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1. general information/trouble diagnosis 1-2

1. Fuel level in carburetor too high 2 Malfunction of throttle valve operation 3 Throttle valve opening too wide Malfunction of automatic by starter 1 9 1 GENERAL INFORMATION TROUBLE DIAGNOSIS S M 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 Air cleaner clogged Engine speed can be Engine speed can not be 2 Poor fuel supply 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 alternator Check cylinder compression pressure using compression pressure gauge sand hole in compression parts Compression pressure correct No compression pressure Valve deterioration Crankcase leakage for Check if carburetor jet is ore compression clogged No clogged Clogged 1 Remove dirt Remove spark plug No foul or discoloration Fouled and discoloration 1 Remove dirt 2 Incorrect spark plug heat range Check if engine over heat Continually drive in acceleration or high speed Cylinder amp piston ring worn out Oylinder gasket leaked OQ N Piston and cylinder worn out Lean mixture Poor fuel quality Too much carbon deposited
2. Installation Install the floor panel according to the reverse procedure of removal SIDE COVER Removal Remove the left right side 2 mounting screws in the front of the side cover iScrews1 x 2 Remove the left right side 2 mounting bolts in the rear of the side cover Remove the left right side cover Installation Install the side cover according to the reverse procedure of removal 11 BODY COVER 11 9 11 BODY COVER UNDER COVER Removal Remove the floor panel Remove the left right side cover Remove the left right side 4 mounting bolts between the under cover and frame Hemove the under cover Installation Install the under cover according to the reverse procedure of removal 11 10 5 12 Brake System Disc Brake Caliper Brake pad replacement Brake Disc Disc Brake System Rear Drum Brake System Maintenance Information Troubleshooting Hydraulic Disc Brake Disc Brake Air Bleed Disc Brake Master Cylinder Rear Drum Brake Disc Brake System A i lt HARC 1 0 1 4kgf m 3 3 3 7kgf m 3 3 3 7kgf m 2 4 3 0kgf m 2 4 3 0kgf m 12 1 12 Brake System D S M Rear Drum Brake System 11 0 13 0kgf m 12 2 5 12 Brake System Maintenance Information Precautions in Operation N Caution Inhaling brake lining ashes may cause disorders of respiration system therefore never use
3. 16 ELECTRICAL EQUIPMENT 16 25 16 ELECTRICAL EQUIPMENT SYM Handle switch headlight s Switch Remove the front handle cover P Disconnect the connector of the handle switch Check the continuity of follow pins listed below columns Headlight switch ory oe Yen starting switch SIN headli ellow Z headlight brown white y switch pink Starting switch yellow red High Low beam switch passing turn signal gt pes horn switch High Low beam Z switch seat open s EL H brown white Horn switch FREE orange turn signal Q gt Bus switch grey s Light green ull NEN Sky blue Black 7 Horn switch 16 26 SYM 16 ELECTRICAL EQUIPMENT Turn signal light switch Sky SS e gt ome turn signal light switch Brake light switch The circuit of black wire and the green yellow wire on the brake light switch should be in continuity when operating the brake lever If the switch damaged replace it with new one Horn Remove the front cover Connect the light blue wire on the horn to the battery positive terminal and the green wire to the battery negative terminal Then the horn should sound Replace it if necessary 16 27 16 ELECTRICAL EQUIPMENT FUEL UNIT Open the seat Remove the luggage box bolts x 4 Remove the R R carrier bolts x 3 Re
4. Sliding pulley Cil seal Guide pin Guide pin roller diameter Clutch outer SM 8 V Type Belt Drive System Kick Starter Clutch weight Clutch weight Measure each clutch weight thickness Replace It if exceeds service limit Driven pulley spring Measure the length of driven pulley spring Replace it if exceeds service limit Free length Driven pulley Check following items f both surfaces are damage or wear f guide pin groove is damage or wear Replace damaged or worn components Measure the outer diameter of driven pulley and the inner diameter of sliding pulley Replace it if exceeds service limit Driven pulley Driven Pulley Bearing Inspection Check if the inner bearing oil seal is damage Replace it if necessary Check if needle bearing is damage or too big Sliding pulley Guide pin groove 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 4 Caution Some of models are equipped with two ball bearings Outer ball bearing 8 11 8 V Type Belt Drive System Kick Starter Clutch Block Replacement Remove clip and washer and then remove clutch weight and spring from drive plate Spring Caution Some of models are equipped with one mounting plate instead of 3 snap clips Check if spring is da
5. Caution The bearing must be replaced when removing the drive shaft Drive shaft is pulled out with it s bearing then remove the bearing with bearing puller and shaft protector Special tool Multi functional bearing puller or Outer bearing puller Shaft protector Remove drive shaft oil seal and bearing from left crankcase Special tool Final shaft Drive shaft Q5 M Remove final gear final shaft and counter gear counter shaft Remove the drive shaft from left crankcase Caution The bearing must be replaced when removing the drive shaft Drive shaft is pulled out with it s bearing then remove the bearing with bearing puller and shaft protector Special tool Multi functional bearing puller or outer bearing puller Shaft protector Remove drive shaft oil seal and bearing from left crankcase 9 Final Driving Mechanism Counter shaft Special tool Final shaft 9 Final Driving Mechanism QS M Inspection of Final Driving Mechanism Check if the drive shaft are burn wear or damage and replace it if necessary Caution f remove the drive shaft from the gear box upper side then its bearing has to be replaced Check if the countershaft is wear or damage and replace it if necessary Check if the final shaft and gear are burn wear or damage and replace it if necessary Check bearings on gearbox cover Rotate each bearing s inner ring with fingers Oil seal Beari
6. Disassembly Remove the engine hanger bracket nut and bolt Disassembly engine hanger bracket A and engine hanger bracket B Check if the engine hanger rubber bushes hanger bushes and collar for damage If so replace with Rubber bush new ones Assembly Install hanger bushes and collar into engine hanger bracket B Install engine hanger bracket A and engine hanger bracket B and tighten the bolts and nuts of engine hanger bracket Rubber bush Torque Value 4 5 5 5kgf m Engine installation Exhaust muffler connection nut Install in the reverse order of removal procedures Tighten the engine mounting bolts and rear cushion upper lower bolts Torque value Engine hanger bolt 4 5 5 5kgf m Rear cushion upper mounting bolt 3 5 4 5kgf m Rear cushion lower mounting bolt 2 4 3 0kgf m Exhaust muffler connection nut 0 8 1 2kgf m Exhaust muffler mounting bolt 2 4 3 0kgf m Perform the following inspection and adjustment after installation e 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 e Adjust rear brake 6 Cylinder Head Cylinder Piston Maintenance Information 6 2 Cylinder QT a 6 3 Troubleshooting 6 2 Cylinder Piston 6 5 1 6 2 0kgf m 6 1 6 Cylinder Head Cylinder Piston OS Maintenance
7. 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 95 Battery A Caution e 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 then go to hospital to see an ophthalmologist If 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 A Caution Inhaling asbestos dust may cause disorders and cancer of the breathing system Brake fluid A Caution Spilling 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 brake fluid beyond reach of children S 1 GENERAL INFORMATION TROUBLE DIAGNOSIS SERVICE PRECAUTIONS Always use with SANYANG genuine pa
8. 5 12 Brake System 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 Tighten the brake hose bolt to the specified torque value Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together Caution Improper routing may damage leads hoses or pipes N Caution Kink of brake leads hose or pipe may reduce brake performance Add specified brake fluid and bleed the system 12 11 12 Brake System Rear Drum Brake To use vacuum cleaner or other alternatives to avoid danger caused from dusts Caution e 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 Hemove 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 Caution Clean the rust onto the brake drum with 120 sandpaper 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 Removal amp C
9. 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 Engine oil pipe Oil pump 2 Service Maintenance Information Oil Pump Control Cable N Caution To adjust the oil pump control cable after adjusted the throttle grip play Remove the luggage box Wide open the throttle valve and check if the calibration point aligns on the oil pump lever with the mark of pump body Loosen the adjustment nut of the oil pump control cable Turn the adjustment nut and align with the point then tighten the mounting nut 4 E Adjustment nut Battery Loosen four screws of battery cover and then remove the cover Check if the battery terminals are loosened 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 amp 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 i
10. SERVICE MANUAL D S M FORWARD This service manual contains the technical data of each component inspection and repair for the SYM JET 4 R 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 JET 4 R 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 INDUSTRY CO LTD HOW TO USE THIS MANUAL DSM This service manual describes basic information of different system parts and system inspection amp service for JET 4 R 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 second chapter covers service maintenance information The third to the tenth chapters cover engine and driving systems The eleventh to fourteenth chapters are contained the parts set of assembly bogy The fifteenth chapter is electrical equipment The sixteenth chapter is wiring diagram The seventeenth chapter is special tool Please see index of content for quick having the special parts and system information All information illustration directions and specifica
11. 2 Worn clutch weight 8 2 S M 8 V Belt Drive System Kick Starter Left Crankcase Cover Left crankcase cover removal Remove rear left body side cover Remove air cleaner 2 bolts Remove kick start arm 1 bolt Remove left crankcase cover 11 bolts Disassembly of Kick Starter Hemove 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 LU Starter spindle Starter spindle Uy Bolt m x OP Kick start arm Snap ring Thrust washer Thrust washer Driven gear Friction spring 8 3 8 V Type Belt Drive System Kick Starter 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 temporary olightly 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 L m 2 i D i s 2 I K E u 4 i F j il cA F w ma i F i oi m VE GE pU um P a E vex
12. Less than 1 mA Disconnect each cable one by one and take measurement of the current of each cable to locate the short circuit 16 5 16 ELECTRICAL EQUIPMENT SYM Battery Removal Remove the battery cover Battery cover M A CAUTION e Electrolyte diluted sulfuric acid is very toxic Once it spreading on clothes skin or eyes it will cause burned or blind case of being spread flush with great quantity of water immediately and then send to hospital When clothes is spread by electrolyte it will contact with skin So it must flush with great quantity water to take off the clothes Remove the battery cover Disconnect the negative cable from the battery first then the positive cable Remove the battery positive negative Install the battery in reverse order of removal A CAUTION e To prevent form circuit short connect positive terminal at first and next negative terminal 16 6 SYM Voltage Check With a digital voltage meter or multi meter to measure battery voltage Voltage Fully charged 13 0 13 2V at 20 C Undercharged Below 12 3 V at 20 C CHARGING Connect the Charger positive to the battery positive terminal Connect the Charger negative to the battery negative terminal otrictly keep flames away from a charging battery The charging ON OFF is controlled by the charger s switch Do not control the cha
13. SW WINKER SW HORN SW OIL LEVER SW FRAME FUEL EARTH WH G 7 lt Sz N B G R G E 5 gt E S Y R G Y wai FUSE 10A __ C liL C S i F UT L Y 1 Y W x Y W lt gt gt 5 REG REC LL pP 4 CDI UNIT CONTROL SW RH RR WINKER 12V 10W SB G TAIL STOP LIGHT 12V 5W 21W B G Y BR G 1 LICENCE LAMP 12V 5W G G 0 LH RR WINKER 12V 10W G1 IG COIL G B Y AUTO SPARK PLUG B S ref Rep _ O ORANGE _ P PM SPECIAL TOOL ITEM ACG FLYWHEEL PULLER SYM 3111000 PURPOSE REMOVE ACG FLY WHEEL ITEM BEARING DISASSEMBLER SYM 62022 6204 PURPOSE REMOVE THE BEARING ITEM CLUTCHSPRING COMPRESSOR SYM 2301000 PURPOSE DISASSEMBLE THE CLUTCH S M ITEM ONE WAY CLUTCH amp STARTING GEAR LOCK NUT PULLER SYM 9020100 PURPOSE REMOVE ONE WAY CLUTCH FIX NUT ITEM UNIVERSAL HOLDER NO SYM 2210100 PURPOSE HOLD THE MDF CLUTCH OUTER ITEM CLUTCH NUT WRENCH SYM 9020200 PURPOSE LOOSE THE CLUTCH NUT
