECTRICAL DIAGRAM SYM Notes 16 2
45. ation Replace the brake lining if the wear limit mark Brake disc closed to the edge of brake disc Caution In order to maintain brake power balance the brake lining must be replaced with one set 2 6 This chapter Contents SYM 2 SERVICE MAINTENANCE INFORMATION Remove the pin bolt cap Loosen the bolt Remove the front wheel shaft bolt Take out the front wheel Remove brake caliper mounting bolt and then remove the brake caliper Caution Do not operate the brake lever after the clipper removed to avoid clipping the brake lining Pry out the brake lining with a flat driver if lining is clipped Remove brake lining bolt Take out the lining Tighten Torque Mounting bolt 2 9 3 5 kgf m Pin bolt 1 5 2 0 kgf m Pin bolt cap 0 8 1 2 kgf m The brake light switch is to light up brake light as brake applied Replace the switch if the light does not light up in properly Caution The brake light switch is un adjustable poe Mounting bolt Brake lining am aum a rt J AT 2 Pin bolt This chapter Contents 2 SERVICE MAINTENANCE INFORMATION SYM Steering System Caution The control cables can not interfere with the rotation of steering handle Lift the front wheel out of ground and check if the steering handle turning is smoothly If handle turning is uneven and bending stuck or the handle can be operated in vertical direct
46. attery Connecta digital voltmeter to the battery terminals Connect an ammeter between both ends of the main fuse Caution When the probe is reversibly connected use an ammeter having an indication that shows both positive and negative direction current The measurement would be at zero if the ammeter is one direction only Caution Do not use short circuit cable e It is possible to measure the current by connecting an ammeter between the battery positive terminal and the cable position terminal however while the starter motor is activated the surge current of the motor draws from the battery may damage the ammeter Use the kick starter to start the engine The main switch shall be turned to OFF position during the process of inspection Never tamper with the ammeter and the cable while there is current flowing through It may damage the ammeter Connect a tachometer Turn on the headlight to high beam and start the engine Accelerate the engine to the specified revolution per minute and measure the charging voltage Specified Charging Current 1 2 A 5000 rpm Control Charging Voltage 14 0 15 0 V 5000 rpm 15 6 SYM X Caution with the same current and voltage The following problems are related to the charging system follow the instructions provided in the checking list to correct it if any one of the problems takes place 1 The charging voltage can not exceed the voltage betwee
47. by spark plug e The spark plug is out of work e cable is poorly connected open or short circuited Between AC G and C D I e Poor connection between C D I and ignition coll Poor connection between C D I and the main switch Poor main switch e Poor AC G is out of work Starter motor does not work e The fuse is blown e The battery is not fully charge Poor main switch Poor starter switch e The front and rear brake switches do not operate correctly e Starter relay is out of work e The ignition coil is poorly connected open or short circuited e The starter motor is out of work 15 ELECTRICAL EQUIPMENT Intermittent power supply e The connector of the charging system becomes loose Poor connection of the battery cable Poor connection or short circuit of the discharging system Poor connection or short circuit of the power generation system Charging system does not operate properly Burnt fuse Poor contact open or short circuit Poor regulator Poor ACG Engine does not crank smoothly e Primary coil circuit Poor ignition coil Poor connection of cable and connectors Poor main switch e Secondary coil circuit Poor ignition coil Poor spark plug Poor ignition coil cable Current leakage in the spark plug cap e Incorrect ignition timing Poor AC G Improper installation of the pulse sensor Poor C D I Weak starter motor Poor chargi
48. chapter Contents 12 BODY COVER Front Inner Box 1 Removal e Remove the front cover e Remove the front under spoiler e Remove 2 bolts from the floor panel e Remove 5 screws of the fuel filling cap Remove hook and 1 screw Hook amp 1 screw Hemove 1 screw from main switch cover Hemove main switch cover Hemove the front inner box 2 Installation e Install in reverse order of removal procedures 12 10 This chapter Contents SYM 12 BODY COVER Floor Panel 1 Removal Remove the luggage box rear carrier right left side covers and body cover Remove 4 plugs of the floor panel e Remove the floor panel 4 bolts 2 Installation e Install in reverse order of removal procedures Front Fender 1 Removal e Remove speedometer cable screw and cable Remove front wheel bolt and then remove the wheel e Remove 3 screws of front fender Remove the front fender 3 Screws 2 Installation e Install in reverse order of removal procedures 12 11 This chapter Contents 12 BODY COVER Steering Handle Cover 1 Removal e Remove 1 screw under front light Remove 3 screws from the handle rear Remove handle front cover Hemove 2 inner screws e Disconnect each switch connectors e Remove speedometer cable Remove rear handlebar guard e Remove handle rear cover and meter 2 Installation e Inst
49. collar 9 3 This chapter Contents 9 CRANKCASE CRANKSHAFT SYM Crankshaft Inspection Measure the clearance of connecting rod big end Service limit 0 60 mm Measure the radial clearance of connecting rod big end at X Y directions as diagram show Service limit 0 04 mm Place the crankshaft on a V block measure run out points and B of the crankshaft with dial gauge Service limit A 0 10 mm B 0 10 mm Check the crankshaft bearing by means of turning it with hand If any noise and bigger clearance are detected replace the bearing with Dee 1 Clearance new one 16 Lateral Radial This chapter Contents SYM 9 CRANKCASE CRANKSHAFT Crankcase Installation CE Clean the crankshaft with solvent and blow it with Bearing driver 6204 compressed air Then check for damage or other foreign materials attached Install new bearing into right crankcase Caution All rotation and sliding surfaces have to be applied with clean engine oil Remove all gaskets onto the crankcase interfaces and flat it with special tool Install new bearing into left crankcase i TIEN Bearing driver 6204 Install crankshaft onto the left crankcase Ff Uma L Crank shaft puller Install left crankshaft puller and install bush onto U crankshaft Collar Screw the left crankshaft puller onto crankshaft Turn the puller in C W direction and then completely screw the puller to bottom Lubrica
50. d at same time and it can not be replaced one ring only It should use same brand name piston ring in an engine and can not mix with other one 5 7 This chapter Contents 5 CYLINDER HEAD CYLINDER PISTON SYM Place a cleaning cloth onto the crankcase opening to prevent the piston pin snap ring from falling into the crankcase Apply with two stroke engine oil onto needle bearing and piston pin and then install the piston pin onto connecting rod Install piston and place EX mark of the piston toward to exhaust side Install new piston pin snap ring Clean all gaskets onto the interfaces of cylinder and crankcase Place a new gasket onto the crankcase Make sure that the piston ring aligns with the lock pin in piston ring groove A Caution Make sure that all rings in the piston ring groove can not be rotated around the lock pin to avoid to damaging the rings piston and cylinder Lubricate cylinder and piston with two stroke engine oil Hold the piston and then install it into cylinder A Caution To avoid to damaging the piston and the cylinder sliding surface Install the cylinder head 5 8 SYM 6 ALTERNATOR Maintenance Information 6 2 Alternator Installation Alternator Removal 6 3 3 8kgf m 6 1 This chapter Contents 6 ALTERNATOR SYM Maintenance Information Precautions in Operation e maintenance service of A C alternator can be carried out directly
