SYM DD 50 User Manual

HOW TO USE THIS MANUAL

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CONTENTS

MECHANISM ILLUSTRATIONS

DD 50

SERVICE MANUAL

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This service manual contains the technical data of each component inspection and repair for the SANYANG DD 50 series scooter. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines.

If the style and construction of the scooter, DD 50 series, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to change without notice.

Service Department

Sanyang Industry Co., LTD.

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Contents

How to Use This Manual

This service manual describes basic information of different system parts and system inspection & service for Sanyang DD 50 scooters. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.

The first chapter covers general information and trouble diagnosis. The second chapter covers service maintenance information. Th third to the tenth nine chapters covers engine and driving systems. The tenth to the fourteenth is contained the parts set of assembly body. The fifteenth chapter is electrical equipment. The sixteenth chapter is wiring diagram

Please see index of content for quick having the special parts and system information.

All information, illustration, directions and specifications included in this manual are current as at 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.

There are 4 buttons, “Forward,” “How to use this manual,” “Mechanism

Illustrations,” and “Contents” on the CD-R version, and can be access to

these items by click the mouse. If user wants to look for the content of each chapter, selecting the words of each chapter on the main contents can reach to each chapter. There are two buttons, Back to homepage and Main contents, onto the top line of first page of the each chapter. Thus, if the user needs to check other chapters, he can click the top buttons to back the homepage or main contents. The content of each chapter can be selected too. Therefore, when needs to checking the content inside of the chapter, click the content words of the chapter so that can back to the initial section of the content. In addition, there is a “This chapter contents” button at the top line of each page so that clicking the button can back to the contents of this chapter.

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CONTENTS

Page Content Index

1-1 ~ 1-16

2-1 ~ 2-14

3-1 ~ 3-6

4-1 ~ 4-6

5-1 ~ 5-8

6-1 ~ 6-4

GENERAL INFORMATION

SERVICE MAINTENANCE INFORMATION

LUBRICATION SYSTEM

ENGINE REMOVAL

CYLINDER HEAD/CYLINDER/PISTON

ALTERNATOR

7-1 ~ 7-14

8-1 ~ 8-6

9-1 ~ 9-6

10-1 ~ 10-10

11-1 ~ 11-12

12-1 ~ 12-14

13-1 ~ 13-10

14-1 ~ 14-4

“V” TYPE BELT DRIVING SYSTEM/KICK-STARTER

FINAL DRIVING MECHANISM

CRANKCASE/CRANKSHAFT

FUEL SYSTEM

BRAKE SYSTEM

BODY COVER

STEERING/FRONT WHEEL/SUSPENSION

REAR WHEEL/SUSPENSION

15-1 ~ 15-18

ELECTRICAL EQUIPMENT

16-1 ~ 16-2

ELECTRICAL DIAGRAM

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MODEL ILLUSTRATION

FT05V

Front turn signal

Head light

Light / Starter switch

Helmet hook

High & Low beam / Turn signal / Horn switch

Fuel tank cap

Battery / Fuses / C.D.I. / Eng. Oil tank cap

Front brake lever

Rear brake lever

Tail light / Rear turn signal

Storage box

Air cleaner

Frame number

Ignition switch

Engine number

Muffler

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Contents

FT05T

MODEL ILLUSTRATION

FT05U

FT05W

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Contents

1. GENERAL INFORMATION

Symbols and Marks··························1-1 General Safety ··································1-2 Service Precautions ·························1-3 Specifications ··································· 1-5

Torque values···································1-6 Cables and Harness Routing ··········1-8 Troubleshooting·······························1-11 Lubrication Points····························1-15

Symbols and Marks

Symbols 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.

Warning

Caution

Engine oil

Means that serious injury or even death may result if procedures are not followed.

Means that equipment damages may result if procedures are not followed.

Limits to use SAE 20 JASO FC class oil. Warranty will not cover the damage that caused by not apply with the limited engine oil. (Recommended oil: MAX-2 serial oils)

Grease

Gear oil Locking

sealant Oil seal

Renew

Brake fluid

Special tools

Correct

Wrong

Indication

Directions

King Mate G-3 is recommended.

King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL # 140)

Apply sealant, medium strength sealant should be used unless otherwise specified.