14. combustion chamber 5 Ignition timing too advanced 1 Too much carbon deposited in combustion chamber 2 Lean mixture 3 Poor fuel quality 4 Lean mixture 1 10 05 1 GENERAL INFORMATION TROUBLE DIAGNOSIS C Engine runs sluggish especially in low speed and idling Check and adjustment and Check and adjustment Fault condition condition Probable causes Check ignition timing using ignition lamp 1 Incorrect ignition timing malfunction of CDI or AC alternator Adjust the air screw of carburetor 2 Lean mixture tighten the screw Air sucked through carburetor gasket Remove spark plug install spark plug into spark plug Poor heat insulation gasket Carburetor lock loose Poor intake gasket Poor carburetor O ring T and perform spark test Spark plug fouled Malfunction of CDI against engine ground Malfunction of AC generator Good spark Malfunction of ignition coil Open or short circuit in spark plug Malfunction of main switch D Engine runs sluggish High speed Check and adjustment and Check and adjustment Fault condition condition Probablecauses 000 Probablecauses 000 Check ignition timing 1 Malfunotion of CD 2 Malfunction of AC alternator Check for fuel supplying system in automatic fuel cup 1 Insufficient fuel in fuel tank 3 Restricted fuel tank v
15. Information Precautions in Operation The inspection and maintenance of the cylinder head cylinder 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 Piston OD 38 955 38 970 Clearance between cylinder and piston 0 030 0 050 Cylinder NENNEN NN Delomation o o ID inner diameter OD outer diameter Tighten torque value Cylinder head 1 6 2 Spark plug 1 171 Exhaust pipe connection nut 0 8 1 2kgf m Exhaust muffler mounting bolt 2 4 3 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 Oylinder worn out or damaged Compression Pressure Too High Overheat Knock 1 Too much carbon deposit built up in combustion chamber 6 2 Cylinder Head Vacuum tube Fuel outp
16. Replace the alternator charging coil if the measured value exceeds standard Alternator lighting coil Check Remove the 3P connector of the alternator Measure the resistance between the yellow wire on the alternator and frame ground by multi meter Standard 0 8 0 10 20 Replace the alternator lighting coil if the measured value exceeds standard Resistor check Remove the front cover Measure the resistance between the resistor wire green black and frame ground Standard 50 5 4 5 5 5 green black Standard 7 50 30W 7 0 8 0 pink 16 10 SYM 16 ELECTRICAL EQUIPMENT IGNITION SYSTEM Ignition System Circuit Blue yellow Black yellow Pluser Engine start control switch spark plug Blue yellow Blue yellow green Black black yellow green C D I unit green CDI UNIT Removal Remove the right body cover then the unit can be removed from the frame Check Disconnect the connector from the CDI unit Make the following inspection at each terminal of the harness side connector Measure at otandard at 20C Pulse Generator Blue Yellow green 50 2000 Black yellow green 0 210 10 DEOR Green high voltage cable w o cap 3 5 Green high voltage cable w 7 12 16 11 16 ELECTRICAL EQUIPMENT Ignition coil Removal Remove the luggage box center cover Remove spark plug cap Remove the primary coil wire of ignition coil Remove the fix bolts for
17. Secondary coil Attached the spark plug cap measure the resistance between plug cap side and green terminal Standard value 7 12 20 C Remove the spark plug cap measure the resistance between plug cap side and green terminal Standard value 3 5 20 Secondary coil is good if resistance within standard Secondary is broken if resistance is infinite If the spark plug cap attached and the measured value is exceed standard value it means the spark plug cap is in not good Replacement Remove the ignition coil bolt to replace the ignition coil if necessary Pulse generator Caution Checking pulse generator can be done on engine But the spark plug must be installed onto the cylinder head and cylinder compression pressure must be in normal condition Check Remove body cover Remove the pulse generator connector Measure the resistance between blue yellow terminal on engine side and frame ground Standard 140 200 20 C Replace the alternator if the measured value exceeds standard value 16 13 16 ELECTRICAL EQUIPMENT SYM STARTING SYSTEM Starting Circuit red ignition switch rear brake black switch start moter rs start e button 1 d bs pre 3 Pgreen yellow start magnetic green witch front brake switch Starter magnetic switch inspection Turn main switch to on and operate the brake lever Then press s
18. Thus ignition timing need not to be adjusted In case of incorrect ignition timing occurred check the CDI unit or alternator system It has to check the ignition timing with the ignition timing light if replaced these components Do not hang or impact the CDI unit of ignition system because the major faulty of CDI unit is caused by impact Therefore take care when disassembling Most of ignition system problems were resulted from poor connecting connector Please check the connectors first when servicing Make sure that the heat range of spark plug is suitable Improper spark plug is the main cause of poor engine operation or combustion Inspection procedures in this manual are based on Max voltage This manual also contains methods of how to check ignition coil resistance and component operation Please follow the continuity chart to check ignition switch Starting System Starting motor can be removed directly from engine Please refer to chapter 10 for starting clutch removal procedures 16 2 SYM 16 ELECTRICAL EQUIPMENT Specification Charging System Item opecification Battery Capacity 12V6Ah 0 7A 5 10 hours standard 3A 1 hour fast Charging rate charging Leak current 1 mA Charging current 2 1 A 5000 rpm 1 Control voltage in charging 14 0 15 0 V 5000 rpm Ignition System Item opecification BR8HSA Recommended Spark plug Ignition coil and 0 19 0 23 resistance Secondary
19. air hose or dry brush to clean brake parts Use vacuum cleaner or other authorized tool instead 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 e 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 e Check the operation of the brake system before you go The thickness of front brake disc Front brake disc run out brake master cylinder inner diameter Specifications brake master cylinder piston outer diameter OD of front brake disc Thickness of front brake lining Torque values Brake hose bolt 3 3 3 7kgf m Bolt for brake caliper 2 4 3 0kgf m Bolts for the brake disc 2 4 3 0kgf m Nuts for the front wheel axle 5 0 7 0kgf m Nuts for the rear wheel 11 0 13 0kgf m Bolt for rear brake arm 0 8 1 2kgf m Rear brake lever nuts 0 8 1 2kgf m Brake master cylinder mounting bolts 1 0 1 4kgf m 12 3 12 Brake System Troubleshooting Disc Brake Soft brake lever 1 Air inside the hydraulic system 2 Hydraulic system leaking 3 Worn master piston 4 Worn brake pad 5 Poor brake caliper 6 Worn brake lining disc 7 Low brake fluid 8 Blocked brake pipe 9 Warp bent brake disc 10 Bent brake lever Drum Brake Poor brake pe
20. amp free play check 8 Steering handle check I LLL p perpe Every 6000KM Every 12000 6 month 1 year Heference C C 9 Cushionoperationcheck 1 I J 0 10 Every screwtighteningcheck 1 1 Gear oil check for leaking 1 1 2 R yc 12 Spark plug check or change 13 Gearoilchange 5000 14 Frame lubrication o 0 15 Exhaustpipe o T T j jq o 0 pe 16 Carburetor I jJ l j _ 17 Drivingbeltcheck 141 18 Ignitiontiming I o 0 19 Emissioncheckiniding 1 1 2 120 despedchek 1 J UJ Brrelnms 01010100 o j o 0 122 Throttle operation j 02 2 23 Engine bolt tightening 1 L T UJ 0 24 Engine screw torque 25 Carbon cleaning for cylinder x head cylinder and 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 C Cleaning replaced if necessary R Replacement L Lubrication The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first Hemarks 1 Clean or replace the air cleaner element more often for pro long engine life span when t
21. brake hose Remove the master cylinder seat and the master cylinder m E a 12 9 12 Brake System Remove the rubber pad Remove the cir clip Remove the piston and the spring Clean the master cylinder with recommended brake fluid 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 Cylinder gauge Measure the outer diameter of the piston Replace the piston if its measured value exceeds Master cylinder allowable limit Master Cylinder Assembly Caution Piston tis 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 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 Micrometer 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 7 x es 2 X 6 ES 5 cr d 7 ES i Master cylinder Spring 12 10
22. clean container Remove the oil level switch wire coupler of the oil indicator Remove the mounting bolt on the oil tank upper and left side two bolts and then remove the oil tank Installation Install in the reverse order of removal The oil tubes air bleeding after installation 3 Lubrication System 3 Lubrication System OSM 3 6 OS M 4 Fuel System Maintenance Information Float Level Inspection Troubleshooting HH 4 2 Carburetor Installation Throttle Valve Reed Valve Carburetor Remove Air Cleaner Auto By Starter Float Float Valve Jet Fuel cap Fuel unit Fuel tank Fuel pump Fuel inlet tube a7 m Fuel filter Carburetor 4 1 4 Fuel System QS M Maintenance Information Precautions in Operations amp Warning Gasoline is a highly flammable material and may explosive under circumstance Thus always work 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 e When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly thas to conduct air bleeding operation as removed the oil tube dle speed adjustment Specification Idle speed 1900 00 rpm Troubleshooting Engine cannot be started Lean Mixture 1 No fuel in fuel tank 1 Clogged carburetor jet 2 Fuel can n
23. onto throttle cable and the sliding surface of handle grip Align the lock pin of the right handle switch with the hole on the handle and then install the right handle switch Tighten the screws 2 screws Align the lock pin of the left handle switch with the hole on the handle and then install the left handle switch Tighten the screws 2 screws Check hoses and cords dispose Install all components in reverse order of removal procedures Conduct following adjustment Oil pump control cable hrottle operation Brake lever free play drum brake 13 4 Handle mounting nut and bolt Front brake hose Meter cord Left handle switch cord Throttle cable Right handle Rear brake hose switch cord Rear brake cable Steering handle pipe S M 13 Steering Front Wheel Front Cushion Front Wheel Removal Support body bottom and lift front wheel free of ground with a stand Remove speedometer cable from speedometer gear box 1 screw Remove front wheel axle nut and then pull out the axle and remove the wheel Axle nut 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 Place the wheel on to a rotation seat and turn the wheel to check its bearing free play f the bearing is noisy or its free play is too much replace it e Wheel axle Free play a Free play 13 5 Place t
24. so that there is enough room below the enlarged ends for tightening the clamps a Groove Clamp Connector Rubber and plastic boots should be properly reinstalled to the original correct positions as designed d rd Boots The tool should be pressed against two inner and outer bearing races when removing a ball bearing Damage may result if the tool is pressed against only one race either inner race or outer race In this case the bearing should be replaced To avoid damaging the bearing use equal force on both races Both of these examples can result bearing damage Lubricate the rotation as assembling Check if positions and operation for installed parts is in correct and properly Cables and Harness Routing 05 1 GENERAL INFORMATION TROUBLE DIAGNOSIS Note the following when routing cables and wire Harnesses e Aloose wire cable or harness may cause safety hazard After clamping check each wire to make sure it is secured e Do not squeeze wires against the weld or its clamp e Secure wires and wire harnesses to the frame with respective wire band at the designated locations Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses e Route harnesses so that they neither pull too tight nor have excessive slack e Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner e Route wir
25. specified torque value Torque value 5 5 6 5kgf m Movable Drive Face Removal Remove fan cover and fan Remove left crankcase cover Hold generator flywheel with universal holder and then remove drive face nut Remove drive face Drive face gt OS M 8 V Type Belt Drive System Kick Starter Removal Drive face boss Remove movable drive face set and drive belt from crankshaft Movable drive face Remove ramp plate Ramp plate Remove weight rollers from movable face Weight roller Inspection The weight roller is to press movable driven face by means of centrifuge force Thus if weight rollers are worn out or damage the centrifuge force will be affected Check if rollers are wearing out or damage Replace it if necessary Measure each roller s outer diameter Replace it if exceed the service limit Weight roller 9 7 Check if movable drive face boss is worn or Movable drive face damage and replace it if necessary Measure the outer diameter of drive face boss and replace it if it exceed service limit Measure the inner diameter of drive face and replace it if it exceed service limit Reassembly Installation Install weight rollers Install ramp plate Apply with some grease to inside of movable drive face and install drive face boss Drive face Caution he drive face has to be free of grease Clean it with cleaning solvent S M 8 V Type Belt Drive System Kick S