51. el filter clogged Malfunction of spark plug Spark plug foul Malfunction of CDI set Malfunction of AC generator Ignition coil is in open or short circuit Ignition coil leads open or short circuit Malfunction of main switch Piston ring seized Malfunction of cylinder valves Worn cylinder and piston ring Cylinder gasket leak Sand hole in compression parts Crankcase leakage for pre compression Malfunction of throttle valve operation Air sucked into intake manifold Incorrect ignition timing Fuel level in carburetor too high Malfunction of throttle valve operation Throttle valve opening too wide Malfunction of auto starter 1 11 This chapter Contents 1 GENERAL INFORMATION SYM B Engine run sluggish Speed does not pick up lack of power Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed 1 Air cl Engine speed can Engine speed can not be 2 d increased Increased 3 Lines in fuel tank evaporation system clogged 4 Exhaust pipe clogged Check ignition timing Using ignition lamp Ignition timing correct Incorrect ignition timing 1 Malfunction of CDI 2 Malfunction of AC generator Check cylinder compression pressure using compression pressure gauge 1 Cylinder amp piston ring worn out 2 Cylinder gasket leaked 3 Sand hole in compression parts 4 Valve deterioration 5 Crankcase leakage for
52. engine speed in stable Repeat the operation on step No 2 No 4 until these value within standard range Compression pressure gauge 2 13 chapter Contents 2 SERVICE MAINTENANCE INFORMATION SYM Headlight Adjustment Loosen headlight mounting bolt i Er cu Move the headlight for adjustment its light beam IW WE RET Ern M T Tighten the headlight mounting bolt after DES adjusted Caution Improper headlight beam adjustment will make po w come e ecu UTR HU L LIE TT i i i in coming driver dazzled or insufficient lighting for safety distance E Lj Headlight mounting bolt 2 14 SYM 3 LUBRICATION SYSTEM Lubrication System Diagram 3 1 Oil Pump Removal 3 3 Precautions In Operation 3 2 Oil Pump Installation 3 3 e D LL DI LC I 3 2 Oil Pump Oil Tube Air Bleeding 3 4 Trouble Shooting MT POETE 3 2 3 5 Lubrication System Diagram Cil tank Oil lever switch a Oil tube Cil output tube 3 1 EET chapter Contents 3 LUBRICATION SYSTEM SYM Precautions In Operation e not let dirt enter into engine or oil hoses when removing or installing the oil pump e lf air is found in the oil tube fro
53. ening torque he ignition timing Adjustment of headlight Removal and installation of AC generator he maintenance free battery requires no inspection of electrolyte level and refilling of distilled water e To recharge the battery remove the battery from the motorcycle without removing ventilation caps e Unless in emergency never rapid charge the battery e The voltage must be checked with the voltmeter while charging the battery e As C D I assembly does not require an ignition timing check In case ignition timing is incorrect check C D I and AC generator Verify with an ignition timing light after replacement if necessary he starter motor can be removed after the engine is removed Specification Charging System Capacity 12V3Ah Battery Charging rate 0 4A 5 hours standard 4A 0 5 hour fast charging Charging current 1 2 A 5000 rpm Control voltage in charging 14 0 15 0 V 5000 rpm Control voltage in headlight 12 6 13 6 V 5000 rpm Ignition System Spark plug Ignition coil and resistance Secondary coil 2 8 34 KO Ignition timing F mark 17 BTDC 1800 rpm 15 2 This chapter Contents SYM Troubleshooting No voltage Battery discharged e The cable disconnected e The fuse is blown e Improper operation of the main switch Low voltage e The battery is not fully charged Poor contact e Poor charging system Poor voltage regulator No spark produced
54. g oil seal is damage Replace it if necessary Check if needle bearing is damage or too big clearance Replace it if necessary Rotate the inside of inner bearing with fingers to check if the bearing rotation is in smooth and silent Check if the bearing outer parts are closed and fixed Replace it if necessary A Caution e Some of models are equipped with two ball bearings Clutch weight Free length Driven pulley Sliding pulley Outer ball bearing Guide pin groove 7 11 This chapter Contents 7 V TYPE BELT DRIVE SYSTEM KICK STARTER SYM Clutch Block Replacement Remove clip and washer and then remove clutch weight and spring from drive plate A Caution e Some of models are equipped with one mounting plate instead of 3 snap clips Check if spring is damage or insufficient elasticity Snap clip i Shock absorption Check if shock absorption rubber is damage or rubber deformation Replace it if necessary Apply with grease onto lock pins Install new clutch weight onto lock pin and then Shock absorption rubber push to specific location Apply with grease onto lock pins But the clutch weight should not be greased If so replace it A Caution e Grease or lubricant will damage the clutch weight and affect the weight s connection capacity Clutch block Install the spring into groove with pliers 7 12 This chapter Contents SYM V TYPE BELT
55. h Hold the clutch spring compressor onto bench vise and then remove mounting nut with clutch nut wrench Release the clutch spring compressor and remove clutch and spring from driven pulley Remove socket from sliding pulley Remove guide pin guide pin roller and driven pulley and then remove O ring amp oil seal seat from sliding pulley Sliding pulley Inspection Clutch outer Measure the inner diameter of clutch outer friction face Replace clutch outer if exceed service limit Service limit 107 5 mm diameter 7 10 SYM Clutch nut TOH wrench C Cil seal pM M ark gt Clutch spring m Guide pin T Guide pin roller Clutch outer This chapter Contents SYM 7 V TYPE BELT DRIVE SYSTEM KICK STARTER Clutch weight Measure each clutch weight thickness Replace it if exceeds service limit Service limit 2 0 mm Driven pulley spring Measure the length of driven pulley spring Replace it if exceeds service limit Service limit 92 7 mm Driven pulley Check following items f both surfaces are damage or wear f guide pin groove is damage or wear Heplace damaged or worn components Measure the outer diameter of driven pulley and the inner diameter of sliding pulley Replace it if exceeds service limit Service limit Outer diameter 33 94 mm Inner diameter 34 06 mm Driven Pulley Bearing Inspection Check if the inner bearin
56. hapter Contents 13 STEERING FRONT WHEEL SUSPENSION SYM Remove wheel hub from wheel rim after 4 nut DISK TYPE removed i Remove dust seal bearing and side collar p Dist collar Dust seal DRUM TYPE Dust seal Bearing Special tools Inner bearing puller SYM 6204020 Installation Fill out the block of bearing by grease Drive the left bearing and install the dist collar Install the right bearing Caution Carefully install the bearing in correct and evenly Bearing outer face should be faced up as bearing installation Install the brake disc and then tighten the bolts disc brake Torque value 4 5kgf m 13 6 This chapter Contents SYM 13 STEERING FRONT WHEEL SUSPENSION Lubricate the soeedometer gear with grease and install the gear into the wheel hub Drum type Lubricate the soeedometer gear box with grease Disk type Align the flange part on the speedometer gear with the slot of wheel hub Caution Contaminated brake lining will reduce brake performance so the brake lining brake drum and disc must be free of grease Apply with grease onto the dust seal Stopper DISK TYPE Install the dust seal and side collar 4 SS uw gt Place the front wheel between the front shock absorbers 5 Caution Align the brake disc groove with the stopper flange i a Frontforkgroove Speedometer cable Insert the
