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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Contents
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
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
yBattery emits explosive gases; flame is
strictly prohibited. Keep the place well
ventilated when charging the battery.
yBattery 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.
yIf 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.
yKeep 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
zAlways use with Sanyang genuine parts and
recommended oils. Using non-designed parts
for Sanyang motorcycle may damage the
motorcycle.
zSpecial tools are designed for remove and
install of components without damaging the
parts being worked on. Using wrong tools may
result in parts damaged.
zWhen 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.
zClean 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.
zRubber 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.
zWhen 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.
zStore complex components such as
transmission parts in the proper assemble
order and tie them together with a wire for ease
of installation later.
zWash 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.
zNever bend or twist a control cable to prevent
stiff control and premature worn out.
zNote the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
zComponents not to be reused should be
replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.
Caution
In addition to damaging paint finish, brake oil
can also damage the structural integration of
plastic or rubber parts.
1-3
This chapter Contents
1. GENERAL INFORMATION
zThe 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.
zTighten 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.
zWhen 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.
zThe 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.
zRubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
Boots
zThe 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
zRemove 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.
zLubricate 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 ReductionBELT
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
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
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
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 month3 month6 month1 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
2-4
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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