Sym RS-50 Service Manual

RS-50
SERVICE MANUAL
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HOW TO USE THIS MANUAL
CONTENTS
MECHANISM ILLUSTRATIONS
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This service manual contains the technical data of each component inspection and repair for the SANYANG RS-21 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, RS-21 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 RS-21 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
CONTENTS
Page Content Index
1-1 ~ 1-18
GENERAL INFORMATION
1
2-1 ~ 2-14
SERVICE MAINTENANCE INFORMATION
2
3-1 ~ 3-6
LUBRICATION SYSTEM
3
4-1 ~ 4-4
ENGINE REMOVAL
4
5-1 ~ 5-8
CYLINDER HEAD/CYLINDER/PISTON
5
6-1 ~ 6-4
ALTERNATOR
6
7-1 ~ 7-14
“V” TYPE BELT DRIVING SYSTEM/KICK-STARTER
7
8-1 ~ 8-6
FINAL DRIVING MECHANISM
8
9-1 ~ 9-6
CRANKCASE/CRANKSHAFT
9
10-1 ~ 10-8
FUEL SYSTEM
10
11-1 ~ 11-12
BRAKE SYSTEM
11
12-1 ~ 12-16
BODY COVER
12
13-1 ~ 13-8
STEERING/FRONT WHEEL/SUSPENSION
13
14-1 ~ 14-4
REAR WHEEL/SUSPENSION
14
15-1 ~ 15-22
ELECTRICAL EQUIPMENT
15
16-1 ~ 16-2
ELECTRICAL DIAGRAM
16
Home page
MODEL ILLUSTRATION
BS05W SERIES
Head light
Front brake lever
Rear brake lever
Tail light
Helmet hook
Fuel tank cap
Engine number
Storage box
Muffler
Battery / Fuses / C.D.I. / start relay
Light / Starter switch
High & Low beam / Turn signal / Horn switch
Air cleaner
Frame number
Front winker light
Ignition switch
Rear winker light
Seat lock
Home page
Contents
Oil tank cap
1. GENERAL INFORMATION
1-1
Symbols and Marks··························1-1 General Safety ··································1-2 Service Precautions ························· 1-3 Specifications ··································· 1-5
Torque values···································1-8 Cables and Harness Routing ··········1-10 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
Means that serious injury or even death may result if procedures are not followed.
Caution
Means that equipment damages may result if procedures are not followed.
Engine oil
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
King Mate G-3 is recommended.
Gear oil
King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL # 140)
Locking sealant
Apply sealant, medium strength sealant should be used unless otherwise specified.
Oil seal
Apply with lubricant.
Renew
Replace with a new part before installation.
Brake fluid
Use recommended brake fluid DOT3 or WELLRUN brake fluid.
Special tools
Special tools.
O
Correct
Meaning correct installation.
X
Wrong
Meaning wrong installation.
Indication
Indication of components.
Directions
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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Contents
1
1. GENERAL INFORMATION
1-2
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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1. GENERAL INFORMATION
1-3
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 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 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 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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1. GENERAL INFORMATION
1-4
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 Remove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if the contact surface has any damage.
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.
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.
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.
Boots
Manufacturer's name
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1. GENERAL INFORMATION
1-5
Specifications
Make SANYANG MODEL BS05W1-6
Overall Length 1870 mm Front TELESCOPIC
Overall Width 700 mm
Suspension
System
Rear UNlT SWING
Overall Height 1130 mm Front 100/90-12 (59J)
DIMENSION
Wheel Base 1335 mm
Tire
Specifications
Rear 130/70-12 (59J)
Front 46 kg
Rear 62 kg
Front
DISK (ψ 273mm)
Curb
Wei
g
ht
Total 108 kg
Brake
System
Rear
DRUM (ψ 110mm)
Passengers/
Weight
Two /110 kg Max. Speed 48 km/hr Below
Front 68 kg Climb Ability 22° Below
Rear 150 kg Primary Reduction BELT
WEIGHT
Total Weight
Total 218 kg
Secondary
Reduction
GEAR
Type Gasoline Clutch Centrifugal, dry type
Installation and
arrangement
Vertical, below center,
incline
PERFORMANCE
Transmission C.V.T.