57. he rear brake lever at the end of the lever Free play 10 20 mm 3 8 3 4 in Adjust the free play by turning the front brake adjustment nut if necessary Brake Confirmation Caution After brake adjustment it has to check the brake operation to make sure the front and rear wheel can be braked 10 20mm 3 8 3 4 in Decreasing free play Increasing play 2 7 This chapter Contents 2 SERVICE MAINTENANCE INFORMATION Brake System Hose Front Disc Brake Type Make sure that the brake hose is corrosion or damage and also check the system for leaking Brake Fluid Check brake fluid level in the brake fluid reservoir If the level is lower than the LOWER limit add brake fluid DOT 3 to UPPER limit Also check Brake fluid brake system for leaking if low brake level found yes PE reservoir Caution e In order to maintain brake fluid in the reservoir in horizontal position do not remove the cap until handle bar stop e Do not operate the brake lever after the cap had been removed Otherwise the brake fluid will soread out if operated the lever e Do not mix non compatible brake fluid together Brake Lining Wear Rear Drum Brake Type Replace the brake lining if the wear limit mark on the brake arm aligning with the indicator of brake drum Brake Lining Wear Front Disc Brake Type The arrow mark on brake lining is the wear limit
58. he time of publication Sanyang reserves the rights to make changes at any time without prior notice and without incurring any obligation whatever Without written consent by SANYANG can not copy any part of this manual There are 4 buttons Forward How to use this manual Mechanism Illustrations and Contents on the CD R version and can be access to these items by click the mouse If user wants to look for the content of each chapter selecting the words of each chapter on the main contents can reach to each chapter There are two buttons Back to homepage and Main contents onto the top line of first page of the each chapter Thus if the user needs to check other chapters he can click the top buttons to back the homepage or main contents content of each chapter can be selected too Therefore when needs to checking the content inside of the chapter click the content words of the chapter so that can back to the initial section of the content addition there is a Ihis chapter contents button at the top line of each page so that clicking the button can back to the contents of this chapter 1 1 1 16 2 1 2 14 3 1 3 6 4 1 4 6 5 1 5 8 6 1 6 4 7 1 7 14 8 1 8 6 9 1 9 6 10 1 10 10 1 11 12 12 1 12 14 13 1 13 10 14 1 14 4 15 1 15 18 16 1 16 2 I I CONTENTS Index Content GENERAL INFORMATION SERVICE MAINTENANCE INFORMATION
59. hrottle cable Engine oil operation cable Engine oil filling pipe Fuel pump Spark plug cap Fuel unit pump Engine oil return pipe This chapter Contents SYM 1 GENERAL INFORMATION Troubleshooting A Engine hard to start or can not be started Loosen carburetor drain bolt Check and adjustment Fault condition Probable causes to check if there is gasoline inside the carburetor Fuel supplied tom No fuel is supplied to 3 carburetor sufficient carburetor 4 Remove spark plug install it into spark plug cap and 7 perform spark test against engine ground Week sparks or no spark Check if sparks at all Perform cylinder compression pressure test 1 2 cylinder compression pressure normal Low compression pressure or no pressure 3 4 Re start by following the 3 starting procedures 6 mM There are some signs of 1 No ignition ignition but engine can 2 not be started 3 Remove the spark plug again and check it Dry spark plug Wet spark plug 2 3 Remove carburetor after 30 minutes and connect a hose onto fuel supplement circuit Then blow the hose with air Blowing in normal Blowing clogged 1 N pr ode m YS No fuel in fuel tank Check if the pipes fuel tank to carburetor and intake vacuum are clogged Float valve clogged Lines in fuel tank evaporation system clogged Malfunction of fuel pump Loosen or damaged fuel pump vacuum hose Fu
60. iagnosis related ignition components CDI Electrical System Circuit Inspection Main Switch Black white green Continuity as main switch OFF Exciter Coil Black Red Green 400 8000 Pulse Generator 00 Pulse Generator 00 Blue Yellow green 50 2000 Black yellow green 0 210 10 Ignition Coil Green high voltage cable w o Cap 3 5 Secondary Green high voltage cable w Cap 7 12 If above checks normal but spark plug is still spark Then it probable causes from CDI set or high voltage coil f abnormal circuits are found in above checks at first check all items and then check each item one by one 15 11 This chapter Contents 15 ELECTRICAL EQUIPMENT SYM Starting System Starter Relay Inspection Remove luggage box Connect both the green yellow and the yellow red pins to battery posts directly If the red and red white pins are also in continuity it means it is in normal Starter Motor Pinion Removal Installation Remove left crankcase cover Remove starter motor pinion Install the starter motor pinion in reverse order of removal Starter Motor Pinion Inspection e Pinion reduction gear for wear out or damage replace it with new one Gear journal for wear out or damage gt replace it with new one Check the pinion for sliding in axial direction smoothly e The pinion sliding in axial direction not in smooth replace it with new one 15
61. ich may cause one to lose consciousness and even result in death Gasoline Gasoline is a low ignition point and explosive material Work in a well ventilated place no flame or spark should be allowed in the work place or where gasoline is being stored Caution Gasoline is highly flammable and may explode under some conditions keep it away from children Used engine oil Caution Prolonged contact with used engine oil or transmission oil may cause skin cancer although it might not be verified We recommend that you wash your hands with soap and water right after contacting Keep the used oil beyond reach of children Hot components Caution Components of the engine and exhaust system can become extremely hot after engine running They remain very hot even after the engine has been stopped for some time When performing service work on these parts wear insulated gloves and wait until cooling off 1 2 SYM Battery Caution Battery emits explosive gases flame is strictly prohibited Keep the place well ventilated when charging the battery Battery contains sulfuric acid electrolyte which can cause serious burns so be careful do not be spray on your eyes or skin If you get battery acid on your skin flush it off immediately with water If you get battery acid in your eyes flush it off immediately with water and then go to hospital to see an ophthalmologist
62. inder and piston can be carried as engine mounted on the body It should clean the engine to prevent dirt from entering into cylinder and crankcase before removal Remove all washes from the interfaces of cylinder head cylinder and crankcase Be careful do not damage cylinder head cylinder and piston when removing Inspect the removed amp cleaned parts thoroughly and apply with oil onto the rotation surfaces before installation Specification Standard value mm Limit mm 39 030 39 045 0 040 0 050 12 002 12 008 11 994 12 000 Pj i 11 970 Clearance between piston and piston pin 0 002 0 014 iston ring end gap 0 100 0 250 D of connecting rod small end 17 05 17 015 0 400 17 025 Cylinder D 5 1 3900039015 39050 Deformation 1 9010 ID inner diameter OD outer diameter Tighten torque value Cylinder head 1 0kgf m Exhaust pipe connection nut 1 2kgf m opark plug 1 4kgf m Exhaust muffler mounting bolt 3 3kgf m Troubleshooting Compression Pressure Too Low Difficult Piston Noise To Start Rough Idling 1 cylinder and piston worn out 1 Cylinder head gasket leaking 2 piston pin or piston pin hole worn out 2 Spark plug not tighten enough 3 connecting rod small end bearing worn out 3 Worn seized or crack piston ring 4 Damaged worn cylinder or piston Piston Ring Noise 5 Poor reed 1 Worn seized or crack piston ring 2 Cylinder worn out or damaged Compression Pressure Too High Ove