Apply with lubricant.

Replace with a new part before installation.

Use recommended brake fluid DOT3 or WELLRUN brake fluid.

Special tools.

Meaning correct installation.

Meaning wrong installation.

Indication of components.

Indicates position and operation directions.

Components assembly directions each other. Indicates where the bolt installation direction, --- means that bolt cross

through the component (invisibility).

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This chapter Contents

1. GENERAL INFORMATION

General Safety

Carbon monoxide

If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor.

Caution

Exhaust contains toxic gas 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

Caution

Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although it might not be verified.

We recommend that you wash your hands with soap and water right after contacting. Keep the used oil beyond reach of children.

Hot components

Caution

Components of the engine and exhaust system can become extremely hot after engine running. They remain very hot even after the engine has been stopped for some time. When performing service work on these parts, wear insulated gloves and wait until cooling off.

Battery

Caution

y Battery emits explosive gases; flame is

strictly prohibited. Keep the place well ventilated when charging the battery.

y Battery contains sulfuric acid (electrolyte)

which can cause serious burns so be careful do not be spray on your eyes or skin. If you get battery acid on your skin, flush it off immediately with water. If you get battery acid in your eyes, flush it off immediately with water and then go to hospital to see an ophthalmologist.

y 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.

y Keep electrolyte beyond reach of children.

Brake shoe

Do not use an air hose or a dry brush to clean components of the brake system, use a vacuum cleaner or the equivalent to avoid dust flying.

Caution

Inhaling dust may cause disorders and cancer of the breathing system.

Brake fluid

Caution

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 the brake fluid beyond reach of children.

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This chapter Contents

1. GENERAL INFORMATION

Service Precautions

z Always use with Sanyang genuine parts and

recommended oils. Using non-designed parts for Sanyang motorcycle may damage the motorcycle.

z 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.

z 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.

z 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.

z 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.

z 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.

z Store complex components such as

transmission parts in the proper assemble order and tie them together with a wire for ease of installation later.

z 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.

z Never bend or twist a control cable to prevent

stiff control and premature worn out.

z Note the reassemble position of the important

components before disassembling them to ensure they will be reassembled in correct dimensions (depth, distance or position).

z Components not to be reused should be

replaced when disassembled including gaskets metal seal rings, O-rings, oil seals, snap rings, and split pins.

Caution

In addition to damaging paint finish, brake oil can also damage the structural integration of plastic or rubber parts.

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This chapter Contents

1. GENERAL INFORMATION

z The length 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.

z 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.

z 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.

z The ends of rubber hoses (for fuel, vacuum, or

coolant) should be pushed as far as they can go to their connections so that there is enough room below the enlarged ends for tightening the clamps.

z Rubber and plastic boots should be properly

reinstalled to the original correct positions as designed.

Boots

z 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.

Manufacturer's name

z Remove residues of the old gasket or sealant

before reinstallation, grind with a grindstone if the contact surface has any damage.

1-4

Both of these examples can result in bearing damage.

z Lubricate the rotation face as assembling.

Check if positions and operation for installed parts is in correct and properly.

This chapter Contents

1. GENERAL INFORMATION

Specifications

Make SANYANG MODEL FT05 Series

Overall Length 1660 mm Front TELESCOPIC

Overall Width 630 mm

Overall Height 1020 mm Front 3.00 - 10 42J(T/L)

DIMENSION

Wheel Base 1155 mm

Front 32 kg

Curb

Passengers/

WEIGHT

Total Weight

Rear 48 kg

Wei

Total 80 kg

Weight

Front 54 kg Climb Ability 20° Below

Rear 136 kg Primary Reduction BELT

Total 190 kg

Suspension

System

Tire

Specifications

Brake

System

Two /110 kg Max. Speed 48 km/hr Below

Secondary

Reduction

Rear UNlT SWING

Rear 3.00 - 10 42J(T/L)

DlSK (ψ160mm)

Front

DRUM (ψ110mm)

Rear

DRUM (ψ95mm)

GEAR

Type Gasoline Clutch Centrifugal, dry type

Installation and

arrangement

Fuel Used Unleaded(92/95) Speedometer 0 ~ 90 km/hr

Cycle/Cooling

Bore 39 mm Muffler Expansion & Pulse Type

Stroke 41.4 mm

Cylinder

Number/Arran

ENGINE

gement

Displacement 49.4 cc Solid Particulate

Compression

Ratio

Max. HP 2.7 kw / 6250 rpm

Max. Torque 4.41 Nm / 5000 rpm E.E.C. Below 2g / test

Ignition C.D.I. P.C.V. X

Vertical, below center,

incline

2-stroke/forced air

cooled

Single Cylinder Lubrication System Separated-lubrication

7.1 : 1 CO

PERFORMANCE

Transmission C.V.T.