Fuel Used Unleaded(92/95) Speedometer 0 ~ 90 km/hr
Cycle/Cooling
2-stroke/forced air
cooled
Horn 80 ~ 112 dB/A
Bore 39 mm Muffler Expansion & Pulse Type
Stroke 41.4 mm
Exhaust Pipe Position
and Direction
Right side, and Backward
Cylinder
Number/Arrang
ement
Single Cylinder Lubrication System Separated-lubrication
Displacement 49.4 cc
Compression Ratio 7.2 : 1
CO Below 1.0 g/km
Max. HP 2.6 kw / 6000 rpm
Exhaust
Concentration
HC+Nox Below 1.2 g/km
Max. Torque 4.2 Nm / 5500 rpm E.E.C. X
Ignition C.D.I. P.C.V. X
ENGINE
Starting System Electrical & kick
Catalytic reaction control
system
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1. GENERAL INFORMATION
1-6
Specifications
Make SANYANG MODEL BS05W-A
Overall Length 1870 mm Front TELESCOPIC
Overall Width 700 mm
Suspension
System
Rear UNlT SWING
Overall Height 1130 mm Front 100/90-12 (T/L)
DIMENSION
Wheel Base 1335 mm
Tire
Specifications
Rear 130/70-12 (T/L)
Front 46 kg
Rear 62 kg
Front
DISK (ψ 273mm)
Curb
Wei
g
ht
Total 108 kg
Brake
System
Rear
DRUM (ψ 110mm)
Passengers/
Weight
Two /110 kg Max. Speed 48 km/hr Below
Front 73 kg Climb Ability 22° Below
Rear 171 kg Primary Reduction BELT
WEIGHT
Total Weight
Total 244 kg
Secondary
Reduction
GEAR
Type Gasoline Clutch Centrifugal, dry type
Installation and
arrangement
Vertical, below center,
incline
PERFORMANCE
Transmission C.V.T.
Fuel Used Unleaded(92/95) Speedometer 0 ~ 90 km/hr
Cycle/Cooling
2-stroke/forced air
cooled
Horn 93 ~ 112 dB/A
Bore 39 mm Muffler Expansion & Pulse Type
Stroke 41.4 mm
Exhaust Pipe Position
and Direction
Right side, and Backward
Cylinder
Number/Arrang
ement
Single Cylinder Lubrication System Separated-lubrication
Displacement 49.4 cc
Compression Ratio 7.2 : 1
CO Below 8.0 g/km
Max. HP 3.2 kw / 7000 rpm
Exhaust
Concentration
HC+Nox Below 4.0 g/km
Max. Torque 4.6 Nm / 6500 rpm E.E.C. X
Ignition C.D.I. P.C.V. X
ENGINE
Starting System Electrical & kick
Catalytic reaction control
system
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1. GENERAL INFORMATION
1-7
Specifications
Make SANYANG MODEL BS05W-8
Overall Length 1870 mm Front TELESCOPIC
Overall Width 700 mm
Suspension
System
Rear UNlT SWING
Overall Height 1130 mm Front 100/90-12 (59J)
DIMENSION
Wheel Base 1335 mm
Tire
Specifications
Rear 130/70-12 (59J)
Front 46 kg
Rear 62 kg
Front
DISK (ψ 273mm)
Curb
Wei
g
ht
Total 108 kg
Brake
System
Rear
DRUM (ψ 110mm)
Passengers/
Weight
Two /110 kg Max. Speed 65 km/hr Below
Front 68 kg Climb Ability 22° Below
Rear 150 kg Primary Reduction BELT
WEIGHT
Total Weight
Total 218 kg
Secondary
Reduction
GEAR
Type Gasoline Clutch Centrifugal, dry type
Installation and
arrangement
Vertical, below center,
incline
PERFORMANCE
Transmission C.V.T.
Fuel Used Unleaded(92/95) Speedometer 0 ~ 90 km/hr
Cycle/Cooling
2-stroke/forced air
cooled
Horn 80 ~ 112 dB/A
Bore 39 mm Muffler Expansion & Pulse Type
Stroke 41.4 mm
Exhaust Pipe Position
and Direction
Right side, and Backward
Cylinder
Number/Arrang
ement
Single Cylinder Lubrication System Separated-lubrication
Displacement 49.4 cc
Compression Ratio 7.2 : 1
CO Below 8.0 g/km
Max. HP 2.8 kw / 6000 rpm
Exhaust
Concentration
HC+Nox Below 4.0 g/km
Max. Torque 4.6 Nm / 5000 rpm E.E.C. X
Ignition C.D.I. P.C.V. X
ENGINE
Starting System Electrical & kick
Catalytic reaction control
system
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1. GENERAL INFORMATION
1-8
Torque values
Standard Torque Values for Reference
Type Torque value Type Torque value
5 mm Bolt, nut 0.45 - 0.6kgf-m 5 mm Bolt 0.35 - 0.5kgf-m 6 mm Bolt, nut 0.8 - 1.2kgf-m 6 mm Bolt, SH nut 0.7 - 1.1kgf-m 8 mm Bolt, nut 1.8 - 2.5kgf-m 6 mm Flange bolt, nut 1.0 - 1.4kgf-m 10 mm Bolt, nut 3.0 - 4.0kgf-m 8 mm Flange bolt, nut 2.4 - 3.0kgf-m 12 mm Bolt, nut 5.0 - 6.0kgf-m 10 mm Flange bolt, nut 3.5 - 4.5kgf-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
Thread Dia.
