SANYANG JOYMAX 250 Service Manual

GTS 250 JOYMAX 250 SERVICE MANUAL FORWARD HOW TO USE THIS MANUAL CONTENTS SERIAL NUMBER

1. General Information 1-5 y Lubricate the rotation face with specified lubricant on the lubrication points before assembling. y Check if positio

8. V-Belt Driving System 8-5 Drive Belt Removal Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. S

8. V-Belt Driving System 8-6 Installation Caution ● Pull out driven face to avoid it closing. ● Cannot oppress friction plate comp in order to av

8. V-Belt Driving System 8-7 Drive Face Removal Remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut.

8. V-Belt Driving System 8-8 Inspection The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are

8. V-Belt Driving System 8-9 With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution y The mov

8. V-Belt Driving System 8-10 Clutch Outer/Driven Pulley Disassembly Remove drive belt, clutch outer and driven pulley. Install clutch spring compre

8. V-Belt Driving System 8-11 Clutch lining Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 3.0 mm

8. V-Belt Driving System 8-12 Clutch weight Replacement Remove snap ring and washer, and then remove clutch weight and spring from driving plate. C

8. V-Belt Driving System 8-13 Install snap ring and mounting plate onto setting pin. Replacement of Driven Pulley Bearing Remove inner bea

8. V-Belt Driving System 8-14 Installation of Clutch Outer/Driven Pulley Assembly Install new oil seal and O-ring onto movable driven face. Apply wi

1. General Information 1-6 y When separating a connector, it locker has to be unlocked firstly. Then, conduct the service operation. y Do not

9. Final Driving Mechanism 9-1 Mechanism Diagram···························· 9-1 Precautions in Operation ···················· 9-2 Trouble Diagnosis

9. Final Driving Mechanism 9-2 Precautions in Operation Specification Application oil: scooter gear oil Recommended oil: KING MATE serial gear oils

9. Final Driving Mechanism 9-3 Disassembly of Final Driving Mechanism Remove the rear wheel. Remove the clutch. Drain out gear oil from gear box. Lo

9. Final Driving Mechanism 9-4 Inspection of Final Driving Mechanism Check if the drive shaft are burn, wear or damage and replace it if necessary.

9. Final Driving Mechanism 9-5 Bearing Replacement Left crankcase side If the drive shaft is pulled out with its bearing, then remove the bearing wi

9. Final Driving Mechanism 9-6 Install assembly directs puller bearing puller. Special Service Tools: Assembly directs puller SYM-2341110 Use scre

9. Final Driving Mechanism 9-7 Install new final shaft bearing and bearing puller onto left crankcase. Special tool: Bearing puller 6205 SYM-9100

9. Final Driving Mechanism 9-8 Re-Assembly of Final Driving Mechanism Install drive shaft. Special tool: Drive shaft puller SYM-2341110- HMA RB1 Dr

10. Alternator / Starting Clutch 10-1 Mechanism Diagram···························10-1 Precautions in Operation ···················10-2 Right Crankc

10. Alternator / Starting Clutch 10-2 Precautions in Operation General information y Refer to chapter 17: The troubleshooting and inspection of alt

1. General Information 1-7 y Do not let the wire harness contact with rotating, moving or vibrating components as routing the harness. y Keep wi

10. Alternator / Starting Clutch 10-3 Right Crankcase Cover Removal Remove left side cover. Remove seat and luggage box. (Refer chapter 13) Remove t

10. Alternator / Starting Clutch 10-4 AC.G. Set Removal Remove 2 mounting screws from pulse generator. Remove 3 screws from right crankcase cover an

10. Alternator / Starting Clutch 10-5 Flywheel Removal Remove right crankcase cover and generator coil. Remove flywheel nut. Installs shaft

10. Alternator / Starting Clutch 10-6 Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear. Check the gear for wear or dama

10. Alternator / Starting Clutch 10-7 Remove the starting gear Loosen 3 starting clutch socket bolts from one way clutch and remove one way clutch.

10. Alternator / Starting Clutch 10-8 AC.G. Flywheel Installation Install starting driven gear onto one way clutch. Align the key on cra

10. Alternator / Starting Clutch 10-9 AC.G. Set Installation Install the AC.G. coil set onto right crankcase cover (3 screws). Install pulse generat

10. Alternator / Starting Clutch 10-10 Notes: To this chapter contents

11. Crankcase / Crank 11-1 Mechanism Diagram ··························11-1 General Information ···························11-2 Trouble Diagnosis···

11. Crankcase / Crank 11-2 General Information Operational precautions y This Section concerns disassembly of the crankcase for repair purpose. y

1. General Information 1-8 y Do not let the wire harness been twisted as installation. y Wire harnesses routed along the handlebar should not be

11. Crankcase / Crank 11-3 Disassembly of Crankcase Remove the cam chain setting plate, and then remove cam chain. Loosen the pivot bolt and remove

11. Crankcase / Crank 11-4 Remove crankshaft and wave washer from right crankcase. Remove gasket and dowel pins. Scrape gasket residues

11. Crankcase / Crank 11-5 Measure the clearance of the big end at the vertical directions. Service limit: 0.05 mm Place the crankshaft o

11. Crankcase / Crank 11-6 Assembly of Crankcase Install new bearing and bearing puller onto left crankcase bearing hole. Special tool: L. crank sha