26. stopper screw of the carburetor body Tighten the carburetor upper part Adjust the free play of throttle valve cable 4 Fuel System Carburetor Remove Remove 2 bolts and then remove the air cleaner Loosen connection hose clamp Disconnect the auto by starter coupler Loosen draining screw and then drain out fuel inside the carburetor Loosen carburetor upper part and remove Fuel hose Carburetor carburetor upper part upper part Remove fuel and oil hoses from carburetor NET Remove carburetor mounting bolt and carburetor Auto By Starter Inspection W gt Connect resistor meter to the terminals of auto clamp W 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 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 S M 4 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 compress
27. 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 rpm e Bulbs used exceed their rate and consume too much power e he replacement battery is aged and does not have enough capacity 2 The charging voltage is normal but the current is not e he replacement battery is aged and does not have enough capacity e Battery used do not have enough electricity or is over charged e The fuse of the ammeter is blown he ammeter is improperly connected 3 The charging current is normal but the voltage is not The fuse of the voltmeter is blown headlight ON SYM 16 ELECTRICAL EQUIPMENT VOLTAGE REGULATOR INSPECTION Remove the front cover screws 4 x 2 Remove the front cover mounting bolt bolt x 1 and remove the left right turnlight wiring connector Disconnect the connector on the diode and check the continuity between main wire terminals according to following method Main wire circuit inspection Item wire color Judgment Check voltage between battery terminal red and Battery voltage ground green Check continuity between ground green and frame Check illumination wire yellow to ground disconnect the connector of Continuity amp the resistor s pin and resistance automatic by starter pin Illumination switch is in OFF Ch
28. the ignition coil and remove the ignition coil Install the ignition coil in reverse order of removal Ignition coil Caution Install primary coil with black yellow lead connected to black connector and green lead connected to green connector Spark plug confirmation Remove the spark plug and install a good plug into plug cap and then ground it to engine ground Make sure its spark condition If it is in not good or burnt spark plug replace the spark plug with new one Caution Make sure each wire connection is correct and test as required Even the wire connection is in correct sometimes it might not be tested occurred Connect the high voltage shunt with a multi meter or input a resistor in the 10 0 100V of voltage meter Connect ignition coil wires and connect a shunt between primary terminal black yellow and green and frame ground Press the starting motor button or starting lever to test the max primary voltage of ignition coil Connection connect terminal to green side and to black yellow side Min voltage Above 95 V high voltage shun Caution Do not touch metal parts on the test probe Disconnect the primary coil connector and chec the resistance between primary coil terminals Standard 0 210 0 Q at 20 Primary coil is good if resistance within standarc Primary coil is broken if resistance is infinite Replace the coil 16 12 SYM 16 ELECTRICAL EQUIPMENT
29. with the retain plate of fuel tank as installation and then turn the retain plate in clockwise direction until matching to the arrow Inspection 1 Connect the fuel unit coupler 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 positions Conduct the step 2 if the needle on the fuel indicator is not moved 2 Measure the coupler resistance while the float in up and down positions _ Float position Resistance value amm _Down empty 90 1000 _ Check the fuel indicator if the resistance is in normal Replace the fuel gauge if the resistance is abnormal Fuel unit plastic 16 19 16 ELECTRICAL EQUIPMENT SYM Tail amp stop light Stop switch Headlight beam switch Main switch Winker relay E Winker switch LE 2 Fuse 10A O Left winker light 16 20 SYM Starting Motor Removal Remove the battery cover Firstly remove the battery negative terminal and then remove the positive terminal Remove the luggage box Remove the starting motor power wire Remove the starting motor mounting bolts and motor Starting Motor Installation Install the motor in reverse order of removal METER Removal Remove the front handle cover Remove the speedometer cable Remove the front cover Remove the power connector of the meter 16 ELECTRICAL EQUIPMENT 16 E
30. Carbon on the combustion chamber or cylinder head 2 12 Pilot screw Idle speed adjustment screw HEADLIGHT ADJUSTMENT Remove the front cover Turn on the main switch Turn the headlight adjustment screw And adjust the headlight beam height Then tighten the adjustment screw after the beam height in proper position Caution To adjust the headlight beam follows related regulations Improper headlight beam adjustment will Headlight adjustment screw make in coming driver dazzled or insufficient lighting NUTS BOLTS TIGHTENESS Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all bolts and nuts on the frame are tightened securely Check all fixing pins snap rings hose pipe clamps and wire holders for security SM 3 Lubrication System Lubrication System Diagram 3 1 Oil Pump Removal 3 3 Precautions In Operation 3 2 Oil Pump Installation 3 3 LUDNICA RL D I I 3 2 Oil Pump Oil Tube Air Bleeding 3 4 Trouble Shooting 3 2 MENOR TIT 3 5 Lubrication System Diagram Oil lever switch Cil tank Oil tube Oil output tube De ZZ Oil pump 3 1 3 Lubrication System OSM Precautions in Operation Be careful not let dirt enters into engine or oil hoses when removi
31. Cycle Cooling a 80 112 dB A Exhaust Pipe Position Right side and Number Arran Single Cylinder idm forced circulation amp gement splashing Sys Cylinder ENGINE Compression ERE razo wogws atio Idle speed 1900 100 rom Fuel tank Capacity 5 20L 2 5KW 6000 rpm Air Filtration Paper filter W n Starting System Electrical amp Kickstarter 1 6 05 1 GENERAL INFORMATION TROUBLE DIAGNOSIS TORQUE VALUES ENGINE x o P REMARKS i 7 amp lemo _ Samoerai 3 s e 0832 Purse e ome amem rom posee Inlet pipe flange bolt 0 8 1 2 Cooling fan flange bolt 0 8 1 2 CetuworsuaedjiTumebor 2 6 0812 uw Movable drive face nut DwepMeypaemt w 8595 Lorankcase covertangebot 59 6 Rearoake soe ancrorpn tarer 1 8 3529 Rearbrake amfangebot 1 6 cere K swwampt 6 0812 Erase o 2 Exhaust pipe comecing ns 2 6 cere 1 7 1 GENERAL INFORMATION TROUBLE DIAGNOSIS S 7 A TORQUE VALUES FRAME THREAD DIA TORQUE n VALUE qum REMARKS Sieerng handle nut _ 4 075 5 09 Front wheel axle nut ER EE EE CERE 5 0 7 y mounting nut Exhaus
32. LECTRICAL EQUIPMENT Remove the rear handle cover Remove the meter mounting screws Take out the meter Fuel Gauge Speedometer Turn Left Signal e Turn Right Signal Indicator al Indicator l Clock Odometer Trip High Beam Indicator 3 D kilometer _ med i __ SELECT A Engine Warning Light High Beam Indicator Speedometer Time meter E Aw ps Turn Left Seri T9 f 9 1 Right Indicator Signal f p i A A rasa Fuel meter Odometer Trip NEL kilometer E A Caution Do not wipe the meter or headlight with organic solvent such as gasoline to prevent from damage these components Installation Install the meter in reverse order of removal 16 22 SYM 16 ELECTRICAL EQUIPMENT LIGHT BULBS Headlight Bulb Replacement Rear the front handle cover Disconnect the headlight wire connector Press down the bulb spring locker and then remove the locker with turning it left motion Remove the bulb Replace the bulb with new one if necessary 12V 35W 35W A Caution Do not touch the bulb surface with fingers because the bulb will create hot spot so that let it be burnt It has to be package with cloth or wear glove as installing Wipe the bulb with cloth to prevent from damaged if the bulb be touched by hands Install the bulb in reverse order of removal Turn the main switch ON OFF to check if th
33. Torque value 5 0 7 0kgf m Connect the speedometer cable to the speedometer gear box Stopper 13 7 13 Steering Front Wheel Front Cushion Front Cushion Removal Remove front cover front fender and front wheel Remove the caliper mounting bolt and the caliper Take out the hose from hose clamp Brake caliper Remove the front cushion upper bolts and the front cushion Installation Align the cover flange with upper level of the cushion clamp and then tighten bolts Torque value 2 4 3 0kgf m Install the removed components in reverse order of removal procedures 13 8 OS M 13 Steering Front Wheel Front Cushion Steering Stem Steering stem Removal mounting nut Remove steering handle front wheel and front cushion Remove the steering stem mounting nut Remove top cone race and front fork dh Place the steel ball onto a parts container to prevent from missing O Top cone race 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 O Do not damage the steering stem Installation Steering stem mounting nut Install a new bottom cone race onto the steering cone stem i x Push the cone race until to mounted position Top ball x bearing seat dh Bottom ball bearing seat a a O Do not tilt
34. Y Y 9 3 Re Assembly of Final Driving Mechanism H 9 8 Bearing 6004UU Oil seal 27x42x7 d Bearing 6201 1 256 Bearing 1 0 1 5kgf m i 2 4 3 0kgf m Oil seal 17x30x6 v 1 0 1 5kgf m 9 1 9 Final Driving Mechanism Maintenance Information Limited usage of gear oil gear oil 140 Recommended oil Bramax serial oil Oil quantity 110 c c 100 c c as replacement Torque Values Mission cover bolt 2 4 3 0kgf m Mission oil drain bolt 1 0 1 5kgf m Mission oil check bolt 1 0 1 5kgf m Troubleshooting Trouble Diagnosis Engine can be started but scooter cannot 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 oll 2 Worn or damage oil seal S M 9s Disassembly of Final Driving Gear Oil filling bolt Mechanism Remove driven pulley Remove gear oil drain bolt and filling bolt Drain gear oil out from gearbox 9 Final Driving Mechanism Remove muffler and rear wheel Rear wheel nut Remove gearbox cover mounting bolts from the 7 bolts clutch side 7 bolts Remove the mission cover from the rear wheel side 9 Final Driving Mechanism Remove final gear final shaft and counter gear counter shaft Counter shaft Remove the drive shaft from left crankcase
35. al Information 2 1 Transmission Oil Periodical Maintenance Schedule 2 2 Spark Plug Rit iot wai dst tie 2 3 Control Cable Lubrication Fuel Lines 2 3 Driver Belt u 2 4 Ignition Timing Engine Oil LiNE usa auqa sunak 2 4 Throttle Valve Operation Oil Pump Control Cable 2 5 Carburetor Idle Speed Adjustment 2 12 Battery awaqa I ULM SO 2 5 Cylinder Compression Pressure Test 2 12 2 6 Headlight Adjustment Rear Drum Brake Free Play 2 6 Disc Brake System Hose 2 LL D EEUE BL LE LI LI Steering System 2 9 5 555 555 2 9 General Information Specification Type HYPOID GEAR OIL Transmission oil Recommendation SAE 140 Quantity 0 12 L Replacement 0 111 2 Service Maintenance Information OS Periodical Maintenance Schedule Maintenance Every Every Maintenance C i mE NEN NENNEN Ed interval RA deme O 1 2 Fuelfilter 3 Engine oil filter cleaning CC 4 Oil pump linkage operation check New C 5 Tirepressure I 6 Battery inspection 1 7 Brake
36. and connecting rod 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 Caution Make sure that all rings in the piston ring groove cannot be rotated around the lock pin to avoid to damaging the rings piston and cylinder 1T top ring 2T 2 ring Piston pin snap ring S 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 6 Cylinder Head Cylinder Piston Install the cylinder head Tighten torque 1 6 2 0kgf m Replace the exhaust pipe washer with new one m Connection nut and then install exhaust pipe a FT Tighten exhaust pipe connection nut Tighten torque 0 8 1 2kgf m Tighten exhaust pipe mounting bolt Tighten torque 2 4 3 0kgf m Install the removed parts in the reverse order of removal procedures Inspect following item after installation Test engine compression pressure Check for engine noise 7 Generator Maintenance Information Generator Removal 0 8 1 2kgf m n 0 8 1 2kgf m p E 7 A C Generator QS M Maintenance Information Precautions in Operation e he maintenance service of A C generator can be carrie