(mm)
Torque Value
(Kgf-m)
Remarks
Cylinder head bolts
4 6 1.0
When engine
cooled
Spark plug
1 14 1.4
Flywheel nut
1 10 3.8
Drive face nut
1 10 3.8
Driven face nut
1 28 5.5
Clutch outer nut
1 10 3.8
Drain bolt
1 8 1.3
Crankcase bolts
6 6 1.0
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1. GENERAL INFORMATION
1-9
Frame
Item Q’ty
Thread Dia.
(mm)
Torque Value
(Kgf-m)
Remarks
Bolt for engine hanger (frame side)
1
10 4.5~5.5
Bolt for engine hanger (engine side)
1
12 5.0~7.0
Upper bolt for rear cushion
1
10 3.5~4.5
Under bolt for rear cushion
1
8 2.4~3.0
Nuts for exhaust pipe
2
6 1.0~1.4
Bolts for exhaust muffler
2
8 3.0~3.6
Brake hose bolts
2
10 3.0~4.0
Brake caliper mounting bolts
2
8 2.9~3.5
Nuts for brake level pivot
2
6 1.0~1.4
Bolt for brake hose clamper
1
6 0.7~1.1
Brake drain valve
1
6 0.5~0.7
Rear brake arm bolts
1
5 0.5~0.6
Front axle nut
1
12 5.0~7.0
Mounting bolt and nut for steering handle post
1
10 4.0~5.0
Steering top cone race
1
- 0.2~0.3
Steering stem lock nut
1
- 1.0~2.0
Bolts for front brake mast cylinder
4
6 1.0~1.4
Bolt for front brake disk
3
8 4.0~4.5
Rear axle nut
1
14 11.0~13.0
Nut for rear hub
4
8 2.4~3.0
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1. GENERAL INFORMATION
1-10
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
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1. GENERAL INFORMATION
1-11
c: Throttle cable d: Front brake cable e: Rear brake cable f: Speedometer cable g: Speedometer and handle switch wire
Main switch
Throttle cable
f
Horn
This chapter Contents
d
c
e
d
f
g
c
e
g
1. GENERAL INFORMATION
1-12
ACG. connector
Ignition coil
Thermo switch
CDI unit
Power filter unit ASS’Y
Air injection cut valve
Thermo switch unit
Thermo switch connector
This chapter Contents
Battery
Fuse
Start relay
Spark plug
Auto by-starter
Fuel unit
Regulator
Oil level switch
Resistor
1. GENERAL INFORMATION
1-13
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.
Perform cylinder compression pressure test.
Check if sparks
Week sparks or no spark at all
cylinder compression pressure normal Low compression
pressure or no pressure
Re-start by following the starting procedures
No ignition
There are some signs of ignition, but engine can not be started
Remove the spark plug again and check it.
Remove carburetor after 30 minutes and connect a hose onto fuel supplement circuit. Then blow the hose with air
Dry spark plug Wet spark plug
Blowing in normal
Blowing clogged
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
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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1. GENERAL INFORMATION
1-14
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
Engine speed can be increased.
Engine speed can not be increased.
Check ignition timing (Using ignition lamp)
Check cylinder compression pressure (using compression pressure gauge)
Ignition timing correct Incorrect ignition timing
Compression pressure correct No compression pressure
Check if carburetor is clogged
Normal Clogged
Remove spark plug
Check if engine over heat
No foul or discoloration Fouled and discoloration
No knock Knock
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
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
Normal Engine overheat
Continually drive in acceleration or high speed
1. Too much carbon deposited in combustion chamber
2. Lean mixture
3. Poor fuel quality
4. Lean mixture
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1. GENERAL INFORMATION
1-15
C.
Engine runs sluggish (especially in low speed and idling)
D.
