Sym RV 250i, GTS 300i, GTS 250i, JOYMAX 300i Service Manual
FOREWORD
HOW TO USE THIS MANUAL
CONTENTS
SERIAL NUMBER
GTS 250i / RV 250i
GTS 300i / JOYMAX 300i
SERVICE MANUAL
Homepage
Contents
Foreword
This service manual contains the technical data of each component inspection and
repair for the SANYANG LM25W5 / LM30W series scooter. The manual is shown
with illustrations and focused on “Service Procedures”, “Operation Key Points”,
and “Inspection Adjustment”, providing technicians with service guidelines.
If the style or the mechanical structures of the scooter, LM25W5 / LM30W series
scooter are different from those of the photos or pictures shown in this manual, the
actual vehicle shall prevail. Specifications are subject to changes without notice.
Service Department
SANYANG INDUSTRY CO., LTD.
Homepage
Contents
How To Use This Manual
This service manual describes the basic information of different system parts and
system inspection & service for SANYANG LM25W5 / LM30W series scooter. In
addition, please refer to the manual contents in detail for the model you serviced in
inspection and adjustment.
The first chapter covers the general information and the trouble diagnosis.
The second chapter covers the periodic maintenance information and the special
tool models.
The third to the 11th chapters cover the engine and the driving systems.
The 12th chapter is the cooling system.
The 13th to the 16th chapter contain the relative parts of the body frame assembly.
The 17th chapter is the electrical system.
The 18th chapter is the emission control system.
The 19th chapter is the wiring diagram.
Please see index of content for quick having the special parts and system
information.
There are 4 buttons, “Foreword”, “Contents”, “How to use this manual” and
“Mechanism Illustrations” on the PDF 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 contents can reach to each chapter. There are two buttons,
“Homepage and 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 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 “To this chapter contents” button at the second page of each
contents so that clicking the button can back to the contents of this chapter.
Homepage
Contents
Page Content Index
1-1 ~ 1-18
2-1 ~ 2-18
3-1 ~ 3-8
4-1 ~ 4-60
5-1 ~ 5-12
6-1 ~ 6-16
7-1 ~ 7-8
General Information
Maintenance Information
Lubrication System
Fuel Injection System
Engine Removal
Cylinder Head / Valve
Cylinder / Piston
1
2
3
4
5
6
7
8-1 ~ 8-14
9-1 ~ 9-8
10-1 ~ 10-10
11-1 ~ 11-8
12-1 ~ 12-14
13-1 ~ 13-14
14-1 ~ 14-12
15-1 ~ 15-10
16-1 ~ 16-6
V-Belt Drive System
Final Drive Mechanism
AC Generator / Start Clutch
Crankshaft / Crankcase
Cooling System
Body Cover
Brake System
Steering / Front Wheel / Front Cushion
Rear Wheel / Rear Fork / Rear Cushion
8
9
10
11
12
13
14
15
16
17-1 ~ 17-22
18-1 ~ 18-10
19-1 ~ 19-2
Electrical Equipment
Emission Control System
Electrical Diagram
17
18
19
Home page
Contents
Serial Number
Homepage
Contents
Symbols and Marks····························1-1
General Safety····································1-2
Before Servicing·································1-3
Torque Values···································· 1-12
Trouble Diagnosis······························ 1-14
Lubrication Points ····························· 1-18
1. General Information
Specifications·····································1-9
Symbols and Marks
Symbols and marks are used in this manual to indicate what and where the special service is needed. If
supplemental information is needed for these symbols and marks, explanations will be added in the text
instead of using the symbols or marks.
Warning
Caution
Means that serious injury or loss of life may happen if procedures are not
correctly followed.
Means that equipment damages may result if procedures are not followed.
Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the
1
Engine oil
Grease King Mate G-3 is recommended.
Gear oil
Locking sealant
Oil seal
Renew
Brake fluid
Special tools
Correct
Wrong
damage that caused by not apply with the limited engine oil.
(Recommended oil: KING MATE G-3 oil)
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 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).
1-1
To this chapter contents
1. General Information
General Safety
Carbon Monoxide
Before you start the engine, make sure the place
is well ventilated. Never start the engine in an
unventilated place. If you have to start the engine
in an unventilated place, an exhaust fume
extractor is needed.