37. ar mirror Handle visor Right body cover Rear carrier Rear handle cover L rear mirror o L F Inner box cover Inner box M Rear pe S N Inner fender V Front cover Under spoiler Floor panel Front fender Right side cover gt Splash board plate Rear fender Under cover mudguard Left side cover 11 1 11 BODY COVER S M MAINTENANCE INFORMATION Body covers disassemble sequence Front Handle cover Luggage box amp Seat Front cover Rear handle cover Front fender Left right side cover Under cover Floor panel Front inner box Tail light Be 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 Align the buckles on the guards with slot on the covers Make sure that each hook is properly installed during the assembly Never compact forcefully or hammer the guard and the covers during assembly 11 2 QS 11 BODY COVER HANDLE COVER Removal Hemove 1 lower mounting screw of the handle front cover Hemove the mounting screws 4 screws between the front handle cover and the rear handle cover turn signal light Removed the head light wire connectors connectors Removed the left right turn signal light connectors Remove the front han
38. around the oil pump Disconnect the oil tube Fill out oil to oil pump connection section by means of the oil pot so that the oil pump body is full with oil Fill out oil to oil tube connection section so that the oil tube is full with oil Then install the tube onto oil pump Make sure whether air is in the oil tube or not after installation amp Caution After bleeding the oil tube and oil pump the oil I U Oil output tube 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 N Caution Motorcycle s exhaust gas includes with CO which causes human to coma or death so perform this operation in well ventilation place Run the engine in extreme low speed to avoid to damaging the engine caused from clogged oil tube Oil output tube m 7 Recommended oil 9 5 Cil Tank Removal Remove the luggage box and seat Remove the right left side covers right left rear side covers center cover rear carrier body covers rear fender and rear inner fender Refer to chapter 11 Remove the oil input tube from oil pump and then drain oil to a
39. asher and final shaft into the gearbox T Sm in pr Install the mission cover and tighten the bolts 7 y ode bolts Mu e 8 Torque value 2 4 3 0kgf m Ta 2 Install driven pulley clutch outer belt T TT Install movable drive face drive face and left crankcase cover Install rear wheel Add gear oil Gear oil quantity 105235c c Final shaft Counter shaft Side washer 10 Crankcase Crankshaft Maintenance Information Crankshaft Removal Troubleshooting Crankshaft Inspection Crankcase Disassembly Crankcase Installation Apply sealant 10 1 10 Crankcase Crankshaft QS Maintenance Information This chapter concerns disassembly of the crankcase for repair purpose Before disassembling crankcase except removing engine firstly following components must be removed too Carburetor chapter 10 Oil pump chapter 3 Reed valve chapter 10 Driving belt chapter 7 Alternator chapter 6 Cylinder head cylinder piston chapter 5 Except above components are needed be removed when disassembling L crankcase following components must be removed too Final driving mechanism chapter 8 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 sid
40. at for crack damage and the clearance between the seat and the valve Replace reed valve if necessary Caution Do not bend the reed valve stopper Otherwise it will cause its strength insufficient and rough engine running f the reed valve or its seat is damaged replace with a set Installation Install in the reverse order of removal procedures Check for leaking after installed 4 8 Reed valve Reed valve seat Carburetor b Fuel hose 4 Fuel System Air Cleaner Removal Installation Remove air cleaner and rear inner fender mounting screw Loosen connection hose clamp Remove 2 bolts and then remove the air cleaner Install in the reverse order of removal procedures 4 9 D S M 5 Engine Removal Maintenance Information 5 2 Engine hanger bracket Engine removal 5 3 Engine installation 4 5 5 5kgf m 4 5 5 5kgf m 5 1 5 Engine Removal Maintenance Information There are parts that require removal of engine for maintenance e Crankcase e Crankshaft Related bolts tightening torque for removal of engine Engine hanger bolt 4 5 5 5kgf m Engine hanger bracket bolt 4 5 5 5kgf m Rear cushion upper mounting bolts 3 5 4 5kgf m Rear cushion lower mounting bolts 2 4 3 0kgf m Exhaust muffler connection nut 0 8 1 2kgf m Exhaust muffler mounting bolt 2 4 3 0kgf m OS 5 Engine removal Remove body cov
41. ation starter motor and gasket Remove 2 bolts for disassembly the starter motor Armature Inspection Check the armature for discoloration or other a Armature damage It may be short circuiting if dark 1 surface on the shifter found V Spring 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 cannot be in continuity Carbon bracke Starter Motor Re Assembly Installation Re assemble and install the starter motor in reverse order of removal procedures 16 16 SYM 16 ELECTRICAL EQUIPMENT Level Switch Troubleshooting fthe oil level in oil tank is in specified level but the oil level indicator still goes on 1 Remove luggage box 2 Disconnect oil level switch wire and turn the main switch to ON position Indicator light up Indicator not light up Short circuit between Malfunction of oil indicator and oil level level switch switch Main switch fthere is no oil in oil tank or low oil level but the oil level indicator still not goes on 3 Remove body cover 4 Disconnect oil level switch wire and connect a jump wire among coupler and then turn the Indicator main switch to ON position Indicator not light up Indicator light up Poor wire Malfunction of oil connection level switch C
42. aution Brake linings must be replaced as a shoe Remove the brake shoes from brake panel 12 12 S M 12 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 Brake efficiency will be reduced if brake shoe is contaminated by oil or grease Install the brake cam and arm after aligning it with the punched point Tighten the bolts and nuts to specified torque Torque value 0 8 1 2kgf m Use a brake cleaner to clean brake hub and Brake shoes replace the two brake shoes if brake linings are contaminated Caution Brake efficiency will be reduced if brake lining is contaminated by oil or grease Install spring onto the brake shoes Install the brake shoes to the brake panel one ARN after one and make sure the shoe springs are in i 7 correct position Brake shoe spring Install the wheel 12 13 12 Brake System 05 M Notes 12 14 S M 13 Steering Front Wheel Front Cushion Maintenance Information Front Wheel Troubleshooting Front Cushion Steering Handle Steering Stem 2 4 3 0kgf m 13 1 13 Steering Front Wheel Front Cushion D S M Maintenance Information Specification Torque Value Steering handle nut 4 07 5 0kgf m Brake master cylin
43. 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 8 13 8 V Type Belt Drive System Kick Starter Installation of Clutch Driven Pulley 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 Install guide pin and guide pin roller 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 Special tool Clutch spring compressor Clutch nut wrench Remove the clutch spring compressor Torque value 3 5 4 5kgf m Install clutch driven pulley and drive belt onto drive shaft 8 14 Oil seal Sliding pulley Oil seal Specified grease Guide pin Or Guide pin roller nut wrench e 9 Final Driving Mechanism Maintenance Information 9 2 Inspection of Final Driving Mechanism 9 6 Bearing Replacement 9 7 Troubleshooting eee 9 2 Disassembly of Final Driving Mechanism X
44. coil 2 8 3 4 KO Ignition timing F mark 13 BTDC 1700 rpm 16 3 16 ELECTRICAL EQUIPMENT TROUBLE DIAGNOSIS Charging System No power supply Dead battery Disconnect battery cable Fuse burned out Faulty ignition switch Low voltage Weak battery Loose battery connection Charging system failure Voltage current regulator failure Intermittent power supply Loosen wire connector in charging system Loose battery cables Loose charging system connection Loose connection in lighting system Charging system failure burn Fuse Loose broken or shorted wire or wire connection Faulty voltage current regulator Faulty alternator Starting System Starter motor does not work The fuse is blown The battery is not fully charge Poor main switch Poor starter switch The front and rear brake switches do not operate correctly Starter magnetic switch is out of work The ignition coil is poorly connected open or short circuited The starter motor is out of work 16 4 SYM Ignition System spark produced by spark plug spark plug is out of work The cable is poorly connected open or short circuited Between alternator and C D I Between CDI and ignition coil Between CDI and main switch Poor main switch Poor C D I alternator is out of work Engine does not crank smoothly Primary coil circuit Poor ignition coil Poor connection of cabl
45. d out directly on the scooter e Please refer to Chapter 15 for the relative A C generator inspection Torque value Flywheel 3 5 4 5kgf m Special Service Tools Flywheel puller Universal holder Coil resistance value for the A C generator Yellow blue PS L blue Y Y ellow AC generator Generator Removal Remove the luggage box and rear side cover Remove 3 bolts and then take out cooling fan COVer 7 Generator Remove 4 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 Remove the flywheel with flywheel puller 7 Generator Disconnect generator wire coupler and pulse coil Generator coupler coupler Remove the pulse coil and generator coil bolts 4 bolts and then take out the generator assembly Caution Care to be taken for not damaging the generator coil Generator Installation Install the generator assembly Connect the generator coupler Caution Connect the generator wire harness properly and then clip the harness with clipper Install the woodruff key onto the crankshaft groove A Caution e Clean dirt and metal pieces inside the flywheel e Make sure that there is no foreign material inside the flywheel Install the flywheel Tighten the flywheel 10 mm nut Torque value 3 5 4 5kgf m Install the removed parts in reverse order of removal proc
46. der mounting bolts 1 0 1 4kgf m Front wheel axle nut 5 07 7 0kgf m Brake disc bolt 2 4 3 0kgf m Front cushion mounting nut 2 4 3 0kgf m Front brake caliper bolt 2 4 3 0kgf m Steering stem mounting nut 1 0 1 2kgf m Special Tools Inner bearing puller Bearing driver 6201 Troubleshooting Hard To Steer The Front Wheel Wobbling 1 The steering shaft bolt is too tight 1 The rim is bent 2 steering shaft bearing are damaged 2 The wheel axle nut is not tightened improperly The ball and the top cone of the steering shaft 3 Bend wheel rim are damaged 4 Side worn or poor tire 4 Insufficient tire pressure 5 bearing play of the wheel axle is too large The Steering Handle Is Tilted 1 Uneven arrangement of the front cushions soft Cushion 2 The front fork is bent 1 Weak front cushion spring 3 front wheel axle is bent Noise In Front Cushion 1 Cushion outer tube noise 2 joint of the cushion gets loose 13 2 S M 13 Steering Front Wheel Front Cushion 2 bolts Steering Handle Removal Remove handle cover and front cover refer to chapter 11 Remove front brake master cylinder disc brake after 2 bolts removed 13 3 13 Steering Front Wheel Front Cushion Remove handle mounting bolt and nut and then remove the handle Installation Installs handle and align with bolt hole Install bolt and nut and then tighten it Torque value 4 0 4 5kgf m Apply with grease
47. dle cover Remove the speedometer cable Remove the rear handlebar cover 3 screws Removed the rear handle cover Installation Install according to the reverse procedure of removal Caution With the clipper to fix the end section of the handlebar cover Do not pull it forcedly to avoid to breaking the hooks Screwsx 3 11 3 11 BODY COVER FRONT COVER 4 Removal Remove the top cover Remove the 1 mounting bolt of front cover from the frame Remove the front under cover 6 mounting screws between the front under cover and the frame Remove the 2 mounting screws between the front cover and the left right side cover 11 4 Q5 11 BODY COVER Remove the 8 mounting screws between the front cover and the front inner box Remove the front cover from the frame Installation Install according to the reverse procedure of removal FRONT INNER BOX Removal Hemove the 8 mounting screws of front cover from the inner box A Remove the hook screw bolt from the front inner box 11 5 11 BODY COVER Remove the main switch cover Main switch cover Remove the front cover and front under Cover Remove the 2 screws between the inner box and the floor panel Remove the front inner box Installation Install the inner box A and the front inner box B according to the reverse procedure of removal 4 bolts BODY COVER REAR CENTER COVER REAR FENDER Removal Open t
48. e Oil seal has to be replaced with new one after assembled the crankcase Standard Lateral clearance of the big end of the connecting rod 1 Radial clearance of the big end of the connecting rod Crankshaft run out point A Crankshaft run out point B x Torque Values Crankcase bolt 0 8 1 2kgf m Troubleshooting Engine noise 1 Worn bearing of connecting rod bog end 2 Bend connecting rod 3 Worn crankshaft bearing 10 2 OSYM 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 Special Tools Crankcase disassemble tool SYM 1120100 G5 Crankshaft Removal As the diagram show with 2 special bolts to install the specified service tool onto the left crankcase Remove the crankshaft amp Caution Do not use iron hammer to knock out the crankshaft Remove crankshaft bearing with bearing puller Remove the right and left side oil seals Caution Replace the oil seal with new one as removing the crankshaft 10 Crankcase Crankshaft ET m ov Crankcase disassemble tool uum ou Crankcase disassemble tool 10 3 10 Crankcase Crankshaft Crankshaft Inspection Measure the clearance of connecting rod big end Measure the radial clearance of connecting rod big end at X Y directions as diagram show Plac
