SYM Jet Euro User Manual

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SERVICE MANUAL
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This service manual contains the technical data of each component inspection and repair for the SANYANG JET 50/100 and JET Euro 50/100 series motorcycle. 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 motorcycle, JET 50/100 and JET Euro 50/100 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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How to Use This Manual
This service manual describes basic information of different system parts and system inspection & service for Sanyang JET 50/100 and JET Euro 50/100 series motorcycles. 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
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CONTENTS
Page Content Index
1-1 ~ 1-18
2-1 ~ 2-14
3-1 ~ 3-6
4-1 ~ 4-4
5-1 ~ 5-8
6-1 ~ 6-4
GENERAL INFORMATION
SERVICE MAINTENANCE INFORMATION
LUBRICATION SYSTEM
ENGINE REMOVAL
CYLINDER HEAD/CYLINDER/PISTON
ALTERNATOR
1
2
3
4
5
6
7-1 ~ 7-14
8-1 ~ 8-6
9-1 ~ 9-6
10-1 ~ 10-10
11-1 ~ 11-12
12-1 ~ 12-12
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
7
8
9
10
11
12
13
14
15-1 ~ 15-22
ELECTRICAL EQUIPMENT
15
16-1 ~ 16-4
ELECTRICAL DIAGRAM
16
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Contents
MODEL ILLUSTRATION
JET 50 / 100 Series
Front turn signal
Light / Starter switch
Fuel tank cap
Rear turn signal
Seat lock
Rear turn signal
Helmet hook
High & Low beam / Turn signal / Horn switch
Battery / Fuses / C.D.I. / Eng. Oil tank cap
Frame number
Head light
Front brake lever Rear brake lever
Tail light
Storage box
Air cleaner
Ignition switch
Engine number
Muffler
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Contents
JET Euro Series
Front turn signal
MODEL ILLUSTRATION
Light / Starter switch
Fuel tank cap
Rear turn signal
Seat lock
Rear turn signal
Helmet hook
High & Low beam / Turn signal / Horn switch
Battery / Fuses / C.D.I. / Eng. Oil tank cap
Frame number
Head light
Front brake lever
Tail light
Storage box
Air cleaner
Ignition switch
Rear brake lever
Engine number
Muffler
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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·································· 1-7 Cables and Harness Routing·········· 1-9 Troubleshooting······························ 1-13 Lubrication Points··························· 1-17
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)
1
O
X
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).
1-1
This chapter Contents
1. GENERAL INFORMATION
General Safety
Carbon monoxide
If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor.
Caution
Exhaust contains toxic gas 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.
1-2
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.
g
This chapter Contents
1. GENERAL INFORMATION
Specifications
Make SANYANG MODEL JET 50 SERIES
Overall Length 1785 mm Front TELESCOPIC
Overall Width 630 mm
Overall Height 1115 mm Front 120 / 70 – 12
DIMENSION
Wheel Base 1275 mm
Front 40 kg
ht
Curb
Passengers /
WEIGHT
Total Weight
Rear 54 kg
Wei
Total 94 kg
Weight
Front 84 kg Climb Ability 22° Below
Rear 120 kg Primary Reduction BELT
Total 204 kg
Suspension
System
Tire
Specifications
Brake System
Two /110 kg Max. Speed 50 km/hr Below
Secondary
Reduction
Rear UNlT SWING
Rear 130 / 70 – 12
Front
Rear
DlSK (ψ190mm)
DRUM (ψ110mm)
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 3.2 kw / 7000 rpm
Max. Torque 4.6 Nm / 6500 rpm E.E.C. Below 2g / test
Ignition C.D.I. P.C.V. X
Horizontal, below
center, incline
2-stroke/forced air
cooled
Single Cylinder Lubrication System Separated-lubrication
7.2 : 1 CO
FORMAN PERCE
Transmission C.V.T.
Horn 80 ~ 112 dB/A
Exhaust Pipe Position
and Direction
Exhaust
Concentration
HC
Right side, and Backward
8.0 g/km
5.0 g/km
Starting System Electrical & kick
Catalytic reaction
control system
1-5
g
This chapter Contents
1. GENERAL INFORMATION
Specifications
Make SANYANG MODEL JET 100 SERIES
Overall Length 1785 mm Front TELESCOPIC
Overall Width 630 mm
Overall Height 1115 mm Front 120 / 70 – 12
DIMENSION
Wheel Base 1275 mm
Front 40 kg
ht
Curb
Passengers /
WEIGHT
Total Weight
Installation and
arrangement
Rear 54 kg
Wei
Total 94 kg
Weight
Front 84.5 kg Climb Ability 22° Below
Rear 122.5 kg Primary Reduction BELT
Total 207 kg
Type Gasoline Clutch Centrifugal, dry type
Two /110 kg Max. Speed 50 km/hr Below
Horizontal, below
center, incline
Suspension
System
Tire
Specifications
Brake System
Secondary
Reduction
FORMAN PERCE
Transmission C.V.T.