63. ing Speedometer gear front Side stand shaft Main stand shaft Hear wheel bearing This chapter Contents 1 GENERAL INFORMATION SYM Note SYM 2 SERVICE MAINTENANCE INFORMATION General Information 2 1 Suspension Periodical Maintenance Schedule 2 2 Transmission Oil Air Cleaner 222 2 3 Spark Plug Fuel Limes 2 3 Control Cable Lubrication 2 12 Fuel Filter eere 2 4 Driver Belt eere 2 12 Engine Oil Line 2 4 Ignition Timing Oil Pump Control Cable 2 5 Throttle Valve Operation eee er re err rer re rrr mer er oe ee 2 6 Carburetor Idle Speed Adjustment 2 13 2 6 Carbon Removing For Exhaust Pipe amp Rear Brake Free Play Drum Brake Type Muffle 2 7 Cylinder Compression Pressure Test Brake System Hose Front Disc Brake 2 13 Type 2 8 Headlight Adjustment Steering 2 10 General Information Specification Front 3 00 10 42J Hear 3 00 10 42J Front 1 5kg cm Tire pressure at cold Only rider Rear 2 25 kg cm Front brake lever free play 10 20 mm Rear brake lever free play 10 20 mm Type HYPOID GEAR OIL Transmission oil Hecommendation Oil SAE 140 Quantity 0 1 L Tire dimension Type BR8HSA Standard
64. ion then adjust the handle top bearing by adjusting the steering nut Suspension A Warning Do not ride the scooter with poor suspension Looseness wear or damage suspension system will make poor stability and drive ability Front Shock Absorber Press down the front shock absorber for several times to check it operation Check if the shock absorber assembly is damage Replace it if damage found and can not be repaired Tighten all nuts and bolts Rear Shock Absorber Park the scooter with its main stand Shake the rear wheel side to side to check engine suspension bushing for wear Replace the bushing if looseness found Check the shock absorber for damage Tighten all nuts and bolts Nuts Bolts Tightness Check if all bolts and nuts on the frame are tightened to specified torque in accord with the interval of Periodical Maintenance Schedule Check all split pins snap rings hose clamps and wire holders for security 2 10 This chapter Contents SYM 2 SERVICE MAINTENANCE INFORMATION Transmission Oil TARN Y SARE Leak level check bolt Check if the transmission is leak did uid a Check Caution Park the scooter on flat ground with its main stand Remove the oil level check bolt and check if the oil level is placed on the hole of check bolt Replacement Remove the oil level check bolt Remove the oil draining bolt and then drain oil out Install the oil dr
65. ke System Disc Brake Air Bleed Front Drum Brake System Disc Brake Caliper Rear Drum Brake System Brake Disc Maintenance Information Disc Brake Master Cylinder Troubleshooting Drum Brake Hydraulic Disc Brake t 7 6 0kgf m 11 1 11 BRAKE SYSTEM SYM Front Drum Brake System 11 2 SYM 11 BRAKE SYSTEM Rear Drum Brake System 11 0kgf m 2 9kgf m 0 55kgf m 11 3 This chapter Contents 11 BRAKE SYSTEM SYM Maintenance Information Precautions in Operation Caution Inhaling brake lining ashes may cause disorders of respiration system therefore never use air hose or dry brush to clean brake parts Use vacuum cleaner or other authorized tool instead e The brake caliper can be removed without removing the hydraulic system After the hydraulic system is removed or the brake system is felt to be too soft bleed the hydraulic system While refilling brake fluid care should be taken not to let the foreign material entering into the brake system Do not spill brake fluid on the painted surfaces plastic or rubber parts to avoid damage Check the operation of the brake system before you go Specifications The thickness of front brake disc Standard mm Limit mm 12 00 12 743 12 55 Front brake disc run out Master cylinder inner diameter Master cylinder piston outer diameter 12 657 12 684 12 654 ID of front brake drum 110 0 110 5 ID
66. lever and wait for a few seconds until it reaches its top position 3 Repeat the steps 1 and 2 until there is no air bubble at the end of the hose 4 Tightly close the drain valve 5 Make sure the brake fluid is in the UPPER level of the master cylinder and refill the fluid if necessary 6 Cover the Disc Brake Caliper Removal Place a container under the brake caliper and loosen the brake hose bolt and finally remove the brake hoses Caution Do not spill brake fluid on painted surfaces Hemove the bolt cap and loosen the lining guide bolts Remove two caliper bolts and the caliper 11 BRAKE SYSTEM Air bubble _ Drain valve 7 Brake hose bolt Installation Install the brake caliper and tighten the attaching bolts securely Torque 3 3kgf m Caution Use M8 x 35 mm flange bolt only Long bolt will impair the operation of brake disc Tighten the lining guide bolt Torque 1 8kgf m Install bolt cap Torque 1 0kgf m Use two seal washers and hose bolts to lock the hose and brake caliper in place Torque 3 5kgf m Refill up the brake fluid to the reservoir and make necessary air bleeding 11 7 This chapter Contents 11 BRAKE SYSTEM Brake Disc Brake disc Inspection Visually check the brake disc for wear or break Measure the thickness of the disc at several places Replace the disc if it has exceeded the service limit Allowable limit 2 0 mm
67. ll too tight nor have excessive slack Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws Keep wire harnesses far away from the exhaust pipes and other hot parts Be sure grommets are seated in their groves properly After clamping check each harness to be certain that it is not interfered with any moving or sliding parts After routing check that the wire harnesses are not twisted or kink Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack be rubbed against or interfere with adjacent or surrounding parts in Correct all steering positions X Wrong Thoroughly clean the surface where tape is to be applied Wrap electrical tape around the damaged parts or replace them 1 8 This chapter Contents SYM 1 GENERAL INFORMATION Speedometer Headlight switch Winker switch Winker rela High low beam switch Starter switch Front brake lamp switch Throttle cable Winker light Throttle cable Main switch Regulato Resistor Front brake cable 1 9 This chapter Contents 1 GENERAL INFORMATION SYM 22 Battery fuse starting relay CDI set Throttle cable Fuel unit arburetor Rear brake cable j 4 F Pc Fuel pump Fuel filter T
68. m oil tank to oil pump or oil tube is removed the oil pump should be conducted air bleeding operation e t should bleed the oil output tube from oil pump to carburetor as hose removed e he adjustment of oil pump control cable Lubricant e Appointed to apply SAE 20 JASO FC class oil Otherwise warranty shall not cover the damage e Recommended Oil MAX 2 oil e Oil tank capacity 1 2 lit Trouble Shooting Too much smoke carbon in spark plug 1 Improperly oil pump adjustment too much oil 2 Poor quality oil 3 Applying with poor quality oil Over heat 1 Improperly oil pump adjustment insufficient oil 2 Poor quality oil 3 Applying with poor quality oil Piston seized 1 No oil in oil tank or clogged hose 2 Improperly oil pump adjustment insufficient oil 3 Air in oil hose 4 Malfunction of oil pump Oil did not flow out the oil tank 1 Clogged breath hole on the oil tank cover This chapter Contents SYM 3 LUBRICATION SYSTEM Oil Pump Removal Caution Before removing the oil pump clean the oil pump and crankcase Remove the luggage box and seat Loosen the mounting nut of the oil pump control cable and remove the control cable Remove the oil tube and clip its end side to prevent oil from flowing out Control cable Mounting nut Adjustment nut Remove the oil output tube form intake manifold Remove the oil pump mounting bolt and then take out the oil pump Inspection