49. e bulb has been installed properly after installation Please conduct the headlight beam adjustment job if replace the headlight bulb headlight beam E The headlight beam adjustment adjustment screw Loosen the adjustment bolt located under the headlight Caution so that the light seat will be moved only when adjusting 16 23 16 ELECTRICAL EQUIPMENT SYM Front Turn Signal Lamp Bulb Replacement Remove the front handle cover Remove the wire connector of the turn signal light Front turn signal light the wire connector of the turn signal light Pull out the bulb and replace it with new one 12V 10W Installation Install the bulb in reverse order of removal Bulbs Replacement of tail light brake light rear turn signal light Remove the 2 screws of the taillight amp left right turn light lens Remove the tail light assembly Replace the bulbs of the tail light brake light 12V 5W 21W Replace the bulbs of the turn signal light 12V 10W Installation Install the bulb in reverse order of removal 16 24 SYM MAIN SWITCH HORN Main Switch Check Remove the headlight connector and the front cover Disconnect main switch leads connector Check connector terminals for continuity LOCK Replacement Remove the main switch connector and fixing bolts bolts x 2 Remove the main switch Install a new main switch and tighten the bolts bolts x2
50. e and connectors Poor main switch Secondary coil circuit Poor ignition coil Poor spark plug Poor high tension cable Current leakage in the spark plug cap Incorrect ignition timing Poor alternator installation of the pulse sensor Poor C D I Weak starter motor Poor charging system battery is not fully charged Poor connection in the windings The motor gear is jammed by foreign material Starter motor is working but engine does not crank Poor starter motor pinion Poor starter clutch The starter motor run in reverse direction Poor battery SYM 16 ELECTRICAL EQUIPMENT CHARGING SYSTEM Charging wire diagram white alternator REG REC e 1 green black d w Auto gt SW by starter 5Q Current Leakage Inspection Turn the main switch to OFF position and remove the negative cable terminal from the battery Connect an ammeter between the negative cable terminal and the battery negative terminal as shown on left diagram Battery terminal Caution e 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 e Do not turn the main switch to ON position during test If the leaked current exceeds the specified value it may indicate a short circuit Allowable current leakage
51. e harnesses to avoid sharp edges or corners e Avoid the projected ends of bolts and screws e Keep wire harnesses far away from the X exhaust pipes and other hot parts e sure grommets are seated in their groves properly e After clamping check each harness to be certain that it is not interfered with any moving or sliding parts e After routing check that the wire harnesses are not twisted or kink e Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack be rubbed against or m interfere with adjacent or surrounding parts ett in all steering positions e Thoroughly clean the surface where tape is to be applied e Wrap electrical tape around the damaged parts or replace them 1 5 1 GENERAL INFORMATION TROUBLE DIAGNOSIS OS JM SPECIFICATIONS SANYANG MODEL Overall Length 1900 mm TELESCOPIC FORK Overall Height 1140 mm Front 120 60 13 Wheel Base 1300 mm 130 70 12 Total 113kg Rear DRUM 110 mm Passengers DIMENSION cations Tire Specifi Curb Weight Brake System WEIGHT Performa nce Climb Ability 18 Below D Primary Reduction Belt 3 00 1 0 n 9 Total 263kg GEAR Clutch Auto Centrifugal clutch equipment Type 2 STROKE ENGINE Installation and Vertical below center arrangement incline 80 Deceleration Fuel Used Unleaded 93 95 opeedometer 0 80 km hr
52. e removed oil pump 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 cannot be disassembled Oil Pump Installation Install the oil pump onto the crankcase N Caution Apply with some grease onto oil pump O ring The 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 Install in the reverse order of removal N 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 3 Lubrication System Adjustment nut Mounting nut d 4 d k i Control cable n j VE Pump gear 3 Lubrication System Oil Pump Oil Tube Air Bleeding B Control cable 77 N Caution 1 The oil tube system has to be conducted air TU AME bleeding operation because air will clog or restraint oil flowing so that causes serious engine damage amp 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 Oil Tube Oil Pump It has to add some oil into the oil tank Place a piece of dry cloth
53. e the crankshaft on a V block measure run out points A and B of the crankshaft with dial gauge Check the crankshaft bearing by means of turning it with hand f any noise and bigger clearance are detected replace the bearing with new one 10 4 Clearance a Lateral Radial Clearance S M 10 Crankcase Crankshaft Crankcase installation Clean the crankshaft with solvent and blow it with Da 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 e Remove all gaskets onto the crankcase interfaces and flat it with special tool Install new bearing into left crankcase Special Tools Bearing driver6204 i Bearing driver 6204 Install crankshaft onto the left crankcase ff Crank shaft puller Install left crankshaft puller and install bush onto gs 71 crankshaft VL Screw the left crankshaft puller onto crankshaft Sen 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 Special Tools v L Crank shaft puller L Crank shaft install bush L Crank shaft install bush Extension bush Apply liquid gasket and dowel pin onto the interface of left crankcase 10 5 10 Crankcase Crank
54. eck charging coil white to Continuity amp ground resistance If the measured value is abnormal check the abnormal wire circuit If components good it could be a poor wire circuit If all items are in good condition then replace the voltage regulator If main wire circuit check is in normal and there is no loose in the pins of voltage regulator connector then measure the resistance between the connector of voltage regulator Voltage Regulator Check Unit O Red White Yellow Green R QW Y G Yellow Y Green 0 04 0 06 160 180 160 180 160 180 If the resistance values abnormal among the pins replace the voltage regulator NEN 0 04 0 06 160 180 Caution Do not touch the probe of multi meter by fingers then the resistance values will be incorrect because there is some resistance existence in human body To use the multi meter recommended by SYM Otherwise the measured resistance might be different Yellow 16 9 16 ELECTRICAL EQUIPMENT SYM Alternator charging coil Charging coil Blight coil A Caution In We by star ssconnector The check of alternator charging coil and illumination coil can be done when the alternator is mounted on engine Check Remove the 3P connector of the alternator Measure the resistance between the white wire on the alternator and frame ground with a multi meter Standard 0 6 0 10 20
55. ection only A Caution Do not use short circuit cable e 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 lever 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 16 8 SYM digital voltmeter ammeter engine Accelerate the engine gradually to the specified revolution per minute and measure the charging voltage current Specified Charging Current headlight OFF 0 6 A or more 2500rpm 1 2 A or more 6000 rpm 0 4 A or more 2500rpm 1 0 A or more 6000 rpm Control Charging Voltage 14 0 0 5 V 2000 rpm A Caution To replace the old battery use a new battery 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 between 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
56. ed air into the fuel rich circuit Air should not flow into the circuit If air flow through the circuit then replace the auto by starter Check 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 Resistor Auto By Starter Removal Installation Remove the cover of the auto by starter yom 2screws Remove screw and mounting plate Remove the auto by starter from carburetor Install in the reverse order of removal procedures 4 5 4 Fuel System QS M 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 Caution Do not tighten the screw forcedly to avoid to damaging the valve seat Remove main jet needle jet seat and idle jet and clean them and each component with compressed air Float cap Installation H Install the
57. edures Start engine and check its ignition timing 10mm flanged nut Maintenance Information 8 2 Trouble 8 2 Left Crankcase Cover 8 3 Reassembly Of Kick Starter 8 4 Installation Of The Left Crankcase Cover 8 V Type Belt Drive System Kick Starter Drive Bellicissexssuauwknguwewcusukh uu aa 8 5 Movable Drive Face 8 6 Clutch Driven Pulley 8 10 5 5 6 5kgf m 3 5 4 5kgf m 8 1 8 V Type Belt Drive System Kick Starter OS M Maintenance Information Precautions In Operation The surfaces of drive belt and driven pulley must be free of grease Specification Standard value mm Divebetwith 1295 300 Thickness of iutch weight 00 ofmovable driven face 3800 ID Inner Diameter OD Outer diameter Torque Values Movable drive face 3 5 4 5kgf m Driven pulley plate 5 5 6 5kgf m Trouble Shooting Engine can be started but motorcycle Insufficient horsepower or poor cannot be moved high 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
58. ent O gt Check if carburetor clogged No clogged Clogged 1 Cleaning 1 11 1 GENERAL INFORMATION TROUBLE DIAGNOSIS S M E CLUTCH DRIVING AND DRIVING PULLEY FAULT CONDITIONS PROBABLE CAUSES 1 12 1 Engine can be started but 2 motorcycle can not be moved EN i D 6 Engine running and misfire as motorcycle initial forward moving 1 or jumping suddenly rear wheel 2 rotating as engine in running 3 Poor initial driving Poor climbing performance Driving belt worn out or deformation Driving disk damaged Driving pulley spring broken Clutch ling broken Driving slide shaft gear groove broken Transmission gear damaged Transmission gear worn out or burned Clutch ling spring broken Clutch outer stick with clutch balance weights Connection parts in clutch and shaft worn out or burned Driving belt worn out or deformation Balance weight roller worn out Driving sliding gear shaft worn out Driving disk spring deformation Driving sliding gear shaft worn out Greased in driving belt and sliding gear 05 1 GENERAL INFORMATION TROUBLE DIAGNOSIS LUBRICATION POINTS JO Seat lock Acceleration cable Front amp rear brake lever pivot Steering shaft bearing amp Speedometer gear Side stand shaft Min shan Rear wheel bearing Front wheel bearing GREASE 4 E So S JM 2 Service Maintenance Information Gener
59. er Remove the spark plug cap from the spark plug 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 couplers of auto by starter and ACG Remove the upper parts of the carburetor from its upper side Remove the carburetor heater electric wire 5 Engine Removal Fuel output tube SS Spark plug M A n M L Control cable 1 T D Carburetor aa upper parts p 77 Lb 4 amp zd k T k i i 5 Engine Removal Drum type rear brake Remove rear brake cable from engine rear lower side Remove brake cable from cable clamp Remove air cleaner and rear inner fender mounting screw Loosen connection hose clamp Remove 2 bolts and then remove the air cleaner 5 4 1 screw Remove two exhaust pipe connection nuts Remove three bolts beside fan cover and exhaust pipe Support the engine and then remove cushion lower mounting bolt Remove engine mounting nut and bolt Each side 1 bolt and 1 nut Remove the engine 5 Engine Removal Engine mounting bolt Connection nuts Rear cushion lower mounting bolt 5 Engine Removal Engine Hanger Bracket Removal Remove the frame side right and left side bolts of engine hanger bracket 1 bolt on each side
60. er switch Front brake level T Ignition switch Rear turn Rear brake level signal light Exhaust muffler Gear oil draining bolt 05 1 GENERAL INFORMATION TROUBLE DIAGNOSIS SYMBOLS AND MARKS TORQUE VALUES ENGINE GENERAL SAFETY TORQUE VALUES FRAME SERVICE PRECAUTIONS TROUBLES DIAGNOSIS SPECIFICATIONS LUBRICATION POINTS 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 or marks Means that serious injury or even death may result if procedures are not Warning followed N Caution Means that equipment damages may result if procedures are not followed Limits to use SAE SAE 20 JASO FC class engine oil Warranty will not cover the damage that caused by not apply with the limited engine Engine oil Recommended oil MAX 2 serial oils King Bramax HYPOID GEAR OIL 140 is recommended Gear oil Se Grease Mate G 3 is recommended Apply sealant medium strength sealant should be used unless otherwise specified Locking sealant d T Oil seal Apply with lubricant Replace with a new part before installation rr Use recommended brake fluid DOT3 or WELLRUN brake fluid um Brake fluid 8 TDOL Special service tools Special tools O cor