Horn 80 ~ 112 dB/A

Exhaust Pipe Position

and Direction

Exhaust

Concentration

HC Below 4000 ppm

Right side, and Backward

15 % ↓

3.5 % ↓

Starting System Electrical & kick

Catalytic reaction control

system

○

1-5

This chapter Contents

1. GENERAL INFORMATION

Torque values

Standard Torque Values for Reference

Type Torque value Type Torque value

5 mm Bolt, nut 0.45 - 0.6 kg-m 5 mm Bolt 0.35 - 0.5 kg-m 6 mm Bolt, nut 0.8 - 1.2 kg-m 6 mm Bolt, SH nut 0.7 - 1.1 kg-m 8 mm Bolt, nut 1.8 - 2.5 kg-m 6 mm Flange bolt, nut 1.0 - 1.4 kg-m 10 mm Bolt, nut 3.0 - 4.0 kg-m 8 mm Flange bolt, nut 2.4 - 3.0 kg-m 12 mm Bolt, nut 5.0 - 6.0 kg-m 10 mm Flange bolt, nut 3.5 - 4.5 kg-m

The torque values listed in below table are for more important tighten torque values. Please see above standard values for not listed in the table.

Engine

Item Q’ty

Cylinder head bolt

Spark plug Flywheel nut Sliding driving disc nut Sliding driving disc nut Clutch outer cover nut Drain bolts Crankcase bolts

Thread Dia.

(mm) 4 1 14 1.4

1 10 3.8 1 10 3.8 1 28 5.5 1 10 3.8 1 8 1.3 6 6 1.0

6 1.0

Torque Value

(Kgf-m)

When engine

Remarks

cooled

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This chapter Contents

1. GENERAL INFORMATION

Frame

Item Q’ty

Bolt for engine suspension

Bolt for engine suspension bracket

Upper bolt for rear shock absorber

Lower bolt for rear shock absorber

Mounting screws for exhaust pipe connection

Nut for exhaust

Brake hose bolts

Thread Dia.

(mm)

10 5.0

12 6.0

10 4.0

8 2.7

6 1.2

8 3.3

10 3.5

Torque Value

(Kgf-m)

Remarks

Brake caliper mounting bolts

Brake cushion guide bolts

Brake cushion guide bolts cap

Brake drain valve

Rear brake arm bolts

Tightening nut for steering rod

Front shaft nut

Mounting bolt for handle

Mounting nut for front hub

Mounting bolt for front brake disc

8 3.1

6 1.8

6 1.0

6 0.6

5 0.55

25.4 7.0

12 6.0

10 5.0

8 2.5

8 4.5

Rear shaft nut

Nut for rear hub

14 11.0

8 2.5

1-7

This chapter Contents

1. GENERAL INFORMATION

Cables and Harness Routing

Note the following when routing cables and wire harnesses:

• A loose wire, cable or harness may cause

safety hazard. After clamping, check each wire to make sure it is secured.

• Do not squeeze wires against the weld or its

clamp.

• Secure wires and wire harnesses to the

frame with respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses.

• Route harnesses so that they neither pull too

tight nor have excessive slack.

• Protect wires or wire harnesses with electrical

tape or tube if they contact a sharp edge or corner.

• Route wire harnesses to avoid sharp edges

or corners.

• Avoid the projected ends of bolts and screws.

• Keep wire harnesses far away from the

exhaust pipes and other hot parts.

• Be sure grommets are seated in their groves

properly.

• After clamping, check each harness to be

certain that it is not interfered with any moving or sliding parts.

• After routing, check that the wire harnesses

are not twisted or kink.

• Wire harnesses routed along the handlebar

should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering positions.