69. n be started but motorcycle can Insufficient horsepower or poor high not be moved speed performance 1 Worn drive Belt 1 Worn drive belt 2 Worn ramp plate 2 Insufficient spring capacity of driven pulley 3 Worn or damaged clutch weight 3 Worn weight roller 4 Broken driven pulley spring 4 Driven pulley operation un smoothly Shudder or misfire when drive 1 Broken clutch weight 2 Worn clutch weight This chapter Contents SYM 7 V TYPE BELT DRIVE SYSTEM KICK STARTER Left Crankcase Cover cover Left crankcase cover removal Remove left body side cover Remove air cleaner Remove kick start arm Remove left crankcase cover Kick start arm Return spring Disassembly of Kick Starter Remove snap clip and thrust washer from left crankcase cover Install kick start arm rotate the lever slightly and then remove driven gear and washer Remove the kick starter arm kick starter spindle and return spring as well as socket Inspection of kick Starter Check if starter spindle driven gear for wear or damage Kick start arm as Snap ring Thrust washer Starter spindle Driven gear 5 Thrust washer Friction spring This chapter Contents 7 TYPE BELT DRIVE SYSTEM KICK STARTER SYM Reassembly of Kick Starter Install bush return spring and starter spindle as diagram shown Install thrust washer and snap clip onto starter spindle Install Kick starter lever tem
70. n roller Guide pin Install socket Install driven pulley spring and clutch into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut to specified torque with clutch nut wrench Remove the clutch spring compressor Torque value 5 0 6 0kgf m Install clutch driven pulley and drive belt onto drive shaft 7 14 Guide pin Guide pin roller Socket Clutch nut wrench n Vs 5 s 1 Clutch spring ompressor SYM 8 FINAL DRIVING MECHANISM Maintenance Information 8 2 Inspection of Final Driving Mechanism Troubleshooting 8 4 Disassembly of Final Driving Mechanism Bearing Replacement 8 4 8 3 Re Assembly of Final Driving Mechanism 8 4 6 1 This chapter Contents 8 FINAL DRIVING MECHANISM Maintenance Information Limited usage of gear gear oil 140 Recommended Bramax serial oil Oil quantity 100 c c 90 as replacement Special tools Inner type bearing puller SYM 6204020 Outer type bearing puller SYM 6204010 Final shaft oil seal installer SYM 9125500 Drive shaft oil seal installer SYM 9120200 Bearing driver 6204 SYM 9110400 Bearing driver 6201 SYM 9610001 Bearing drive
71. n two battery terminals and the charging current is in the discharging direction 2 The charging voltage and current are too much higher than the standard values The following problems are not related to the charging system correct it if any by following steps indicate in the checking list 1 The standard charging voltage and current can only reach when the revolution of the engine exceeds the specified rom Bulbs used exceed their rate and consume too much power replacement battery is aged and does not have enough capacity 2 The charging voltage is normal but the current is not replacement battery is aged and does not have enough capacity Battery used do not have enough electricity or is over charged fuse of the ammeter is blown ammeter is improperly connected 3 The charging current is normal but the voltage is not fuse of the voltmeter is blown This chapter Contents 15 ELECTRICAL EQUIPMENT SYM Headlight Voltage Inspection Connect a tachometer Do not disconnect the headlight harness connector after engine started Turn the headlight ON and to high beam position Measure the voltage between the blue wire and green wire while the headlight harness is still in connection Measure alternating current voltage with a voltmeter Gradually increase engine speed and read the voltage in each specified rpm Control voltage 12 0 14 0 V
72. nal position according to the marks as removal Adjust the screws if replace with new ones Float valve yg Float n Float pin Throttle valve stopper screw Idle 7 Needle jet seat Main jet Screw i Draining screw 10 6 SYM 10 FUEL SYSTEM Float Level Inspection Measure float fuel level to have the upper end of float just contact with the float Float fuel level 8 8 mm Carefully bend the float arm for adjustment Check the float operation and the install it Carburetor Installation u Carburetor Caution JOD Do not let foreign materials into the carburetor Install the carburetor and insulator onto intake pipe with bolts Install fuel and vent pipes onto carburetor Install the carburetor upper part Tighten the connection hose Tighten the draining screw Draining screw Connect the automatic by starter connector Install air cleaner cap Conduct following operations Adjustment of throttle valve cable Adjustment of oil pump Adjustment of idle speed Reed Valve Removal Remove the body cover Remove the carburetor Remove carburetor insulator Remove inlet pipe Remove the reed valve 10 7 chapter Contents 10 FUEL SYSTEM Inspection Check the reed valve for damage and its reed strength Check the reed valve seat for crack damage and the clearance between the seat and the valve Replace reed valve if necessary
73. ng system e The battery is not fully charged e Poor connection in the windings e The motor gear is jammed by foreign material Starter motor is working but engine does not crank e Poor starter motor pinion e The starter motor run in reverse direction e Poor battery 15 3 This chapter Contents 15 ELECTRICAL EQUIPMENT Battery Negative terminal Battery Removal Installation Turn off main switch Open seat Remove screw and the open battery cover Disconnect the negative cable terminal first then the positive cable terminal Remove the battery from the scooter Install the battery in reverse order of removal Voltage Check Open seat and battery cover Remove wires from battery Check battery voltage Voltage Fully charged 13 0 13 2V Undercharged 12 V Charging Remove the battery Connect the positive terminal of the charger to the battery positive terminal Connect the negative terminal of the charger n dE to the battery negative terminal Standard charging current time 0 4A 5 hrs Fast charging current hrs 4A 0 5 hr Caution otrictly keep flames and sparks away while recharging to avoid to explosion causing by hydrogen Stop charging battery when electrolyte temperature is over 45 C 117 F Caution Fast charging the battery is for in emergency only Battery should be charged in standard 15 4 SYM Positive terminal This chapter Contents
74. oid danger caused from dusts Caution Inhaling brake lining ashes may cause disorders of respiration system therefore never use compressed air or dry brush to clean brake parts Brake performance will be reduced by grease on brake lining Remove wheel and brake drum Inspection Check brake drum for damage or wear out and replace it if necessary Measure the inner diameter of brake drum and record the max value Allowable limit Front 110 5mm Rear 95 5mm Caution Clean the rust onto the brake drum with 120 sand paper Measure the inner diameter of brake drum with micrometer Measure the thickness of brake lining at three points both ends and center If the thickness is less than specified value or if it is contaminated by oil or grease replace as a set Service limit Rear 2 0 mm Removal Caution Brake linings must be replaced as a shoes Remove the brake linings from brake panel 11 11 This chapter Contents 11 BRAKE SYSTEM Installation Apply with a thin coat of grease to the brake cam and the anchor pin Install brake cam Never allow brake linings to be contaminated by oil or grease Wipe off the excessive grease from brake cam and the anchor pin Caution Rear brake arm Brake efficiency will be reduced if brake linings is contaminated by oil or grease Install the brake cam and arm after aligning it with the punched point Tighten the bolts and