Caution
Exhaust fume contains toxic gas which may
cause one to lose consciousness and even result
in loss of life.
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 the
children.
Used Engine Oil
Caution
Prolonged contact with the used engine oil (or
transmission oil) may cause skin cancer although
it might not be verified yet. We recommend that
you wash your hands with soap right after
contacting. Keep the used oil beyond reach of the
children.
Hot Components
Caution
Components of the engine and exhaust system
can be extremely hot after engine running. They
remain very hot even after the engine has been
stopped for a period of time. Before performing
service work on these parts, wear the heat
insulation gloves or wait until the temperature
drops.
Battery
Caution
‧ Battery emits explosive gases; flame is strictly
prohibited. Keep the place well ventilated
when the battery is being charged.
‧ Battery contains sulfuric acid (electrolyte)
which can cause serious burns, be careful not
to spill it on your skin or eyes. If you get
battery fluid on your skin, flush it off with water
immediately. If you get battery fluid in your
eyes, flush it off immediately with water and
go to hospital to see an ophthalmologist
doctor.
‧ If you swallow the battery fluid by mistake,
drink a lot of water or milk, and take some
laxative such as Epsom salts or vegetable oil
and then go to see a doctor.
‧ Keep the battery and battery fluid beyond
reach of the children.
Brake Shoes
Do not use compressed air or brush to clean the
components of the brake system. Use a vacuum
cleaner or the equivalent to avoid dust drifting in
the air.
Caution
Inhaling brake shoes dust may cause disease or
even cancer of the respiratory system.
Brake Fluid
Caution
Brake fluid spilled on painted, plastic, or rubber
parts may cause damage to the parts. Place a
clean towel on the top of the parts for protection
when servicing the brake system. Keep the brake
fluid beyond reach of the children.
1-2
To this chapter contents
Before Servicing
y Always use SANYANG genuine parts and
recommended oil. Using improper parts may
cause damage to or destruction of the vehicle.
y Special tools are designed for removal and
installation of component parts without
damaging them. Using wrong tools may result in
parts damage.
y When servicing this vehicle, use only metric
tools. Metric bolts, nuts, and screws are not
interchangeable with the Britain system, using
wrong tools and fasteners may damage this
vehicle.
1. General Information
y Never bend or twist control cables to avoid
unsmooth control and premature worn out.
y Rubber parts may become deteriorated when
old, and be damaged by solvent and oil easily.
Check these parts before installation to make
sure that they are in good condition, replace if
necessary.
y 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.
y Store complex components such as
transmission parts in the proper assemble order
and tie them together with a wire for ease of
installation later.
y Clean the outside of the parts or the cover
before removing it from the vehicle. Otherwise,
dirt and deposit accumulated on the part's
surface may fall into the engine, chassis, or
brake system to cause damage.
y Wash and clean parts with high flash point
solvent, and then blow dry with compressed air.
Pay special attention to O-rings or oil seals
because most of the cleaning agents have bad
effect on them.
y Note the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
y Components not to be reused should be
replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.
1-3
To this chapter contents
1. General Information
y 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.
y 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.
y Remove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.
y 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.
Groove
Clamp
Connector
y Rubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
y When oil seal is installed, fill the groove with
grease, install the oil seal with the name of the
manufacturer facing outside, and check the
shaft on which the oil seal is to be installed for
smoothness and for burrs that may damage the
oil seal.
Manufacturer's name
1-4
Boots
y 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.
To this chapter contents
y Lubricate the rotation face with specified
lubricant on the lubrication points before
assembling.
y Check if positions and operation for installed
parts is in correct and properly.
y Make sure service safety each other when
conducting by two persons.
1. General Information
y After service completed, make sure all
connection points is secured.
Battery positive (+) cable should be connected
firstly.
y And the two posts of battery have to be greased
after connected the cables.
y Make sure that the battery post caps are
located in properly after the battery posts had
been serviced.
y Note that do not let parts fall down.
y Before battery removal operation, it has to
remove the battery negative (-) cable firstly.
Notre tools like open-end wrench do not contact
with body to prevent from circuit short and
create spark.
y If fuse burned, it has to find out the cause and
solved it. And then replace with specified
capacity fuse.