• Thoroughly clean the surface where tape is to

be applied.

• Wrap electrical tape around the damaged

parts or replace them.

O：Correct X：Wrong

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This chapter Contents

1. GENERAL INFORMATION

Starter switch

Front brake lamp switch

Speedometer

Headlight switch

Throttle cable

Winker relay

Winker switch

High/low beam switch

Rear brake lamp switch

Horn switch

Headlight

Winker light

Main switch

Regulator

Resistor

Front brake cable

Throttle cable

Speedometer cable

Rear brake cable

Horn

Speedometer cable

Front brake cable

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This chapter Contents

1. GENERAL INFORMATION

Battery/fuse/starting relay/CDI set

Throttle cable

Fuel unit

Carburetor

Spark plug cap

Fuel filter

Fuel pump

Throttle cable

Rear brake cable

Engine oil operation cable

Engine oil filling pipe

Fuel pump

Fuel unit

1-10

Oil pump

Engine oil return pipe

This chapter Contents

1. GENERAL INFORMATION

Troubleshooting

A. Engine hard to start or can not be started

Check and adjustment Fault condition Probable causes

Loosen carburetor drain bolt to check if there is gasoline inside the carburetor

Fuel supplied tom carburetor sufficient

No fuel is supplied to carburetor

Remove spark plug, install it into spark plug cap, and perform a spark test against engine ground.

Check if sparks

Week sparks or no spark at all

Perform cylinder compression pressure test.

cylinder compression pressure normal Low compression

pressure or no pressure

Re-start by following the starting procedures

1. No fuel in fuel tank

2. 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

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

1. Piston ring seized

2. Malfunction of cylinder valves

3. Worn cylinder and piston ring

4. Cylinder gasket leak

5. Sand hole in compression parts

6. Crankcase leakage for pre-compression

No ignition

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 supplement circuit. Then blow the hose with air

Blowing in normal

There are some signs of ignition, but engine can not be started

Blowing clogged

1. Malfunction of throttle valve operation

2. Air sucked into intake manifold

3. Incorrect ignition timing

1. Fuel level in carburetor too high

2. Malfunction of throttle valve operation

3. Throttle valve opening too wide

1. Malfunction of auto-starter

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This chapter Contents

1. GENERAL INFORMATION

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

Engine speed can be increased.

Engine speed can not be increased.

Check ignition timing (Using ignition lamp)

Ignition timing correct Incorrect ignition timing

Check cylinder compression pressure (using compression pressure gauge)

Compression pressure correct No compression pressure

Check if carburetor is clogged

Normal Clogged

1. Air cleaner clogged

2. Poor fuel supply

3. Lines in fuel tank evaporation system clogged

4. Exhaust pipe clogged

1. Malfunction of CDI

2. Malfunction of AC generator

1. Cylinder & piston ring worn out

2. Cylinder gasket leaked

3. Sand hole in compression parts

4. Valve deterioration

5. Crankcase leakage for pre-compression

1. Remove dirt

Remove spark plug

No foul or discoloration Fouled and discoloration

Check if engine over heat

Continually drive in acceleration or high speed

1-12

Normal Engine overheat

No knock Knock

1. Remove dirt

2. Incorrect spark plug heat range

1. Piston and cylinder worn out

2. Lean mixture

3. Poor fuel quality

4. Too much carbon deposited in 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

This chapter Contents

1. GENERAL INFORMATION

Engine runs sluggish (especially in low speed and idling)

Check and adjustment Fault condition Probable causes

Check ignition timing (using ignition lamp)

Adjust the air screw of carburetor

Air sucked through carburetor gasket

Remove spark plug, install spark plug into spark plug cap and perform spark test against engine ground

Engine runs sluggish (High speed)