75. or marks Means that serious injury or even death may result if procedures are not Warning followed Caution 5 in equipment damages may result if procedures are not Limits to use SAE 20 JASO FC class oil Warranty will not cover the damage that caused by not apply with the limited engine oil Recommended oil MAX 2 serial oils King Mate G 3 is recommended King Mate gear oil serials are recommended Bramax HYPOID GEAR OIL 140 Locking Apply sealant medium strength sealant should be used unless otherwise YE specified with lubricant Replace with new part before installation Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid 25 pecia tools Special tools O oorrect Meaning correct installation Wes 2 Meaning wrong installation gt Indication Indication of components pem Indicates position and operation directions m Components assembly directions each other Indicates where the bolt installation direction means that bolt cross through the component invisibility 1 1 This chapter Contents 1 GENERAL INFORMATION General Safety Carbon monoxide If you must run your engine ensure the place is well ventilated Never run your engine in a closed area Run your engine in an open area if you have to run your engine in a closed area be sure to use an extractor Caution Exhaust contains toxic gas wh
76. porary Slightly rotate the lever and then align driven gear with width tooth on the starter spindle Install the friction spring of drive gear onto convex part of the cover Return spring Width tooth Installation of the Left Crankcase Cover Install the dowel pin and gasket Install the left crankcase cover Install kick start arm 7 4 This chapter Contents SYM 7 V TYPE BELT DRIVE SYSTEM KICK STARTER Drive Belt Removal Remove left crankcase cover Hold clutch outer with universal holder and remove nut and clutch outer A Caution e Using special tools for tightening or loosening the nut Fixed rear wheel or rear brake will damage reduction gear system Push the drive belt into belt groove as diagram shown so that the belt can be loosened and then remove the driven pulley Remove driven pulley clutch Do not remove drive belt Remove the drive belt from the groove of driven pulley Inspection Check the drive belt for crack or wear Replace it if necessary Measure the width of drive belt as diagram shown Service Limit 16 5 mm Replace the belt if exceeds the service limit A Caution e Using the genuine parts for replacement he surfaces of drive belt or pulley must be free of grease Clean up all grease or dirt before installation Installation A Caution e Pull out driven pulley to avoid it closing Install drive belt onto driven pulley
77. r 6203 6004UZ SYM 9620000 L crank puller SYM 1130000 L L crank shaft install bush 5 1130010 Troubleshooting Trouble Diagnosis Engine can be started but scooter can not be moved 1 Damaged drive gear 2 Burnt out or seized drive gear Noise 1 Seized worn or damage gear 2 Worn or loose bearing Gear oil leaks 1 Excessive gear oil 2 Worn or damage oil seal SYM This chapter Contents SYM Disassembly of Final Driving Mechanism Remove driven pulley Drain gear oil out from gearbox Remove rear wheel Remove gearbox cover mounting bolts from the clutch side and then remove the cover from the rear wheel side Remove final gear final shaft and counter gear counter shaft Remove the drive shaft from left crankcase A Caution he bearing must be replaced when removing the drive shaft Remove drive shaft oil seal and bearing from left crankcase 8 FINAL DRIVING MECHANISM Final gear amp shaft Cil seal Cil filling hole __ Counter gear amp shaft This chapter Contents 8 FINAL DRIVING MECHANISM Inspection of Final Driving Mechanism Check if the drive shaft counter shaft and final gear shaft are worn or damage Check if the gear box cover bearing oil seal and the inner diameter of counter shaft are worn or damage Check if the left crankcase cover bearing oil seal and the inner diameter of countershaft are worn or damage Bearing Replacement A Cau
78. r cleaner mounting bolts 2 bolts Support the engine and then remove shock absorber lower mounting bolt Remove two exhaust pipe connection nuts Remove two bolts beside fan cover and exhaust pipe Exhaust pipe Bolt This chapter Contents SYM 4 ENGINE REMOVAL Remove engine mounting nut and bolt Engine mounting bolt Engine installation Install in the reverse order of removal procedures Tighten the engine mounting and rear shock absorber upper lower bolts Torque value Engine hanger bolt 5 0kgf m Rear shock absorber upper mounting bolts 4 0kgf m Rear shock absorber lower mounting bolts 2 7kgf m Exhaust pipe connection nut 1 2kgf m Muffle mounting bolt 3 3kgf m Perform the following inspection and adjustment after installation Check if control cable is correct e Check if throttle valve cable is correct e Check if oil pump control cable is correct e Oil input and output of the oil pump Adjust rear brake 4 5 4 ENGINE REMOVAL Note This chapter Contents SYM SYM 5 CYLINDER HEAD CYLINDER PISTON Maintenance Information 5 2 Cylinder 27 5 3 Troubleshooting 5 2 Cylinder Piston 5 5 This chapter Contents 5 CYLINDER HEAD CYLINDER PISTON SYM Maintenance Information Precautions in Operation The inspection and maintenance of the cylinder head cyl
79. retor Installation Throttle Valve Reed Valve Carburetor Remove Fuel Pump Auto By Starter Air Cleaner Float Float Valve Jet Throttle valve cable Air hose Oil tube Vacuum hose Carburetor Fuel unit Vacuum tube Fuel filter Fuel tank 10 1 This chapter Contents _ 10 FUEL SYSTEM Maintenance Information Precautions in Operations Warning Gasoline is a highly flammable material and may explosive under circumstance Thus always work SYM in a well ventilated place and strictly prohibit flame when working with gasoline Care must be taken when dealing with gasoline and always work in a well ventilated place and strictly prohibit flame When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly It has to conduct air bleeding operation as removed the oil tube e Idle speed adjustment Specification DD 50 Venturi diameter Fuel level 8 6 H 0mm 1 3 8 Idle speed Throttle handle free play 2 20004100 rpm Main jet Fuel pump output 20 c c minimum Troubleshooting Engine can not be started 1 No fuel in fuel tank 2 Fuel can not reach to carburetor 3 Too much fuel in cylinder 4 Clogged air cleaner Stall after started Incorrect idle speed adjustment No spark on the spark plug Low compression pressure Rich mixture Lean mixture Clogged air cleaner Inlet pipe leaking
80. rheat Knock 1 Too much carbon deposit built up in combustion chamber This chapter Contents SYM 5 CYLINDER HEAD CYLINDER PISTON Cylinder Head Tightening bolt Cylinder Removal Removal body covers Remove spark plug cap Remove fan cover Remove engine shield Remove two connection nuts of the exhaust pipe Remove exhaust muffle mounting bolt and then remove the exhaust pipe Cylinder Head Removal Remove the 4 cylinder head bolts and then remove the cylinder head A Caution Loosen the cylinder head bolts with diagonal direction to avoid to damaging it Cleaning Carbon in Combustion Chamber Clean carbon deposit in which built up in combustion chamber with shown chisel A Caution Do not scratch to the interfaces of combustion chamber and cylinder Chisel This chapter Contents 5 CYLINDER HEAD CYLINDER PISTON SYM Cylinder Head Inspection Use a straight edge and a feeler gauge to measure the cylinder head for warp Service limit 0 10 mm Cylinder Head Installation Replace the cylinder head gasket with new one and place the cylinder head onto cylinder Tighten the 4 bolts with diagonal direction and by 2 3 sequences Tighten torque 1 0kgf m Install spark plug Tighten torque 1 4kgf m Replace the exhaust pipe washer with new one and then install exhaust pipe Tighten exhaust pipe connection nut Tighten torque 1 2kgf m Tighten exhaust pipe mounting bolt Tighten torque 3