Capacity
verification
1-5
To this chapter contents
1. General Information
y When separating a connector, it locker has to
be unlocked firstly. Then, conduct the service
operation.
y Do not pull the wires as removing a connector
or wires. Hold the connector body.
y Make sure if the connector pins are bent,
extruded or loosen.
y Insert the terminal completely.
Check if the terminal is covered by the boot.
Do not let boot open facing up.
y 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.
y Insert the connector completely.
If there are two lockers on two connector sides,
make sure the lockers are locked in properly.
Check if any wire loose.
y Check if the connector is covered by the twin
connector boot completely and secured
properly.
y Wire band and wire harness have to be
clamped secured properly.
y Do not squeeze wires against the weld or its
clamp.
y Before terminal connection, check if the boot is
crack or the terminal is loose.
1-6
To this chapter contents
y Do not let the wire harness contact with rotating,
moving or vibrating components as routing the
harness.
y Keep wire harnesses far away from the hot
parts.
Never Touch
1. General Information
y Protect wires or wire harnesses with electrical
tape or tube if they contact a sharp edge or
corner. Thoroughly clean the surface where
tape is to be applied.
y Secure the rubber boot firmly as applying it on
wire harness.
y Route wire harnesses to avoid sharp edges or
corners and also avoid the projected ends of
bolts and screws.
y Route harnesses so that they neither pull too
tight nor have excessive slack.
y Never use wires or harnesses which insulation
has been broken. Wrap electrical tape around
the damaged parts or replace them.
y Never clamp or squeeze the wire harness as
installing other components.
Never clamp or
squeeze the wire
harness
Never too tight
1-7
To this chapter contents
1. General Information
y Do not let the wire harness been twisted as
installation.
y 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.
y With sand paper to clean rust on connector
pins/terminals if found. And then conduct
connection operation later.
Clean rust
y Before operating a test instrument, operator
should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.
Do you know how to set the
instrument to its
measurement position and
the insert locations of its
two probes?
1-8
To this chapter contents
Specifications
MAKER SANYANG MODEL LM25W5-6/7
Overall Length
Overall Width
Dimension
Weight
Overall Height
Wheel Base
Front
Curb
Weight
Passengers/Weight
Rear
Total
Front
2165 mm
870 mm
1395 mm
1495 mm
79 kg
111 kg
190 kg
Two / 150 kg
134 kg
Suspension
System
Tire
Specifications
Brake System
Performance
1. General Information
Front
Rear
Front
Rear
Front
Rear
Max. Speed
Climb Ability
TELESCOPIC FORK
UNlT SWING
110 / 90-13 56P
130 / 70-13 57P
DISK (ø 240 mm)
DISK (ø 220 mm)
128 km/hr
<27°
Total
Weight
Type
Installation and
arrangement
Fuel
Cycle/ Cooling
Bore
Stroke
Cylinder
Number/Arrange
Engine
Displacement
Compression Ratio
ment
Max. HP
Rear
Total
206 kg
340 kg
4-STROKE ENGINE
Vertical, below center,
incline 80°
Above 92 unleaded
4-stroke/
Liquid-cooled
71 mm
63.3 mm
SINGLE CYLINDER
250.6 cc
10.5 : 1
23.4 ps / 8000 rpm
Primary
Reduction
Secondary
Reduction
Speedometer
Exhaust Pipe Position and
Direction
Lubrication System
n
Exhaust