Normal

Good Poor

No air sucked

Good spark

Abnormal

Air sucked

Poor

1. Incorrect ignition timing (malfunction of CDI or AC generator)

1. Rich mixture (loosen the screw)

2. Lean mixture (tighten the screw)

1. Poor heat insulation gasket

2. Carburetor lock loose

3. Poor intake gasket

4. Poor carburetor O-ring

1. Spark plug fouled

2. Malfunction of CDI

3. Malfunction of AC generator

4. Malfunction of ignition coil

5. Open or short circuit in spark plug leads

6. Malfunction of main switch

CHECK AND ADJUSTMENT FAULT CONDITION PROBABLE CAUSES

Check ignition timing

Check for fuel supplying system in automatic fuel cup

Normal

Good

Check if carburetor clogged

Abnormal

Poor

1. Malfunction of CDI

2. Malfunction of AC generator

1. Insufficient fuel in fuel tank

2. Fuel filter clogged

3. Restricted fuel tank vent

Normal

Clogged

1. Cleaning

1-13

This chapter Contents

1. GENERAL INFORMATION

. CLUTCH, DRIVING AND DRIVING PULLEY

FAULT CONDITION PROBABLE CAUSES

Engine can be started but motorcycle can not be driving

Engine running and misfire as motorcycle initial forward moving or jumping sudden (rear wheel rotating as engine in running)

Poor initial driving (Poor climbing performance)

1. Driving belt worn out or deformation

2. Driving disk damaged

3. Driving pulley spring broken

4. Clutch ling broken

5. Driving slide-shaft gear groove broken

6. Transmission gear damage

7. Transmission gear worn out or burned

1. Clutch ling spring broken

2. Clutch outer cover stuck with clutch balance weights

3. Connection parts in clutch and shaft worn out or burned

1. Driving belt worn out or deformation

2. Balance weight roller worn out

3. Driving sliding gear shaft worn out

4. Driving disk spring deformation

5. Driving sliding gear shaft worn out

6. Greased in driving belt and sliding gear.

1-14

This chapter Contents

1. GENERAL INFORMATION

Lubrication Points

Steering shaft bearing

Throttle cable/ Front & rear brake lever pivot

Engine suspension bushing

Seat lock

Speedometer gear/ front wheel bearing

Side stand shaft

Main stand shaft

Rear wheel bearing

1-15

This chapter Contents

1. GENERAL INFORMATION

Note:

1-16

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Contents

2. SERVICE MAINTENANCE INFORMATION

General Information··························2-1 Periodical Maintenance Schedule···2-2 Air Cleaner ········································2-3 Fuel Lines··········································2-3 Fuel Filter ··········································2-4 Engine Oil Line ·································2-4 Oil Pump Control Cable ···················2-5 Tire·····················································2-6 Battery···············································2-6 Rear Brake Free Play: (Drum Brake Type)

····························································2-7

Brake System Hose: (Front Disc Brake Type)··················································2-8

Steering System································2-10

Suspension····································· 2-10 Transmission Oil···························· 2-11 Spark Plug ······································ 2-11 Control Cable Lubrication············· 2-12 Driver Belt······································· 2-12 Ignition Timing ······························· 2-12 Throttle Valve Operation················ 2-12 Carburetor Idle Speed Adjustment 2-13 Carbon Removing For Exhaust Pipe &

Muffle ·············································· 2-13 Cylinder Compression Pressure Test 2-13 Headlight Adjustment···················· 2-14

General Information

Specification

Tire dimension

Tire pressure at cold Only rider Front brake lever free play 10~20 mm

Rear brake lever free play 10~20 mm

Transmission oil Recommendation

Spark plug Recommendation

Driving belt width Ignition timing F mark

Front: 3.00-10 42J Rear: 3.00-10 42J

Front: 1.5kg/cm Rear: 2.25 kg/cm

Standard 18.0mm Allowable limit: replace it if below 16.5mm

17°, BTDC/1500 rpm

Type: HYPOID GEAR OIL Oil: SAE #140 Quantity: 0.1 L

Type: NGK BR8HSA Plug gap: 0.6-0.7mm

Acceleration operation 2~6 mm Idle speed Cylinder compression pressure

2000±100 rpm 7±1 kgf/cm²

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This chapter Contents

2. SERVICE MAINTENANCE INFORMATION

Periodical Maintenance Schedule

Check item

☆

1. Air cleaner

☆

2. Fuel filter

☆

3. Engine oil filter cleaning

4. Oil pump linkage operation

☆

☆ ☆

☆

☆ ☆ ☆

☆

Have your scooter checked, adjusted periodically by your SYM Authorized Dealer to maintain the scooter at the optimum condition

Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement

The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.