61. f the electrolyte sprays to eyes medical care should be done quickly 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 2 0 for one 2 0 person 2 25 for two persons 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 e If the tread bend too much replace the tire e f tire wear exceeds limitation replace the tire and check it for un even wear N Caution Wear indicator is distributed on average along the wall rubber for check Rear Drum Brake Free Play Measure the free play of the rear brake lever at the end of the lever Free play 10 20 mm 3 8 3 4 in Tire pressure cold kg cm Adjust the free play by turning the front brake adjustment nut if necessary Brake Confirmation N Caution After brake adjustment it has to check the brake operation to make sure the front and rear wheel can be braked Wear indicator 10 20mm 3 8 3 4in Decreasing y play RN Increasing 4 free play P S JM 2 Service Maintenance Information Disc Brake System Hose Front Disc Brake Type Make sure that the brake hose is corro
62. for several times to check cushion operation Install all components in reverse order of removal procedures Lower mounting bolt 14 5 14 Rear Wheel Rear Cushion OS JM Note 14 6 SYM 16 ELECTRICAL EQUIPMENT MECHANISM DIAGRAM PRECAUTIONS IN OPERATION TROUBLE DIAGNOSIS LIGHTS BULBS CHARGING SYSTEM SWITCH IGNITION SYSTEM FUEL UNIT MECHANISM DIAGRAM Resistor Comp Reg Rec Comp Winker Relay Horn Main Switch Fuse CDI Unit Thermo Switch Spark Plug IG Coil AC Generator Carburetor heater Fuel Unit Oil Level Switch 16 1 16 ELECTRICAL EQUIPMENT SYM PRECAUTIONS IN OPERATION Charging System 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 MF Maintenance Free battery does not need to check add electrolyte or distilled water Battery must be taken out from scooter when charging the battery But do not open the battery caps Do not quick charge the battery unless in emergency A voltmeter must be used when checking battery charging condition Battery can be charged or discharged alternately To set a discharged battery idle for a prolonged period will shorten its service life and reduce its capacity Usually battery s capacity will reduce after 1 2 years After low capacity battery was charged its voltage will increase If it connects to an addit
63. gine 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 Service Maintenance Information Transmission Oil Leak Check if the transmission is leak Check N 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 Draining bolt Replacement Remove the oil level check bolt Remove the oil draining bolt and then drain oil Out Install the oil draining bolt Tighten torque 1 0 1 5kgf m amp Caution Check if oil seal and washer is in good condition Replacement Quantity 110cc 100cc for change Recommended oil King Bramax HYPOID GEAR OIL 140 Spark Plug Recommended plug 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 a constant thickness Replace the spark plug if there is Side electrode apparent wear or if the insulator is cracked and or chipped If the spa
64. h 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 11 2 Service Maintenance Information Carburetor Idle Speed Adjustment Caution e Inspection amp adjustment for idle speed 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 warned up around operates engine from 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 19002100 rpm Cylinder Compression Pressure Test Remove the left body cover and warn up engine otop 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 1 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
65. he 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 2 2 2 Service Maintenance Information Air Cleaner e Remove the mounting screws from the air cleaner cover e Remove the air cleaner cover Air cleaner element Remove the air cleaner element Clean the element with non flammable or high flash point solvent and then squeeze it for dry amp Caution Never use gasoline or acid organized solvent to clean the element Soap the element into cleaning engine oil and then squeeze it out Install the element onto the element seat and then install the air cleaner cover e Limit to use SAE 20 JASO FC class engine oil otherwise SYM is no responsible for the warranty e Recommended engine oil MAX 2 serial oils iT 1 i E w Z J NL Squeeze oil out Squeeze out remaining oil Fuel Lines Remove the luggage box Check fuel lines and replace damaged lines if found Install the luggage box 2 3 2 Service Maintenance 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
66. he seat Remove 4 bolts in front of the luggage box 2 bolts Remove 2 bolts in rear of the luggage box Remove the luggage box Remove the rear carrier 3 bolts 3 bolts 11 6 Q5 11 BODY COVER Hemove the 2 mounting bolts of the rear fender _ 2 screws Remove the 2 mounting screws between the body cover and the frame Remove the left right side 2 mounting bolts under rear of the body cover between the body cover and the frame Remove the rear fender Remove the left right body cover Installation Install the body cover and rear fender according to the reverse procedure of removal 11 7 11 BODY COVER FRONT CENTER COVER Removal Remove the 4 screws bolt Remove the front center cover Installation Install the front center cover according to the reverse procedure of removal LUGGAGE BOX Removal Open the seat Remove the 4 bolts from the luggage box Hemove the luggage box and the double seat Installation Install the luggage box according to the reverse procedure of removal FLOOR PANEL Removal Remove the 4 bolts from the luggage box Remove the luggage box and the double seat Remove the front center cover Remove the 2 bolts between the floor panel and the body cover 11 8 m Front center cover 5 Hemove the front cover and front under cover Remove the 2 mounting screws between the floor panel and the front inner box Remove the floor panel
67. he 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 Bearings replacement Remove 5 bolts and brake disc Remove left side dust seal bearing and dist collar Special tools Inner bearing puller Installation Fill out the block of bearing by grease Drive the left bearing dust seal into wheel rim and install the dist collar Dust seal Install the right bearing and dust seal N Caution Carefully install the bearing in correct and evenly Bearing Bearing outer face should be faced up as bearing installation 13 6 Dist collar Bearing Dust seal S M 13 Steering Front Wheel Front Cushion Install the brake disc and then tighten the bolts disc brake Torque value 2 4 3 0kgf m Lubricate the speedometer gear with grease and install the gear into the wheel hub Align the flange part on the speedometer gear with the slot of wheel hub amp 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 left side dust seal Install the left side collar Place the front wheel between the front cushions N Caution Align the front cushion groove with the speedometer gear box stopper flange Insert the wheel axle into the wheel and then install the wheel axle nut Tighten the nut to specified torque
68. id reservoir becomes horizontal and 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 Diaphragm 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 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 brakes fluid Caution To reuse the spent brake fluid will affect brake pd lt V il performance Py k emen 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 a
69. idle jet the needle jet seat and main jet zx i fuel rich Then install the throttle valve stopper and air 2 circuit screws to their original position according to the marks as removal Adjust the screws if replace with new ones Float valve Float pin Air screw Idle jet EN Throttle valve stopper screw Main jet Screwx 4 Draining screw 4 6 4 Fuel System Float Level Inspection Measures 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 i Carburetor Carburetor Installation 22 T P upper part amp Caution 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 Connect the automatic by starter connector Install air cleaner cap Conduct following operations e Adjustment of throttle valve cable e Adjustment of oil pump Adjustment of idle speed Draining screw Reed Valve Removal Remove the luggage box Remove the carburetor Remove carburetor insulator Remove inlet pipe Remove the reed valve 4 7 4 Fuel System Inspection Check the reed valve for damage and its reed strength Check the reed valve se
70. il level switch 5 Disconnect oil level switch coupler and check voltage between wire and ground No voltage Voltage Open circuit Malfunction of oil level between oil level switch Oil level switch switch and indicator Poor connection of oil Blown bulb level switch Removal Installation Remove luggage box Drain out oil from oil outlet tube Pull up oil level switch and then remove oil level switch from the oil tank Install the oil level switch in reverse order of removal procedures Oil level switch 16 17 16 ELECTRICAL EQUIPMENT SYM Power filter Thermo switch Fuse 10A Main switch R _ E i Battery Removal Installation Remove luggage box rear carrier and body cover Remove carburetor heater wire pins Remove carburetor heater Inspection Thermo switch coupler Remove power filter coupler and thermo switch UR X m x coupler and then remove power filter and thermo k d P P switch be ty 16 18 SYM 16 ELECTRICAL EQUIPMENT Fuel Unit Removal Installation Remove luggage box rear carrier and body cover Disconnect fuel unit coupler from rear wheel side Turns the fuel unit retain plate in counter clockwise direction and then remove the fuel unit retain plate Remove the fuel unit amp Caution Do not bend the float arm Install in reverse order of removal procedures Remark Aligning the slot of fuel unit
71. ional load the voltage will reduce suddenly and then go up again Over charged battery Usually the over charged battery can be seen externally If a short circuit occurred inside the battery there will be no voltage on the terminals of battery if voltage regulator does not operate Then the battery s voltage will be too high that may reduce battery s life The battery will be self discharged if it was set idle for a long time An idle battery must be charged about every 2months A new battery filled with electrolyte will generate a voltage after filled out electrolyte The voltage should be in 12 5V or more after 10 minutes When electrolyte is not enough the battery must be filled with electrolyte and then charged to prolong the battery s life span Please check electrical device according to the procedure of diagnosis chart Do not disconnect and connect the connector of electrical devices when current is passing these devices because this will generate high voltage and the electrical components in the voltage current regulator will be damaged The ignition switch must be turned OFF before performing any work Please do not replace with traditional type battery as replacement Please refer to the removal instruction when removing the alternator and the pulse generator Ignition System Please follow the procedure of trouble diagnosis chart to check ignition system The ignition system equipped with a auto advanced timing device in CDI unit
72. iston pin Piston Ring Inspection Measure the end gap of each piston ring Caution With the piston push each piston ring into cylinder correctly Connecting Rod Inspection Measure the ID of connecting rod small end Install bearing and piston pin onto connecting rod small end and then check its clearance 6 Cylinder Head Cylinder Piston Piston Cylinder Installation Install the expanding ring into the groove of 27 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 The top ring and the 274 ring cannot be changeable each other 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 replaced at same time and it cannot be replaced one ring only It should use same brand name piston ring in an engine and cannot mix with other one 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 install needle bearing into connecting rod small end Install piston and place EX mark of the piston toward to exhaust side and then install the piston pin onto piston
73. k plug install it into spark plug cap and perform a spark test against engine ground Check if sparks Weak sparks no spark at all Perform cylinder compression pressure test Cylinder compression Low compression pressure normal pressure or no pressure Re start by following the starting procedures There are some signs of ignition nut engine can not be started Remove the spark plug again and check it Dry spark plug Wet spark plug Remove carburetor after 30 minutes and connect a hose onto fuel rich circuit Then blow the hose with air Blowing in normal Blowing clogged No fuel in fuel tank Check if the pipes fuel tank to carburetor and intake vacuum are clogged 3 Float valve clogged 4 Lines in fuel tank evaporation system clogged 5 Malfunction of fuel pump 6 Loosen or damaged fuel pump vacuum hose 7 Fuel filter clogged N 1 Malfunction of spark plug 2 Spark plug foul 3 Malfunction of CDI set 4 Malfunction of AC generator 5 Ignition coil is in open or short circuit 6 Ignition coil leads open or short circuit 7 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 1 Malfunction of throttle valve operation 2 Air sucked into intake manifold 3 Incorrect ignition timing