Concentratio
Reduction
Clutch
Transmission
Horn
Muffler
CO
HC
NOx
Belt
Gear
Centrifugal, dry type
CVT
0 ~ 160 km/hr
<110 dB/A
Expansion & Pulse
Type
Right side, and
Backward
Forced circulation &
splashing
<2.0 g/km
<0.3 g/km
<0.15 g/km
Max. Torque
Ignition
Starting System
2.3 kg-m / 5500 rpm
Full transistor ignition
Electrical starter
Catalytic reaction control
E.E.C. -
P.C.V. √
system
√
1-9
To this chapter contents
1. General Information
Specifications
MAKER SANYANG MODEL
Overall Length
Overall Width
Dimension
Weight
Overall Height
Wheel Base
Front
Curb
Weight
Passengers/Weight
Rear
Total
Front
Two / 150 kg
2165 mm
870 mm
1395 mm
1495 mm
79 kg
111 kg
190 kg
134 kg
Suspension
System
Tire
Specifications
Brake System
Performance
Front
Rear
Front
Rear
Front
Rear
Max. Speed
Climb Ability
LM25W5-P
LM25W7-7
TELESCOPIC FORK
UNlT SWING
110 / 90-13 56P
130 / 70-13 57P
DISK (ø 240 mm)
DISK (ø 220 mm)
128 km/hr
<27°
Total
Weight
Type
Installation and
arrangement
Fuel
Cycle/ Cooling
Bore
Stroke
Cylinder
Number/Arrange
Engine
Displacement
Compression Ratio
ment
Max. HP
Rear
Total
206 kg
340 kg
4-STROKE ENGINE
Vertical, below center,
incline 80°
Above 92 unleaded
4-stroke/
Liquid-cooled
71 mm
63 mm
SINGLE CYLINDER
249.4 cc
10.5 : 1
23.4 ps / 8000 rpm
Primary
Reduction
Secondary
Reduction
Speedometer
Exhaust Pipe Position and
Direction
Lubrication System
n
Exhaust
Concentratio
Reduction
Clutch
Transmission
Horn
Muffler
CO
HC
NOx
Belt
Gear
Centrifugal, dry type
CVT
0 ~ 160 km/hr
93~112 dB/A
Expansion & Pulse
Type
Right side, and
Backward
Forced circulation &
splashing
<2.0 g/km
<0.3 g/km
<0.15 g/km
1-10
Max. Torque
Ignition
Starting System
2.3 kg-m / 5500 rpm
Full transistor ignition
Electrical starter
E.E.C. -
P.C.V. √
Catalytic reaction control
system
√
To this chapter contents
Specifications
MAKER SANYANG MODEL LM30W-6/T
Overall Length
Overall Width
Dimension
Weight
Overall Height
Wheel Base
Front
Curb
Weight
Passengers/Weight
Rear
Total
Front
2165 mm
870 mm
1395 mm
1495 mm
79 kg
111 kg
190 kg
Two / 150 kg
134 kg
Suspension
System
Tire
Specifications
Brake System
Performance
1. General Information
Front
Rear
Front
Rear
Front
Rear
Max. Speed
Climb Ability
TELESCOPIC FORK
UNlT SWING
110 / 90-13 56P
130 / 70-13 57P
DISK (ø 240 mm)
DISK (ø 220 mm)
128 km/hr
<27°
Total
Weight
Type
Installation and
arrangement
Fuel
Cycle/ Cooling
Bore
Stroke
Cylinder
Number/Arrange
Engine
Displacement
Compression Ratio
ment
Max. HP
Rear
Total
206 kg
340 kg
4-STROKE ENGINE
Vertical, below center,
incline 80°
Above 92 unleaded
4-stroke/
Liquid-cooled
73 mm
63 mm
SINGLE CYLINDER
263.7 cc
10.1 : 1
23.3 ps / 7500 rpm
Primary
Reduction
Secondary
Reduction
Speedometer
Exhaust Pipe Position and
Direction
Lubrication System
n
Exhaust
Concentratio
Reduction
Clutch
Transmission
Horn
Muffler
CO
HC
NOx
Belt
Gear
Centrifugal, dry type
CVT
0 ~ 160 km/hr
93~112 dB/A
Expansion & Pulse
Type
Right side, and
Backward
Forced circulation &
splashing
<2.0 g/km
<0.3 g/km
<0.15 g/km
Max. Torque
Ignition
Starting System
2.5 kg-m / 5500 rpm
Full transistor ignition
Electrical starter
Catalytic reaction control
E.E.C. -
P.C.V. √
system
√
1-11
To this chapter contents
1. General Information
Torque Values
The torque values listed in below are for more important tightening torque values. Please see standard
values for those not listed in the table.