Rear UNlT SWING
Rear 130 / 70 – 12
Front
Rear
DlSK (ψ190mm)
DRUM (ψ110mm)
GEAR
ENGINE
Fuel Used Unleaded (92/95) Speedometer 0 ~ 120 km/hr
Cycle/Cooling
Bore 51 mm Muffler Expansion & Pulse Type
Stroke 49.6 mm
Cylinder
Number/Arran
gement
Displacement 101.3 cc Solid Particulate
Compression
Ratio
Max. HP 7.0 ps / 6500 rpm
Max. Torque 0.89 kg-m / 5500 rpm E.E.C. Below 2g / test
Ignition C.D.I. P.C.V. X
Starting System Electrical & kick
2-stroke/forced air
cooled
Exhaust Pipe Position
Single Cylinder Lubrication System Separated-lubrication
6.3 : 1 CO
Exhaust
Catalytic reaction
Horn 80 ~ 90 dB/A
and Direction
Concentration
control system
HC
Right side, and Backward
7000 ppm
4.5 %
X
1-6
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
4
Thread Dia.
(mm)
6
Torque Value
(Kg-m)
1.0
Remarks
When engine
cooled Spark plug Flywheel nut Sliding driving disc nut Sliding driving disc nut Clutch outer cover nut Drain bolts Crankcase bolts
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
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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
Brake caliper mounting bolts
Brake cushion guide bolts
1
1
1
1
2
2
2
2
2
Thread Dia.
(mm)
10 5.0
12 6.0
10 4.0
8 2.7
6 1.2
8 3.3
10 3.5
8 3.1
6 1.8
Torque Value
(Kgf-m)
Remarks
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
Rear shaft nut
Nut for rear hub
2
1
1
1
1
1
4
3
1
4
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
14 11.0
8 2.5
1-8
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.
OCorrect XWrong
1-9
This chapter Contents
1. GENERAL INFORMATION
Starter switch
Headlight switch
Speedometer
Winker switch
High/low beam switch
Horn switch
Front brake lamp switch
Headlight
Throttle cable
Rear brake lamp switch
Front brake cable
Throttle cable
Main switch
Speedometer cable
Rear brake cable
Winker relay
1-10
Regulator
Horn
Resistor
Front brake hose
Speedometer cable
This chapter Contents
Front brake hose
Throttle cable
1. GENERAL INFORMATION
Speedometer cable
Rear brake cable
Winker relay
Fuel unit
Throttle cable
Front brake hose
Rear brake cable
Front brake hose
Rear brake cable
Throttle cable
Fuel unit cord
Fuel pump
Speedometer cable
Fuel filter
1-11
This chapter Contents
1. GENERAL INFORMATION
Fuse
Purge control valve
Battery
Fuel pump
Fuel filter
Oil control cable
Fuel hose
C.D.I. UNIT
Carburetor
Rear brake cable
Oil hose
Vacuum hose
Oil lever switch
1-12
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
1-13
This chapter Contents
1. GENERAL INFORMATION
Engine run sluggish (Speed does not pick up, lack of power)
B.
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
1-14
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)
C.
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)
D.
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
1-15
This chapter Contents
1. GENERAL INFORMATION
. CLUTCH, DRIVING AND DRIVING PULLEY
E
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.
1-16
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
1-17
This chapter Contents
1. GENERAL INFORMATION
Note:
1-18
Home page
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
2
General Information
Specification
Item
Tire dimension Front: 120 / 70 – 12, Rear: 130 / 70 - 12 Tire pressure at cold Only rider Front: 1.75kg/cm
Rear brake lever free play 10~20 mm Transmission oil / Recommendation
Spark plug / Recommendation
Driving belt width Ignition timing F mark
Acceleration operation 2~6 mm Idle speed Cylinder compression pressure
Type: HYPOID GEAR OIL Oil: SAE #140 Quantity: 0.12 L Replacement: 0.11L
Type: NGK BR8 HSA
Plug gap: 0.6-0.7mm
JET 50 JET 100
Allowable limit: replace it if below 16.5mm
17 °, BTDC/1500 rpm
2000 ±100 rpm 2100 ±100 rpm
7 ±1 kgf/cm² 10 ±2 kgf/cm²
Model
2
Rear: 2.0 kg/cm2
Type: NGK BR6 HSA
Plug gap: 0.6-0.7mm
Standard 18.0mm
2-1
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 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
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
2-3
This chapter Contents
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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This chapter Contents
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
2-5
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