74. l Remove cylinder head 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 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 Piston pin Piston Ring Removal A Caution Pry out the opening end of each piston ring and then remove the ring from piston 6 Cylinder Head Cylinder 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 Use a straight edge and a feeler gauge to measure the cylinder head for warp In X and Y direction measure the cylinder for worn out as the three levels shown in the figure With the maximal value to decide cylinder wear out condition Measure the OD of piston at the 7 mm from the bottom of the piston Calculate the clearance between piston and cylinder OS JM 6 Cylinder Head Cylinder Piston Measure the piston pinhole ID of piston The ID of piston pinhole Measure the OD of piston pin The OD of p
75. lace the brake lining if the wear limit mark A on the brake arm aligning with the indicator of brake drum Brake lining replacements refer to chapter 12 Brake pad Wear Disc Brake Type The arrow mark on brake pad is the wear limitation Replace the brake pad if the wear limit mark closed to the edge of brake disc amp Caution In order to maintain brake power balance the brake lining must be replaced with one set Brake pad replacements refer to chapter 12 Ji i l Brake pad EM Brake caliper Brake disc S 7 A 2 Service Maintenance Information Steering System N Caution The control cables cannot 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 direction then adjust the handle top bearing by adjusting the steering nut Suspension N 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 en
76. lt only Long bolt will impair the operation of brake disc Use two seal washers and hose bolts to lock the hose and brake caliper in place Torque value 3 3 3 7kgf m Refill up the brake fluid to the reservoir and make ry air bl ing necessary air bleeding Brake hose bolt Brake pad replacement Front brake Loosen the 2 pad guide pin bolts Remove brake caliper Lining guide bolts Remove the brake pad guide pin bolts and then remove brake pads 12 7 12 Brake System Install the new brake pads onto brake caliper Install the brake pad guide pin bolts Install the brake caliper and tighten the mounting bolts Torque value 2 4 3 0kgf m Tighten the lining guide pin bolts Torque value 1 5 2 0kgf m 12 8 S 05 M 12 Brake System 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 Remove the brake disc from wheel Check the disc for deformation and bend Allowable limit 0 30 mm Disc Brake Master Cylinder Master Cylinder Removal N Caution Do not let foreign materials enter into the cylinder he whole set of master cylinder piston spring diaphragm and cir clip should be replaced as a set Remove the leads of brake light switch Drain out the brake fluid Remove the brake lever from the brake master cylinder Remove the
77. mage or insufficient elasticity Snap clip Check if shock absorption rubber is damage or deformation Replace it if necessary Apply with grease onto lock pins Shock absorption rubber Install new clutch weight onto lock pin and then push to specific location Apply with grease onto lock pins But the clutch weight should not be greased If so replace it Caution Grease or lubricant will damage the clutch weight and affect the weight s connection capacity Clutch block Install the spring into groove with pliers 8 12 S M 8 V Type Belt Drive System Kick Starter Install snap clip and mounting plate onto lock pin Snap clip Replacement of Driven Pulley Bearing Remove inner bearing Caution f the inner bearing equipped with oil seal on side in the driven pulley then remove the oil seal firstly f the pulley equipped with ball bearing it has to remove snap clip and then the bearing Remove snap clip and then push bearing forward to other side of inner bearing Place new bearing onto proper position and its sealing end should be forwarded to outside A Apply with specified grease Specified grease Outer bearing Sealing end Install new inner bearing Caution Inner bearing Sealing end ts sealing end should be forwarded to outside as bearing installation Install needle bearing with hydraulic presser Install ball bearing
78. move the body cover Disconnect the fuel unit wire connector A Caution Do not damage or bend the float arm as removing The resistance values are listed below when the float arm in F and E positions Float arm position Resistance value E empty 97 5 107 5Q 4 10Q F full DOWN empty Connect the fuel unit to the main harness Turn the main switch ON position Move the float arm in UP amp DOWN and then check if the fuel unit indication needle is in correct position Caution Turn on the turn signal light to make sure battery is in good condition before this test Float arm position Indicator needle UP full E empty DOWN empty F full Installation Install the fuel unit in reverse order of removal 16 28 SYM Jet 4 R 50cc wiring diagram STOP SW LIGHT START COMB 4 O O kB G Y kl G Y G Y ki G Y SB G 1 RH FR WINKER Exec 12V10W LH FR WINKER 0 pt 12V10W G 1 ELEC METER B B Y R Y R TURN L SB SB TURN R G Y A HI BEAM HH ME BR BR IGN G 1 Y Y Y W Y W FUEL IN 0 0 ILLUMI GND EI P G 2 G 2 G R R HEAD LIGHT HS1 12V35W 35W ij POSITION LIGHT 12V 5W P G B B eo 2 WANKER RELAY ss 22 22 8 1414 LIGHT SW DIMMER PASS SW puc CET DIMMER PASS WINKER HORN SW 550 START COMB
79. nd operate the brake lever to check whether air bubble is in brake system or If brake is still soft please bleed the system as described below 12 5 12 Brake System Disc Brake Air Bleed Air bubble Drain valve Tightly hold the brake lever and open the drain valve around 1 4 turns and then close the valve We _ ag Caution o 5 4 m V LL E Ek sd Do notrelease the brake lever before the drain valve is closed e Always check the brake fluid level when carrying out the air bleeding procedure to avoid air enters into the system Slowly release the brake lever and wait for a few seconds until it reaches its top position Repeat the steps 1 and 2 until there is no air bubble at the end of the hose Front brake Tightly close the drain valve Make sure the brake fluid is in the UPPER level of the master cylinder and refill the fluid if necessary Cover the cap AS Drain hose io Drain valve 12 6 S M 12 Brake System Disc Brake Caliper Brake hose bolt Removal HW 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 Remove two caliper bolts and the caliper Installation Install the brake caliper and tighten the attaching bolts securely Torque value 2 4 3 0kgf m Caution Use M8 x 35 mm flange bo
80. ng Check if bearings can be turned in smooth and silent and also check if bearing outer ring is mounted on gear tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Check oil seal for wear or damage and replace it If necessary Check gearbox bearing as the same way above and replace it if necessary S M 9 Final Driving Mechanism Bearing Replacement Special tool Remove gearbox bearing from left crankcase and gearbox cover using following tools Caution Never install used bearings Once bearing removed it has to be replaced with new one Install new bearings into left crankcase Install new bearings into gearbox cover Special tool Bearing driver Special tool Apply with grease onto final shaft oil seal Install the oil seal into gearbox cover Special tool Oil seal driver FL a Oil seal 9 Final Driving Mechanism Re Assembly of Final Driving w tom Extension bush re Shaft install bush Mechanism Install drive shaft With the special service tools to install drive shaft by through the bearing Special tool R Crank shaft puller L Crank shaft install bush Extension bush Extension bush Apply with grease onto drive shaft oil seal Install the oil seal to left crankcase Special tool Drive shaft socket amp oil seal driver 17x30x6 Install 2 dowel pins amp new gasket Dowel pins Install counter shaft counter shaft side w
81. ng or installing the oil pump If air is found in the oil tube from oil tank to oil pump or oil tube is removed the oil pump should be conducted air bleeding operation It should bleed the oil output tube from oil pump to carburetor as hose removed The adjustments of oil pump control cable Lubricant Appointed to apply SAE 20 JASO FC class oil Otherwise warranty shall not cover the damage Recommended oil MAX 2 oil Cil tank capacity 1 2lit Trouble Shooting Too much smoke carbon in spark plug 1 Improperly oil pumps adjustment too much oil 2 Poor quality oil 3 Applying with poor quality oil Over heat 1 Improperly oil pumps adjustment insufficient oil 2 Poor quality oil 3 Applying with poor quality oil Piston seized 1 Nooil in oil tank or clogged hose 2 Improperly oil pumps 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 Oil Pump Removal N 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 Remove the oil output tube form intake manifold Remove the oil pump mounting bolt and then take out the oil pump Inspection Inspect the following items on th
82. ot reach to carburetor 2 Clogged hose from carburetor to canister 3 Too much fuel in cylinder 3 Bend squeezed or clogged fuel lines 4 Clogged air cleaner 4 Clogged fuel filter 5 Malfunction of float valve 6 Low fuel level in float chamber 7 Clogged vent pipe Stall after started 8 Malfunction of fuel pump 5 Incorrect idle speed adjustment 6 No spark on the spark plug 7 Low compression pressure 8 Rich mixture Rich Mixture 9 Lean mixture 13 Malfunction of float valve 10 Clogged air cleaner 14 Low fuel level in float chamber 11 Inlet pipe leaking 15 Clogged carburetor air injector 12 Polluted fuel OS M 4 Fuel System Throttle Valve Carburetor upper part Removal K 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 Sealed cap a 3 ES meu valve spring Needle clamp Throttle valve d N Fuel needle clip ur F Fuel needle Carburetor upper part E d Washer S 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 body Caution Align the groove inside the throttle valve with the throttle
83. part Friction spring Installation of the Left Crankcase Cover Install the dowel pin and gasket Install the left crankcase cover Install kick start arm kick start arm OS M 8 V Type Belt Drive System Kick Starter Drive Belt Removal left crankcase cover Hold clutch outer with universal holder and remove nut and clutch outer Caution Using special tools for tightening or loosening the nut Fixed rear wheel or rear brake will damage reduction gear system Special tool 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 Belt tooth Replace the belt if exceeds the service limit Caution 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 Pull out driven pulley to avoid it closing Install drive belt onto driven pulley 8 V Type Belt Drive System Kick Starter Install the driven pulley that has installed the belt Drive face Drive belt Drive shaft onto drive shaft Hold the clutch outer and then tighten nut to
84. parts in the proper assemble order and tie them together with a wire for ease of installation later 1 3 1 GENERAL INFORMATION TROUBLE DIAGNOSIS helength of bolts and screws for assemblies cover plates or boxes is different from one another be sure they are correctly installed In case of confusion Insert the bolt into the hole to compare its length with other bolts if its length 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 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 When oil seal is installed fill the groove with grease install the oil seal with the name of the manufacturer facing outside check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal Manufacturer s Remove residues of the old gasket or sealant before reinstallation grind with a grindstone if the contact surface has any damage 1 4 The ends of rubber hoses for fuel vacuum or coolant should be pushed as far as they can go to their connections
85. rect Meaning correct installation gt Wrong Indication of components Indicates position and operation directions a Components assembly directions each other Meaning wrong installation Indicates where the bolt installation direction means that bolt cross through the component invisibility 1 GENERAL INFORMATION TROUBLE DIAGNOSIS 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 A Caution Exhaust contains toxic gas which 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 A Caution Prolonged contact with used engine oil or transmission oil may cause skin cancer although it might not be verdict We recommend that you wash your hands with soap and water right after contacting Keep the used oil beyond reach of children Hot components A Caution Components of the engine and exhaust system can become extremely hot after engine running They remain very hot even