Standard Torque Values for Reference
Type Tighten Torque Type Tighten Torque
5 mm bolt、nut
6 mm bolt、nut
8 mm bolt、nut
10 mm bolt、nut
12 mm bolt、nut
Engine Torque Values
Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Cylinder stud bolt 4 10 1.0~1.4
Cylinder head nut 4 8 3.6~4.0
Cylinder head right bolt 2 8 2.0~2.4
Cylinder head side cover bolt 2 6 1.0~1.4
Cylinder head cover bolt 4 6 1.0~1.4
Cylinder head stud bolt (inlet pipe) 2 6 1.0~1.4
Cylinder head stud bolt (EX. pipe) 2 8 2.4~3.0
Air inject pipe bolt 4 6 1.0~1.4
Air inject reed valve bolt 2 3 0.07~0.09
Tappet adjustment screw nut 4 5 0.7~1.1 Apply oil to thread
Spark plug 1 10 1.0~1.2
Camshaft Chain Tensioner bolt 2 6 1.0~1.4
Carburetor insulator bolt 2 6 0.7~1.1
Oil pump screw 2 3 0.1~0.3
Water pump impeller 1 7 1.0~1.4
Engine left cover bolt 9 6 1.1~1.5
Engine oil draining bolt 1 12 3.5~4.5
Engine oil strainer cap 1 30 1.3~1.7
Mission draining bolt 1 8 0.8~1.2
Mission filling bolt 1 10 1.0~1.4
Clutch driving plate nut 1 28 5.0~6.0
Clutch outer nut 1 14 5.0~6.0
Drive face nut 1 14 8.5~10.5
ACG. Flywheel nut 1 14 5.0~6.0
Crankcase bolt 7 6 0.8~1.2
Mission case bolt 7 8 2.6~3.0
Muffler mounting bolt 3 10 3.2 ~3.8
Muffler mounting nut 2 8 1.0 ~1.2
0.45~0.6kgf-m 5 mm screw 0.35~0.5kgf-m
0.8~1.2kgf-m
1.8~2.5kgf-m
3.0~4.0kgf-m
5.0~6.0kgf-m
6 mm screw、SH nut
6 mm bolt、nut
8 mm bolt、nut
10 mm bolt、nut
0.7~ 1.1kgf-m
1.0 ~1.4kgf-m
2.4 ~3.0kgf-m
3.5~4.5kgf-m
1-12
To this chapter contents
1. General Information
Frame Torque Values
Item Q’ty Thread Dia. (mm) Torque Value (Kg-m) Remarks
Mounting bolt for steering handle
post
Lock nut for steering stem 1 BC1 1.0~2.0
Steering top cone race 1 BC1 2.0~3.0
Front wheel axle nut 1 12 5.0~7.0
Rear wheel axle nut 1 16 11.0~13.0
Front cushion mounting bolt 4 10 3.5~4.5
Rear cushion upper connection bolt 1 10 3.5~4.5
Rear cushion under connection bolt 1 8 2.4~3.0
Rear fork mounting bolt 2 10 4.0~5.0
Brake hose bolt 2 10 3.0~4.0
Brake air-bleeding valve 1 6 0.8~1.0
Front brake disc mounting bolt 5 8 4.0~4.5
Rear brake disc mounting bolt 5 8 4.0~4.5
Brake clipper mounting bolt 2 8 2.9~3.5
Engine hanger link bolt 2 12 7.5~9.5 On frame side
Engine hanger link nut 1 12 7.5~9.5 On engine side
Main standard nut 1 10 4.0~5.0
Air cleaner bolts 2 6 1.0~1.4
1 10 4.0~5.0
1-13
To this chapter contents
r
1. General Information
Trouble Diagnosis
A. Engine hard to start or can not be started
Check and adjustment Failure condition Possible causes
Loosen carburetor drain bolt
to check if there is gasoline
inside the carbureto
Fuel supplied tom
carburetor sufficient
Remove spark plug, install it
into spark plug cap, and
perform a spark test against
engine ground.
Check if sparks Weak sparks, no spark
Perform cylinder
compression pressure test.
No fuel is supplied to
carburetor
at all
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
Cylinder compression
pressure normal
Re-start by following the
starting procedures
No ignition There are some signs of
Remove the spark plug again
and check it.
Dry spark plug Wet spark plug
Remove carburetor after 30
minutes and connect a hose
onto fuel rich circuit. Then
blow the hose with air
Low compression
pressure or no pressure
ignition, nut engine can
not be started
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
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
1-14
Blowing in normal Blowing clogged
1. Malfunction of automatic by- starter
To this chapter contents
1. General Information
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
Check ignition timing
(Using ignition lamp)
Engine speed can be
increased.
Ignition timing correct Incorrect ignition timing
Check cylinder compression
pressure (using compression
pressure gauge)
Compression pressure
correct
Engine speed can not be
increased.