81. s Conduct the step 2 if the needle on the fuel indicator is not moved 2 Measure the connector resistance while the float in up and down positions Float position Resistance value Up full 3 100 Down empty 90 1000 Check the fuel indicator if the resistance is in normal Replace the fuel gauge if the resistance is abnormal 15 ELECTRICAL EQUIPMENT Fuel unit Fuel unit plastic 15 15 This chapter Contents 15 ELECTRICAL EQUIPMENT Switch Horn Remove handle covers and front cover Remove main switch cover Remove front inner box Check continuity on each switch The connected circles with a line are that they should be in continuity Main Switch Wire Black dor Be We Green Rea ock OFF light switch Horn Switch Light green Beam switch Winker light switch This chapter Contents 15 ELECTRICAL EQUIPMENT SYM Headlight Switch Front Rear Brake Light Switch If the switch is in continuity as braking it is in normal The switch is non adjustable Horn If the horn give out sound as connecting to 12V battery it means that it is in normal Headlight switch Headlight switch connector Starter switch connector 15 17 This chapter Contents 15 ELECTRICAL EQUIPMENT SYM Bulb Replacement Headlight Remove handle front cover Remove bulb seat and replace the bulb Install the all removed p
82. seat X 2 a r p AI 13 3 This chapter Contents 13 STEERING FRONT WHEEL SUSPENSION SYM Place master cylinder onto handle and align its connection surface with bolt hole on the handle disc brake Install the mounting seat Tighten the upper part bolt and then tighten lower bolt Install all components in reverse order of removal procedures Conduct following adjustment e Oil pump control cable e Throttle operation Brake lever free play DISK TYPE Master cylinder Front Wheel Removal Remove speedometer cable from speedometer gear box Remove front brake cable Drum type Speedometer cable Remove front wheel axle nut and then pull out the axle and remove the wheel Axle nut DURM TYPE Axle nut 13 4 This chapter Contents SYM 13 STEERING FRONT WHEEL SUSPENSION Inspection Place the axle onto a V block to measure Its run out with a dial gauge The dial gauge indicated 1 2 run out Service limit 0 20 mm Wheel axle Place the wheel on to a rotation seat and turn Free play the wheel to check its bearing free play Ifthe bearing is noisy or its free play is too much replace it Place the wheel on to a rotation seat to check its rim wobbling Turn the wheel with hand and measure its rim wobbling value with a dial gauge Service limit Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in Remove 3 bolts and brake disc This c
83. stop to running for 10 minutes Remove the body cover Park the scooter with main stand after warned up engine According to the required idling and air screw to adjust to specified idle speed Idle speed 20002100 rpm Carbon Removing For Exhaust Pipe amp Muffle Remove the body cover Remove the exhaust pipe amp muffler Clean the carbon deposits on the muffler amp cylinder exhaust edge Cylinder Compression Pressure Test Remove the left body cover and warn up engine Stop the engine and remove the spark plug Insert the compression gauge and wide open the throttle and then rotate the engine by means of the starting motor Compression pressure 7 041 kg cm Probable causes for low compression pressure e Damaged cylinder head gasket e Worn piston ring e Worn cylinder Probable causes for high compression pressure e Carbon on the combustion chamber or cylinder head Pilot screw Idle speed adjustment screw Adjust the idling after warn up engine for 10 minutes 1 2 3 Connect tachometer Adjust the idle speed screw to let engine speed in 2000 100 rpm Insert the sampling pipe of the CO HC meter to the test hole on the front end of exhaust pipe Adjust the idling emission value to standard range CO 1 8 2 6 Slightly accelerate the throttle valve and release it Repeat this operation for 1 2 times Read the engine idle speed and the emi ssion value after
84. t Service limit 19 98 mm Measure the inner diameter of drive face and replace it if it exceed service limit Service limit 20 120 mm Reassembly Installation Install weight rollers Install ramp plate Ramp plate Apply with grease 4 5g to inside of movable Dilve face drive face and install drive face boss A Caution e he drive face has to be free of grease Clean it with cleaning solvent 7 8 SYM Movable drive face Weight roller This chapter Contents SYM 7 V TYPE BELT DRIVE SYSTEM KICK STARTER Install movable drive face assembly onto Drive face boss Movable drive face crankshaft Drive Face Installation Press drive belt into pulley groove and then pull the belt on to crank shaft Drive belt Press down Install drive face washer and nut A Caution e Make sure that two sides of drive face have to be free of grease Clean it with cleaning solvent Hold flywheel with universal holder 5 s Flywheel di M Tighten nut to specified torque Torque value 3 8kgf m Install left crankcase cover This chapter Contents 7 TYPE BELT DRIVE SYSTEM KICK STARTER Clutch Driven Pulley Disassembly Remove drive belt and clutch driven pulley Install clutch spring compressor onto the pulley assembly and operate the compressor to let nut be installed more easily A Caution Do not press the compressor too muc
85. t specified oil quantity into gearbox 8 5 This chapter Contents 8 FINAL DRIVING MECHANISM SYM Notes 8 6 Contents O 9 CRANKCASE CRANKSHAFT SYM I gt o E C c 0 C ES O Maintenance Information Q Crankshaft Inspection 9 Troubleshooting Qe Crankcase Installation 9 Crankcase Disassembly 9 Apply liquid gasket 9 1 This chapter Contents 9 CRANKCASE CRANKSHAFT Maintenance Information e his chapter concerns disassembly of the crankcase for repair purpose Before disassembling crankcase except removing engine firstly following components must be removed too e Carburetor chapter 10 e Oil pump chapter 3 e Reed valve chapter 10 Driving belt chapter 7 Alternator chapter 6 e Cylinder head cylinder piston chapter 5 Except above components are needed be removed when disassembling L crankcase following components must be removed too e Final driving mechanism chapter 8 e When assembling both crankcase and crankshaft it has press the inner ring edge of the crankshaft bearing to push the crankshaft into the crankcase hole by using the specified service tools The old bearing onto the crankshaft has to be removed Then install a new bearing onto the crankshaft on the crankcase side Oil
86. te crankshaft bearing and bearing seat with 2 stroke engine oil Apply liquid gasket and dowel pin onto the interface of left crankcase guid gasket TE 9 5 This chapter Contents 9 CRANKCASE CRANKSHAFT Assemble the right crankcase with assembly tools Install right crankcase onto the crankshaft Install right crankshaft puller and install bush onto crankshaft screw the right crankshaft puller onto crankshaft Turn the puller in C W direction and then completely screw the puller to bottom Lubricate crankshaft bearing and bearing seat with 2 stroke engine oil x R Crank shaft puller R Crank shaft install bush Install the bolts and tighten them Torque value 1 0kgf m With right crank shaft install bush install new oil AF Tex seal into the right crankcase Its installation depth 2 UR Crank shaft install bush is 4mm as the diagram shown install bus With the specified tool to install a new oil seal onto the left crankcase to the depth of 1 mm as the diagram shown Caution freely after tightening the bolts Install the following components Final driving mechanism chapter 8 Alternator chapter 6 Piston cylinder cylinder head chapter 7 Oil pump chapter 3 Reed valve and carburetor chapter 10 Engine chapter 4 9 6 SYM 10 FUEL SYSTEM Maintenance Information Flaot Level Inspection Troubleshooting Carbu