Remarks:

check

5. Tire pressure

6. Battery inspection

7. Brake & free play check

8. Steering handle check

9. Cushion operation check

10. Every screw tightening check

11. Gear oil check for leaking

12. Spark plug check or change

13. Gear oil change

14. Frame lubrication

15. Exhaust pipe

16. Carburetor

17. Driving belt check

18. Ignition timing

19. Emission check in Idling

20. Idle speed check

21. Fuel lines

22. Throttle operation

23. Engine bolt tightening

24. Engine screw torque

25. Carbon cleaning for cylinder head, cylinder, piston head, and exhaust system.

C ~ Cleaning (replaced if necessary) L ~ Lubrication

1. Clean or replace the air cleaner element more often for pro-long engine life-span when the scooter is operated on dusty roads or in the Heavily- polluted environment.

2. Maintenance should be performed more often if the scooter is frequently operated in high speed and after the scooter has accumulated a higher mileage.

Maintenance kilometer

Maintenance interval

300KM

New 1 month 3 month 6 month 1 year

I C R

C C

I I I I

I I I I I I I I I I I I I R

R Replacement for every 5000km

L I I I I

I I I I I I I I I I I I I

Every

1000KM

Every

3000KM

Every

6000KM

Every

12000KM

Reference

2-2

This chapter Contents

2. SERVICE MAINTENANCE INFORMATION

Air Cleaner

• Remove the mounting screw from the air cleaner cover

• Remove the air cleaner cover

Remove the air cleaner element Clean the element with non-flammable or high-flash point solvent and then squeeze it for dry.

Caution

Never use gasoline or acid organized solvent to clean the element.

Mounting screw X 7

Air cleaner 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.

• Limit to use SAE 20 JASO FC class engine oil, otherwise, SYM is no responsible for the warranty.

• Recommended engine oil: MAX-2 serial oils.

Fuel Lines

Remove the body cover Check fuel lines and replace damaged lines if found. Install the body cover.

Squeeze oil out

Fuel pump

Clean

Soap

Squeeze out remaining oil

Carburetor

Fuel line

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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. 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.

Fuel filter

Engine oil pipe

Oil pump

Oil filling pipe

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2. SERVICE MAINTENANCE INFORMATION

Oil Pump Control Cable

Caution

To adjust the oil pump control cable after adjusted the throttle grip play.

Remove the body cover. Wide open the throttle valve, and check if the calibration point aligns on the oil pump lever with the mark of pump body. Loosen the adjustment nut of the oil pump control cable. Turn the adjustment nut and align with the point, then tighten the nut.

Mounting nut

Adjustment nut

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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

Tire size Tire pressure

(cold) kg/cm

Check if the tire tread and wall rubber for crack or damage, and replace if necessary. Check if foreign materials such as nail, metal pieces, and stones stuck on tire. The thread depth can be checked by visual inspection or by a depth gauge.

• If the tread bend too much, replace the tire.

• If tire wear exceeds limitation, replace the tire,

and check it for un-even wear.

Front:

3.00-10 42J

1.75 2.0

Rear:

3.00-10 42J

Caution

Wear indicator “△” is distributed on average along the wall rubber for check.

Battery

Open the seat. Loosen two screws of battery cap and then remove the cap. Check if the battery terminals are loosen. Remove the battery if its terminals are corroded obviously.

Battery Removal

1. Remove the Negative (-) battery cable at

first.

2. Then, remove the Positive (+) battery cable.

3. Remove the battery.

Clean the rust with steel brush. Install the battery in reverse order of removal, and apply with grease onto two terminals.

Caution

The electrolyte is contained sulfuric acid so be careful not to let it touch to eyes, skin, or clothes. If touched by accident, flush them with clean water immediately. However, if the electrolyte sprays to eyes, medical care should be done quickly.

Wear indicator

△ Mark

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2. SERVICE MAINTENANCE INFORMATION

Rear Brake Free Play: (Drum Brake Type)

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)

Adjust the free play by turning the front brake adjustment nut if necessary.

Brake Confirmation

Caution

After brake adjustment, it has to check the brake operation to make sure the front and rear wheel can be braked.

10∼20mm (3/8∼3/4 in)

Adjustment nut

Decreasing free play

Increasing free play

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