No compression pressure
1. Air cleaner clogged
2. Poor fuel supply
3. Lines in fuel tank evaporation system
clogged
4. Exhaust pipe clogged
5. Fuel level too low in carburetor
6. Fuel nozzle clogged in carburetor.
1. Malfunction of CDI
2. Malfunction of AC alternator
1. Cylinder & piston ring worn out
2. Cylinder gasket leaked
3. Sand hole in compression parts
4. Valve deterioration
5. Seized piston ring
Check if carburetor jet is
clogged
No clogged Clogged
Remove spark plug
No foul or discoloration Fouled and discoloration
Check if engine over heat
Normal Engine overheat
Continually drive in
acceleration or high speed
No knock Knock
1. Remove foreign
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
6. Poor circuit on the cooling system
1. Too much carbon deposited in
combustion chamber
2. Lean mixture
3. Poor fuel quality
4. Ignition timing too advanced
1-15
To this chapter contents
1. General Information
C. 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
Normal Abnormal
Good Poor
Air sucked through
carburetor gasket
No air sucked Air sucked
Remove spark plug, install
spark plug into spark plug
cap and perform spark test
against engine ground
1. Incorrect ignition timing (malfunction
of CDI or AC alternator)
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
5. Vacuum hose crack
Good spark Poor
D. Engine runs sluggish (High speed)
Check and adjustment
Check ignition timing
Normal Abnormal
Check for fuel supplying
system in automatic fuel cup
Good Poor
Check if carburetor clogged
Fault condition Probable causes
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. Malfunction of CDI
2. Malfunction of AC alternator
1. Insufficient fuel in fuel tank
2. Fuel filter clogged
3. Restricted fuel tank vent
1-16
No clogged Clogged
1. Cleaning
To this chapter contents
1. General Information
E. Clutch, Driving And Driving Pulley
FAULT CONDITIONS
Engine can be started but
motorcycle can not be moved.
Engine running and misfire as
motorcycle initial forward moving or
jumping suddenly (rear wheel
rotating as engine in running)
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 damaged
1. Clutch ling spring broken
2. Clutch outer cover stickled with clutch balance
weights
3. Connection parts in clutch and shaft worn out or
burned
1. Driving belt worn out or deformation
Poor initial driving
(Poor climbing performance)
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.
1-17
To this chapter contents
1. General Information
Lubrication Points
Steering shaft bearing
Acceleration cable/
Front & rear brake lever pivot
Seat locker
1-18
Speedometer gear/
front wheel bearing
Side stand shaft
Main stand shaft
Clutch bearing
Home page
Contents
Precautions in Operation···················· 2-1
Periodical Maintenance Schedule······ 2-2
Engine Oil············································· 2-3
Engine Oil Strainer Clean···················· 2-3
Gear Oil················································· 2-4
Fuel Lines / Cable································ 2-4
Air Cleaner ··········································· 2-5
P.C.V. System ······································ 2-6
Valve Clearance··································· 2-6
Spark Plug············································ 2-7
Drive Belt··············································2-8
Steering Handle Top Bearing·············· 2-9
Cushion ················································2-9
Disk Brake System·······························2-10
Brake Light Switch / Start Switch·······2-12
Headlight Distance Adjustment·········· 2-12
Wheel / Tire···········································2-12
Battery ··················································2-13
Nuts, Bolts Tightness··························2-13
Special Tools List ································ 2-14
2. Maintenance Information
Cylinder Compression Pressure········ 2-8
Precautions in Operation
Model
Fuel Tank Capacity 12,000 c.c.
capacity 1,400 c.c.
Engine Oil
change 1,200 c.c.
LM25W5-6/7/P
LM25W7-7
2
LM30W-6/T
Transmission
Gear oil
Clearance of throttle valve 2~6 mm
Spark plug CR8E (gap:0.6~0.7 mm)
Timing advance idle speed BTDC 10º / 1,650 rpm
Full timing advanced BTDC 30º
Idling speed 1,650±100 rpm
Cylinder compression pressure 12 ± 2 kgf/cm²
Valve clearance
Tire dimension Front 110/90-13 56P
Tire dimension Rear 130/70-13 57P
Tire pressure
(cold)
Battery 12V10Ah (MF battery) / YTX12-BS
Capacity of
coolant
capacity 180 c.c.
change 160 c.c.