87. the brake disc from wheel Check the disc for deformation and bend Allowable limit 0 30 mm Disc Brake Master Cylinder Master Cylinder Removal Caution Do not let foreign materials enter into the cylinder Caution The whole set of master cylinder piston spring diaphragm and cir clip should be replaced as a set Remove the front and rear handlebar covers Remove the leads of brake light switch Drain out the brake fluid Remove the brake lever from the brake master cylinder Remove the brake hose Remove the master cylinder seat and the master cylinder Remove the rubber pad Remove the cir clip Remove the piston and the spring Clean the master cylinder with recommended brake fluid Master cylinder 2 11 8 This chapter Contents SYM Master Cylinder Inspection Check the master cylinder for damage or scratch Replace it if necessary Measure the cylinder inner diameter at several points along both X and Y directions Replace the cylinder if the measured values exceed allowable limit Allowable limit 12 550 mm Master cylinder Measure the outer diameter of the piston Replace the piston if its measured value exceeds allowable limit Allowable limit 12 654 mm Master Cylinder Assembly s Caution Rubber bush It is necessary to replace the whole set comprising piston spring piston cup and cir clip Make sure there is no dust on all components before assembling
88. thness and for burrs that may damage the or outer race In this case the bearing should oil seal be replaced To avoid damaging the bearing use equal force on both races _ Manufacturer s name e Remove residues of the old gasket or sealant before reinstallation grind with a grindstone if the contact surface has any damage Both of these examples can result in bearing damage e Lubricate the rotation face as assembling Check if positions and operation for installed parts is in correct and properly This chapter Contents SYM 1 GENERAL INFORMATION Specifications Make SANYANG MODEL 05 Series Overall Length 1660 mm TELESCOPIC System Overall Height 1020 mm Tire 3 00 10 42J T L Wheel Base 1155 mm Specifications Rear 3 00 10 42J T L DISK 160mm DRUM 110mm DRUM 95mm r P Bri Two 110 kg Max Speed 48 km hr Below assengers Weight Installation and Vertical below center bu Transmission arrangement incline Fuel Used Unleaded 92 95 0 90 km hr Cycle Cooling 80 112 Stroke 41 4mm Exhaust Pipe Position Right side and Backward and Direction Number Arran TN IM gement Single Cylinder Lubrication System Separated lubrication Displacement Solid Particulate 15 96 Compression 4 41 Nm 5000 rpm Below 2g test Starting System Electrical amp kick Catalytic reaction control 02 system DI
89. tion e Never install used bearings Once bearing removed it has to be replaced with new one Remove gear box bearing from left crankcase and gear box cover using following tools Special tool Inner type bearing puller Re Assembly of Final Driving Mechanism Re assemble the gearbox cover and left crankcase with special tools Special tool Gear Box Cover Final shaft bearing Bearing driver 6203 6004UZ SYM 9620000 Bearing driver 6201 SYM 9610001 Final shaft oil seal installer SYM 9125500 Left Crankcase Drive shaft bearing Bearing driver 6203 6004UZ SYM 9620000 Bearing driver 6201 SYM 9610001 L crank puller SYM 1130000 L L crank shaft install bush SYM 1130010 Drive shaft oil seal installer SYM 9120200 With the special service tools to install drive shaft by through the bearing Install a new drive shaft oil seal Install a new final shaft oil seal 8 4 SYM Final driven gear amp shaft he Countershaft 7 6 Drive shaft rato Adapter This chapter Contents SYM 8 FINAL DRIVING MECHANISM Install countershaft final driven gear and thrust gFinal driven gear amp shaft washer o a gt Counter gear amp shaft Install new gasket and lock pin Install gearbox cover Install clutch driven pulley assembly Install driven pulley drive belt and left crankcase side cover Install body cover Install rear wheel Fill ou
90. to oil pump connection section by means of the oil pot so that the oil pump body is full with oil e Fill out oil to oil tube connection section so that the oil tube is full with oil Then install the tube onto oil pump e Make sure whether air is in the oil tube or not after installation Caution After bleeding the oil tube and oil pump the oil tube has to be conducted air bleeding operation too Oil Tube Air Bleeding Remove the oil output tube and plug its input connector Bend the oil tube into U shape and fill out new oil into the output tube Connect the oil output tube to the oil pump connection part Start engine and run it in idling as the oil control lever in wide open position Make sure oil flows out from the oil output tube Caution e Motorcycle s exhaust gas includes with CO which causes human to coma or death so perform this operation in well ventilation place e Run the engine in extreme low speed to avoid to damaging the engine caused from clogged oil tube 3 4 This chapter Contents SYM Oil Tank Oil tank cap Removal Installation Remove the battery and oil tank cap Remove the luggage box and seat Remove the oil input tube from oil pump and then drain oil to a clean container Remove the oil level switch wire of the oil indicator Remove the mounting bolt on the oil tank upper side and then remove the oil tank Installation in the reverse order of remo
91. um 3 Worn brake drum lever 3 Dirty brake lining 4 Worn brake cam 1 Worn broken crack return 4 Dirty brake drum 5 Improper brake lining spring installation 2 wom drum 6 Seized brake cable 3 Dirty brake lining 7 Dirty brake lining 4 Brake seized caused from 8 Dirty brake drum E brake drum 9 Brake pad worn in brake 5 Seized brake cable cam area 6 Worn brake cam 7 Improper brake lining installation 10 Poor contact between brake arm and camshaft indent 11 5 This chapter Contents 11 BRAKE SYSTEM Hydraulic Disc Brake Close the drain valve of the hydraulic disc brake Replace the brake fluid Before the brake fluid reservoir is removed turn the handle so that the brake fluid reservoir becomes horizontal then remove the brake fluid reservoir Cover the painted surfaces plastic or rubber components with a rag when servicing brake system Caution opilled brake fluid on painted surfaces plastic or rubber components may result in their damages Remove the master cylinder cap and diaphragm Use brake fluid to clean the dirty brake disc Caution The dirty brake lining or disc will reduce the brake performance Refill up same grade brake fluid into the reservoir Caution To mixed non compatible brake fluid will reduce brake performance Foreign materials will block the system causing brake performance to be reduced or totally lost Connect drain hose to drain valve
92. val Air bleeding the oil tubes after installed 3 LUBRICATION SYSTEM 3 5 This chapter Contents 3 LUBRICATION SYSTEM SYM Notes 3 6 SYM 4 ENGINE REMOVAL Maintenance Information 4 2 Engine installation 4 5 Engine 4 3 This chapter Contents 4 ENGINE REMOVAL SYM Maintenance Information There are parts that require removal of engine for maintenance e Crankshaft Related bolts tightening torque for removal of engine Engine hanger bolt 5 0kgf m Engine bracket bolt 6 0kgf m Rear shock absorber upper mounting bolts 4 0kgf m Rear shock absorber lower mounting bolts 2 7kgf m Exhaust pipe connection nut 1 2kgf m Muffle mounting bolt 3 3kgf m 4 2 This chapter Contents SYM 4 ENGINE REMOVAL Engine removal Remove body cover Remove the spark plug cap from the spark plug section Remove the fuel output and the vacuum tubes from fuel pump Remove the oil control cable from oil pump Remove the oil tube from oil pump and then clip the tube Remove the wire connectors of auto by starter and AC G Remove the upper parts and cable of the carburetor from its upper side Remove the vapor emission vacuum tube from carburetor intake manifold This chapter Contents 4 ENGINE REMOVAL Remove rear brake cable from engine rear lower side Remove ai

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