Engine runs sluggish (High speed)
Check and adjustment Fault condition Probable causes
Check ignition timing (using ignition lamp)
Check for fuel supplying system in automatic fuel cup
Check if carburetor clogged
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
1. Insufficient fuel in fuel tank
2. Fuel filter clogged
3. Restricted fuel tank vent
Good
Poor
Good spark
Poor
No air sucked
Air sucked
Good Poor
Normal
Abnormal
Air sucked through carburetor gasket
Adjust the air screw of carburetor
Remove spark plug, install spark plug into spark plug cap and perform spark test against engine ground
CHECK AND ADJUSTMENT FAULT CONDITION PROBABLE CAUSES
Check ignition timing
1. Malfunction of CDI
2. Malfunction of AC generator
Normal
Abnormal
Normal
Clogged
1. Cleaning
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1. GENERAL INFORMATION
1-16
E
. CLUTCH, DRIVING AND DRIVING PULLEY
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
Engine can be started but motorcycle can not be driving
FAULT CONDITION PROBABLE CAUSES
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
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. 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.
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1. GENERAL INFORMATION
1-17
Lubrication Points
Engine hanger bushing
Seat lock
Rear wheel bearing
Steering shaft bearing
Speedometer gear/ front wheel bearing
Side stand shaft
Main stand shaft
Throttle cable/ Front & rear brake lever pivot
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1. GENERAL INFORMATION
1-18
Note:
This chapter Contents
2. SERVICE MAINTENANCE INFORMATION
2-1
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 Test2-13 Headlight Adjustment··························2-14
General Information
Specification
Tire dimension
Front: 100/90-12 Rear: 130/70-12
Tire pressure at cold Only rider
Front: 1.75kg/cm
2
Rear: 2.25 kg/cm
2
Front brake lever free play 10~20 mm Rear brake lever free play 10~20 mm
Transmission oil Recommendation
Type: HYPOID GEAR OIL Oil: SAE #140 Quantity: 0.12L Replacement: 0.11L
Spark plug Recommendation
Type: NGK BR8HSA Plug gap: 0.6~0.7mm
Driving belt width
Standard 18.0mm Allowable limit: replace it if below 16.5mm
Ignition timing F mark
17°, BTDC/1500 rpm Acceleration operation 2~6 mm Idle speed
2000±100 rpm Cylinder compression pressure
7±1 kgf/cm²
2
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Contents
2. SERVICE MAINTENANCE INFORMATION
2-2
Periodical Maintenance Schedule
Maintenance kilometer
300KM
Every
1000KM
Every
3000KM
Every
6000KM
Every
12000KM
Check item
Maintenance interval
New 1 month 3 month 6 month 1 year
Reference
1. Air cleaner
I C R
2. Fuel filter
C
3. Engine oil filter cleaning
C C
4. Oil pump linkage operation check
I I
5. Tire pressure
I I
6. Battery inspection
I I
7. Brake & free play check
I I
8. Steering handle check
I I
9. Cushion operation check
I I
10. Every screw tightening check
I I
11. Gear oil check for leaking
I I
12. Spark plug check or change
I R
13. Gear oil change
R Replacement for every 5000km
14. Frame lubrication
L
15. Exhaust pipe
I I
16. Carburetor
I I
17. Driving belt check
I
18. Ignition timing
I I
19. Emission check in Idling
I I
20. Idle speed check
I I
21. Fuel lines
I I
22. Throttle operation
I I
23. Engine bolt tightening
I I
24. Engine screw torque
I
25. Carbon cleaning for cylinder head, cylinder, piston head, and exhaust system.
I
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
C ~ Cleaning (replaced if necessary) L ~ Lubrication
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.
Remarks:
1. Clean or replace the air cleaner element more often for pro-long engine life-span when the scooter is operated on dusty roads or in the Heavily- polluted environment.
2. Maintenance should be performed more often if the scooter is frequently operated in high speed and after the scooter has accumulated a higher mileage.
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2. SERVICE MAINTENANCE INFORMATION
2-3
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.
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 luggage box. Check fuel lines and replace damaged lines if found. Install the luggage box.
Air cleaner element
Squeeze out remaining oil
Soap
Clean
Squeeze oil out
Fuel cock
Vacuum hose
Fuel line
Mounting screw X 5
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2. SERVICE MAINTENANCE INFORMATION
2-4
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
Oil filling pipe
Engine oil pipe
Oil pump
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2. SERVICE MAINTENANCE INFORMATION
2-5
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
2-6
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
Front:
100/90-12
Rear:
130/70-12 Tire pressure (cold) kg/cm
2
1.75 2.25
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.
Caution
Wear indicator “” is distributed on average along the wall rubber for check.
Battery
Remove battery cover (3 screws). Loosen two screws of battery band and then remove the band. 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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Negative
Positive
2. SERVICE MAINTENANCE INFORMATION
2-7
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.
1020mm
(
3/83/4in
)
Adjustment nut
Increasing free play
Decreasing free play
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