Engine + radiator 850 c.c.
Reservoir upper 420 c.c.
IN 0.10±0.02 mm
EX 0.15±0.02 mm
single Front: 1.75 kg/cm² Rear: 2.25 kg/cm²
Load 90 Kg (full load) Front: 2.25 kg/cm² Rear: 2.5 kg/cm²
2-1
☆
A
R
☆
R
☆
R
☆
☆
RRep
k
☆
R R
☆
p
☆
☆
A
☆
☆
g
☆
R
☆
☆
A
A A
☆
☆
p
☆
☆
p
To this chapter contents
2. Maintenance Information
Periodical Maintenance Schedule
1 Month
every
1,000KM
ICC
ICC
II
II I I I
II I I I
II I I I
II I
II I
II I I I
II I I I
II
No item
1
2
3
4
5
ir cleaner
2nd air jet leaner
Fuel filter
Oil filter
Engine oil change
6 Tire pressure
7 Battery inspection
8 Brake & free ply check
9 Steering handle chec
10 Cushion operation check
11 Every screw tightening check
12 Gear oil check for leaking
13
14
Spark plug check or change
Gear oil change
Every
300KM
CC C
RRe
15 Frame lubrication
16 Exhaust pipe
17
18
19
20
21
22
Ignition timing
emission check in Idling
Throttle operation
Engine bolt tightenin
CVT driving device(belt﹞
CVT driving device(roller)
23 Lights/electrical equipment/multi-meters
24 Main/side stands & springs
25 Fuel lines
II I I I
II I I I
II I I
III I
III I
II I I I
II I
III I
26 Shock absorbers
27 Cam chain
28
29
30
31
32
Valve clearance
Crankcase evaporative control system
Crankcase blow-by over-flow pipe
2nd air jet system
Evaporative control system
33 Lines & connections in cooling system
34 Coolant reservoir
35 Coolant
III I
I
ICC C
IIC C
II I I I
II I I I
IRe
lace
36 ECU input voltage
37 EFi sensor coupler
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication
Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to
maintain the motorcycle at the optimum condition
The above maintenance schedule is established by taking the monthly 1,000 kilometers as a reference which ever comes first.
Remarks: 1. These marks “ ☆” in the schedule are emission control items. According to EPA regulations, these items must be
performed normally period ica l mainte nanc e fol lo wing the use r man ual i nstruc tions . They are prohibited to be
adjusted or repaired by unauthorized people. Otherwise, SYM is no responsible for the charge.
2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the
Heavily- polluted environment.
3. Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the
motorcycle has accumulated a higher mileage.
4. Preventive maintenance
a. Ignition system－Perform maintenance and check when continuous abnormal ignition, misfire, after-burn, overheating occur.
b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads, exhaust system when power is obvious
lower. Than ever
c. Replace worn out pistons, cylinder head.
II
3 month
every
3,000KM
6 month
every
6,000KM
lacement for every 1,000 km
lacement for every 5,000 km
L L
I
C C
II I
Re
lacement for every 2,000 km
II I
I
1 year
every
12,000KM
2-2
To this chapter contents
Engine Oil
Turn off engine, and park the motorcycle in flat
surface with main stand.
Check oil level with oil dipstick
So not screw the dipstick into engine as checking.
If oil level is nearly low level, fill out recommended
oil to upper level.
Oil Change
Caution
y Drain oil as engine warmed up so that make
sure oil can be drained smoothly and
completely.
Place an oil pan under the motorcycle, and
remove oil drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.
Torque value: 3.5~4.5kgf-m
Add oil to crankcase (oil viscosity SAE 10W-30)
Recommended using King serial oil.
Engine oil capacity:
Disassembly 1400c.c.
Replacement 1200c.c.
Install dipstick, start the engine for running several
minutes.
Turn off engine, and check oil level again.
Check if engine oil leaks.
Engine Oil Strainer Clean
Drain engine oil out.
Remove oil strainer and spring.
Clean oil strainer.
Check if O-ring can be re-used.
Install oil strainer and spring.
Install oil strainer cap.
Torque value：1.3~1.7kgf-m
2. Maintenance Information
2-3
To this chapter contents
2. Maintenance Information
Gear Oil
Oil level inspection
Park the motorcycle on flat surface with main
stand.