86. rformance Improper brake adjustment Worn brake lining Worn brake drum Worn brake cam Improper brake lining installation Seized brake cable Dirty brake lining Dirty brake drum Brake pad worn in brake cam area 10 Poor contact between brake arm and camshaft indent 12 4 Hard operation of brake lever 1 Blocked brake system 2 Poor brake caliper 3 Blocked brake pipe 4 Seized worn master cylinder piston 5 Bent brake lever Uneven brake 1 Dirty brake lining disc 2 Poor wheel alignment 3 Clogged brake hose 4 Deformed or warped brake disc 5 Restricted brake hose and fittings Tight operation or low return speed of brake lever 1 Worn broken crack return spring 2 Worn drum 3 Dirty brake lining 4 Brake seized caused from dirty brake drum Seized brake cable Worn brake cam Improper brake lining installation S Tight brake 1 Dirty brake lining disc 2 Poor wheel alignment 3 Deformed or warped brake disc Brake noise 1 Dirty lining 2 Deformed brake disc 3 Poor brake caliper Installation 4 Imbalance brake disc or wheel Brake noise 1 Worn brake lining 2 Worn drum 3 Dirty brake lining 4 Dirty brake drum 5 12 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 flu
87. rging by battery jump wires Turn the charger s switch OFF at first before or after charging to prevent from sparks created on the connectors and explosion To charge a battery must be based on the battery s ampere hour showed on label Quick charge a battery should be used only in an emergency Make sure the current and charging time of above description The battery will be damaged by too much current or too rush charging When finishing charge it is necessary to measure voltage after 30 minutes After installing the battery coat the terminals with clean grease 16 ELECTRICAL EQUIPMENT 16 7 16 ELECTRICAL EQUIPMENT Charging Voltage Current Inspection A Caution Before conducting the inspection be sure that the battery is fully charged Use a fully charged battery having a voltage larger than 13 1 V If undercharged the current changes dramatically While starting the engine the starter motor draws large amount of current from the battery Thus do not start the engine with battery After the engine is warmed up replace original battery with a fully charged battery Connect a digital voltmeter to the battery terminals Connect an ammeter between both ends of the main fuse A Caution When the probe is reversibly connected use a voltmeter having an indication that the current flows from the positive or the negative direction and the measurement should be at zero ammeter at one dir
88. rk 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 2 10 9 5 Center electrode Oil level check bolt 05 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 Belt width Driver Belt e Remove left crankcase cover e Check if the belt is crack or worn out Replace the belt if necessary e Measure the driving belt width Ignition Timing N Caution e C D I ignition timing cannot be adjusted If the ignition timing is incorrect check the C D I device and the alternator and replace damaged components e Check ignition timing with standard instrument Remove 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 mark then it means that the ignition timing is correct Ignition lamp Throttle Valve Operation Check if each steering positions are operated in smoot
89. rts and recommended oils Using non designed parts for SANYANG motorcycle may damage the motorcycle e 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 e 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 to cause a damage e 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 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
90. shaft 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 Special Tools R Crank shaft puller R Crank shaft install bush Install the bolts and tighten them Torque value 0 8 1 2kgf m With right crankshaft install bush install new oil seal into the right crankcase Its installation depth is 4mm as the diagram shown 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 Make sure that the crankshaft can be rotated freely after tightening the bolts Install the following components Final driving mechanism chapter 9 Alternator chapter 7 Piston cylinder cylinder head chapter 6 Oil pump chapter 3 Reed valve and carburetor chapter 4 Engine remove chapter 5 10 6 95 R Crank shaft puller R Crank shaft install bush 8 7 Bolts amp R Crank shaft install bush Oil seal driver 11 BODY COVER MAINTENANCE INFORMATION FRONT CENTER COVER HANDLE COVER LUGGAGE BOX FRONT COVER FLOOR PANEL FRONT INNER BOX SIDE COVER BODY COVER REAR CENTER UNDER COVER COVER REAR FENDER R re
91. sion 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 system for leaking if low brake level found N Caution In order to maintain brake fluid in the reservoir in horizontal positon do not remove the cap until handle bar stop Do not operate the brake lever after the cap had been removed Otherwise the brake fluid will spread out if operated the lever Do not mix non compatible brake fluid together Filling Out Brake Fluid Tighten the drain valve and add brake fluid Place the diaphragm in Operate the brake lever so that brake fluid contents inside the brake system hoses Air Bleed Operation Connect a transparent hose to draining valve Hold the brake lever and open air bleeding valve Perform this operation alternative until there is no air inside the brake system hoses amp Caution Before closing the air bleeding valve do not release the brake lever Added Brake Fluid Add brake fluid to UPPER limit lever Recommended brake fluid DOT3 or DOT 4 WELL RUN brake fluid N Caution Never mix or use dirty brake fluid to prevent from damaging brake system or reducing brake performance Master cylinder cover _ Tranaparent draining nose 2 Service Maintenance Information S SM Brake Lining Wear Rear Drum Brake Type Rep
92. st muffler mounting bolt 2 4 3 0kgf m Troubleshooting Rear wheel wobbling 1 Bend wheel rim 2 Poor tire 3 Loosen wheel shaft Cushion too soft 1 Insufficient cushion 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 QUESO Dee 14 2 S JM 14 Rear Wheel Rear Cushion Rear Wheel Connection nuts Remove Remove exhaust pipe nut 2 connection nuts Remove exhaust muffler bolt 3 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 14 3 14 Rear Wheel Rear Cushion Brake disc removal install Installation Install the rear wheel and tighten the nut Tighten torque 11 0 13 0kgf m Install exhaust pipe amp muffler Tighten torque bolt 2 4 3 0kgf m Tighten torque nut 0 8 1 2kgf m 14 4 S M 14 Rear Wheel Rear Cushion Rear Cushion 77 Upper mounting bolt Removal l 2 Remove luggage box Remove air cleaner Remove rear cushion upper amp lower bolts Remove rear cushion Installation Install the rear cushion Tighten the upper amp lower mounting bolts to specified torque Torque value Upper mounting bolt 3 5 4 5kgf m Lower mounting bolt 2 4 3 0kgf m Press down the tail of the scooter
93. t pipe connection nut E RM E EE 08 12kg m 0 E muffler mounting 3 2 4 3 0kgf m Rear cushion upper Rear cushion lower mounting bolt 2 4 3 0kgf m EM 11 0 13 0kgf m Bolts for the brake disc 2 473 ui m Engine hangerbot 2 19 _ Engine hanger bracket bolt 2 4 5 5 5kgf m 15 IMMER Brakehosebot 2 10 3337gm Reabakeamlvernus 1 6 mounting bolts Speedometer cable locking screw The torque values listed in above table are for more important tighten torque values Please see standard values for not listed in the table Standard Torque Values for Reference TYPE TIGHTEN TORQUE TYPE TIGHTEN TORQUE 5mm bolt nut 0 45 0 60kgf m 0 05 0 08kgf m 6mm bolt nut 0 80 1 20kgf m 0 10 0 15kgf m 8mm bolt nut 1 80 2 50kgf m 0 35 0 50kgf m 10mm bolt nut 3 00 4 00kgf m 6mm screw SH nut 0 70 1 10kgf m 12mm bolt nut 59 00 6 00kgf m 6mm bolt nut 1 007 1 40kgf m rnin btn 2 40 3 00kgf m oF fOmmboijnu 350 450kgkm 1 8 1 GENERAL INFORMATION TROUBLE DIAGNOSIS TROUBLES DIAGNOSIS A Engine hard to start or can not be started Check and adjustment and Check and adjustment Fault condition condition Probable causes causes Loosen carburetor drain bolt to check if there is gasoline inside the carburetor Fuel supplied tom No fuel is supplied to carburetor sufficient carburetor Remove spar
94. tarter Install movable drive face assembly onto crankshaft Drive Face Installation Press drive belt into pulley groove and then pull the belt on to crankshaft Install drive face washer and nut Caution Make sure that two sides of drive face have to be free of grease Clean it with cleaning solvent Hold flywheel with universal holder Tighten nut to specified torque Torque value 3 5 4 5kgf m Install left crankcase cover Drive face boss Press down Flywheel Drive face amp 7 Movable drive face Drive belt 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 Special tool Clutch spring compressor Clutch nut wrench A Caution not press the compressor too much 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 Inspection Clutch outer Measure the inner diameter of clutch outer friction face Replace clutch outer if exceed service limit 6 10 Clutch nut o LN wrench Clutch spring compressor
95. tarting button to check if there a click sound Itis normal if there is a click sound Remove the luggage box Disconnect the battery negative terminal Remove the battery positive connection and starting motor wires from the starter magnetic switch large pin Remove the power control connector of the Starter magnetic switch Connect a Ohmmeter between the Starter magnetic switch large pins Connect the green yellow wire to battery positive terminal and yellow red to battery negative terminal Check the continuity between the Starter magnetic switch large pins If it is not continuity then replace the starter magnetic switch 16 14 SYM Starter Motor Pinion Removal Installation Remove left crankcase cover and drive face 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 replace it with new one Check the pinion for sliding in axial direction smoothly he pinion sliding in axial direction not in smooth replace it with new one 16 ELECTRICAL EQUIPMENT Starter motor pinion 16 15 16 ELECTRICAL EQUIPMENT Starter Motor Removal Disassembly F ME Remove bolt and oil pump control cable Disconnect starter motor harness coupler Remove 2 bolts for separ
96. the ball bearing seats as installation Apply with grease onto the ball bearing seats and ET k xQ Steel balls install steel balls onto the seats 26 balls bottom 29 balls Bottom cone race Lubricate the top cone race seat with grease ocrew the cone race in to top ball bearing seat till touching and then screw out the cane race 1 4 3 8 turns di a A Return 1 2 turns a ia Y Check the steering stem that should be rotated Fi B freely and no clearance in vertical direction LU p i kW i fi j O zi E Locking to 1 4 3 8 turns Top cone race 13 9 Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body Torque value 1 0 1 2kgf m Install in reverse order of removal procedures Top cone race 13 10 S M 14 Rear Wheel Rear Cushion Maintenance Information 14 2 Rear Wheel 14 3 Troubleshooting 14 2 Rear Cushion 14 5 11 0 13 0kgf m 14 1 14 Rear Wheel Rear Cushion S M Maintenance Information Specification Torque Value Rear cushion upper mounting bolt 3 5 4 5kgf m Rear cushion lower mounting bolt 2 4 3 0kgf m Rear wheel nut 11 0 13 0kgf m Bolts for the brake disc 2 4 3 0kgf m Exhaust pipe connection nut 1 0 1 4kgf m Exhau
97. tions included in this manual are current as at the 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 S M CONTENTS CONTENTS GENERAL INFORMATION TROUBLE DIAGNOSIS SERVICE MAINTENANCE INFORMATION LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL CYLINDER HEAD CYLINDER PISTON ALTERNATOR V TYPE BELT FINAL DRIVING MECHANISM CRANKCASE SHAFT BODY COVER BRAKE SYSTEM STEERING FRONT WHEEL FRONT SHOCK ABSORBER REAR WHEEL REAR SHOCK ABSORBER ELECTRICAL EQUIPMENT WIRING DIAGRAM SPECIAL TOOL MECHANISM ILLUSTRATIONS DSM Fuel tank oil cap Front turn signal light Front light Position light Air Cleaner Kick starter pedal Side stand Engine number A ut t Storage box Frame number diis Tail light High amp Low beam Turn signal Horn switch Headlight switch starter switch Front brake level Ignition switch Rear turn Rear brake level signal light Gear oil Exhaust muffler filling bolt Gear oil draining bolt MECHANISM ILLUSTRATIONS Fuel tank oil cap Front turn signal light Front light Position light 9 Air Cleaner Kick starter pedal Side stand Engine number Storage box Tail light High amp Low beam Turn signal Horn switch Headlight switch start
98. ut tube Cylinder Head Removal iim i Removal luggage box body covers and center Cover Remove fuel pump tubes Remove spark plug cap Remove fuel pump bracket 2 nuts Remove vacuum tube and oil pump control cable from engine shield Remove fan cover 3 bolts Remove engine shield mounting bolt 1 bolt 6 Cylinder Head Cylinder Piston Remove engine shield Cylinder Head Removal Remove spark plug 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 Cylinder Head Inspection Use a straight edge and a feeler gauge to measure the cylinder head for warp 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 6 2 0kgf m Install spark plug Tighten torque 1 1 1 7kgf m 05 Cylinder Piston Remove spark plug Remove fan cover Remove engine shield Remove two connection nuts of the exhaust pipe Remove exhaust muffle mounting bolt and then remove the exhaust muffler 6 Cylinder Head Cylinder Piston Cylinder Remova

1. general information/trouble diagnosis 1-2

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