Turn off the engine.
Gear Oil Change
Remove oil inspection bolt.
Remove drain plug and drain oil out.
Install the drain plug after drained.
Torque value: 0.8~1.2kgf-m
Add gear oil to specified quantity from the
inspection hole.
Install the inspection bolt.
Torque value: 1.0~1.4kgf-m
Gear Oil Quantity: 170 c.c. when replacing
Make sure that the bolt washer can be re-used,
and install the bolt.
Start engine and run engine for 2-3 minutes.
Turn off engine and make sure that oil level is in
correct level.
Make sure that no oil leaking.
Fuel Lines / Cable
Remove luggage box.
Remove rear carrier.
Remove body covers.
Check all lines, and replace it when they are
deterioration, damage or leaking.
Warning
Drain plug
Oil inspection bolt
2~6 mm
y Gasoline is a low ignition material so any kind
of fire is strictly prohibited as dealing it.
Acceleration Operation
Have a wide open of throttle valve as handle bar in
any position and release it to let back original (full
closed) position.
Check handle bar if its operation is smooth.
Check acceleration cable and replace it if
deteriorated, twisted or damaged.
Lubricate the cable if operation is not smooth
Measure handle bar free play in its flange part.
Free play: 2~6 mm.
Adjustment can be done in either end.
Secondary adjustment is conducted from top side.
Remove rubber boot, loosen fixing nut, and then
adjust it by turning the adjustment nut.
Rubber
Adjustment nut
2-4
To this chapter contents
Primary adjustment is conducted from bottom
side.
Loosen fixing nut, and adjust by turning the
adjustment nut.
Tighten the fixing nut, and check acceleration
operation condition.
Air Cleaner
Air Cleaner Element
Remove 8 screws from the air cleaner cover and
then remove the cover.
Remove the body cover.
Loosen bolt from the air cleaner air hose.
Remove 6 screws, and then remove the air
cleaner element.
2. Maintenance Information
Adjustment nut
8 screws
Bolt
6 screws
Caution
y The air cleaner element is made of paper so
do not soap it into water or wash it with water.
2-5
To this chapter contents
2. Maintenance Information
P.C.V. system
Remove the plug from lower of the breather
chamber hose.
Release the dry internal deposit.
Every 2,000 kilometers release oil
Caution
y A In releases the breather chamber hose in
the transparent section as worthy of looking
at as any deposit
y In the multi- rain or the accelerator in the
situation rides, must reduce the maintenance
traveling schedule
y In releases the breather chamber hose in the
transparent section as worthy of looking at as
any deposit
Valve Clearance
Caution
y Checks and adjustment must be performed
when the engine temperature is below 35℃.
2 bolts
Breather chamber hose
Timing mark
Remove luggage box.
Remove cylinder head cover & side cover.
Remove ignition timing hole cap located in front
upper side of engine right cover
Turn camshaft bolt in C.W. direction and let the “T”
mark on the camshaft sprocket aligns with cylinder
head mark so that piston is placed at TDC position
in compression stroke.
Caution
y Do not turn the bolt in C.C.W. direction to
prevent from camshaft bolt looseness.
Valve clearance inspection and adjustment:
Check & adjust valve clearance with feeler gauge.
Valve clearance (IN)：0.10±0.02 mm.
Valve clearance (EX)：0.15±0.02 mm.
Loosen fixing nut and turn the adjustment nut for
adjustment.
Caution
y Re-check the valve clearance after tightened
the fixing nut.
Special tool: Tappet adjuster
SYM-9001200-08
SYM-9001200-09
SYM-9001200-10
Special tool: Tappet adjuster wrench
SYM-9001200
2-6
To this chapter contents
Spark Plug
Recommended spark plug: CR8E
Remove luggage box
Remove central cover.
Remove spark plug cap.
Clean dirt around the spark plug hole.
Remove spark plug.
Measure spark plug gap.
Spark plug gap: 0.6~0.7 mm
Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold spark plug washer and install the spark plug
by screwing it.
Tighten the plug by turning 1/2 turn more with plug
socket after installed.
Tighten torque: 1.0~1.2kgf-m
Connect spark plug cap
2. Maintenance Information
Ground electrode
Central electrode
Spark plug
0.6~0.7mm
2-7
Loading...