11. Crankcase / Crank 11-7 Hold left crank shaft puller, and turn the shaft puller nut by clutch nut wrench to pull in crank shaft into left crankca

11. Crankcase / Crank 11-8 Apply a layer of grease on the lip of oil seal Clean the crankshaft with clean solvent. Install the oil seal

12. Cooling System 12-1 Mechanism Diagram ··························· 12-1 General Information ···························· 12-2 Trouble Diagnosis··

12. Cooling System 12-2 General Information General Warning: While the engine is running, never attempt to open the radiator filler cap, the pressu

12. Cooling System 12-3 Trouble Diagnosis for Cooling System The temperature indicated is too h

12. Cooling System 12-4 E-4. Remove thermostat from holder then heats it by water directly to check i

1. General Information 1-9 Specifications MAKER SANYANG MODEL LM25W Overall Length 2165 mm Front TELESCOPE Overall Width 870 mm Suspension System

12. Cooling System 12-5 Change of coolant Warning y Never attempt to carry out service work on the cooling system unless the engine is completely

12. Cooling System 12-6 Check reserve tank y Open the inner box lid. y Check the liquid level in the reservoir. y Add coolant to proper level if

12. Cooling System 12-7 Disconnect the couplers for the thermo switch and fan motor. Remove engine coolant inlet pipe, reserve tank inlet pipe and r

12. Cooling System 12-8 Water Pump Check water pump seal / cooling system divulges inspection y Disassembles the refrigerant drain bolt, overflows

12. Cooling System 12-9 Check any wear and damage of the mechanical seal and inside seal. Caution The mechanical seal and inside seal must be repla

12. Cooling System 12-10 Install the new inner seal onto the right crankcase. Special tools: Water pump oil seal driver (inner) Install a

12. Cooling System 12-11 Install the seal washer into the rotor. Caution y Washer must be replaced together with the mechanical seal. Ins

12. Cooling System 12-12 Thermostat Please refer to chapter 17 for inspection of thermo unit. Removal Remove the luggage box and body cover. Drain

12. Cooling System 12-13 Place the thermostat into heated water to check its operation. Caution y Whenever the thermostat and the thermometer are

12. Cooling System 12-14 Notes: To this chapter contents

1. General Information 1-10 Torque Values The torque values listed in above table are for more important tighten torque values. Please see standard

13. Body Cover 13-1 Mechanism Diagram···························13-1 Maintenance········································13-2 Handle Cover···········

13. Body Cover 13-2 Maintenance Body covers disassemble sequence: y Be careful not to damage various covers in ass

13. Body Cover 13-3 Handle Cover Remove Loosen the 2 screws from handle upper cover front end. Loosen the 2 screws from handle upper cover

13. Body Cover 13-4 Front Cover Remove Loosen 4 screws from the wind screen garnish and remove the wind screen garnish. Loosen 8 screws f

13. Body Cover 13-5 Loosen 2 bolts from the front cover under side. Loosen 2 screws and 2 bolts from the front cover upper side.

13. Body Cover 13-6 Meter Panel Remove Remove wind screen garnish, wind screen, meter visor and front cover. Remove reserve tank cap. Loosen 4scre

13. Body Cover 13-7 Inner Box Remove Remove wind screen garnish, wind screen, meter visor, front cover, meter panel, R/L side cover and front under

13. Body Cover 13-8 Remove the filler pipe cover. Loosen 3 screws of the filler pipe. Loosen 2 bolts from inner box under side.

13. Body Cover 13-9 Side Cover Remove Loosen 2 screws from the side cover side end. Loosen 2 screws from the side cover upper end.

13. Body Cover 13-10 Front under Spoiler Remove Remove wind screen garnish, wind screen, meter visor, front cover and R/L side cover. Loosen 2 scre

1. General Information 1-11 Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value (Kg-m) Remarks Mounting bolt for steering handle post 1 10

13. Body Cover 13-11 Luggage Box Remove Open the seat. Loosen 2 screws from the luggage box rear cover. Disconnect the luggage box light and switch

13. Body Cover 13-12 Rear Body Cover Remove Loosen right and left side screws from rear end of floor panel. Loosen right and left side sc

13. Body Cover 13-13 Floor Panel Remove Remove wind screen garnish, wind screen, meter visor, front cover, R/L side cover, front under spoiler, inne

13. Body Cover 13-14 Rear Fender Loosen 4 bolts from rear fender. Remove the rear fender. Installation Install in reverse order of re

14. Brake System 14-1 Mechanism Diagram···························· 14-1 Maintenance Description ···················· 14-2 Trouble Diagnosis ·······

14. Brake System 14-2 Maintenance Description Operational precautions Caution Inhaling asbestos may cause disorders of respiration system or cance

14. Brake System 14-3 Trouble Diagnosis Soft brake lever 1. Air inside the hydraulic system 2. Hydraulic system leaking 3. Worn master piston 4.

14. Brake System 14-4 Disk Brake System Inspection Inspection By visual examination whether divulges or the damage, with spanner inspection brake t

14. Brake System 14-5 Adding Brake Fluid Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes hori

14. Brake System 14-6 Brake fluid replacement / Air-bleed Connect drain hose to air-bleed valve. Open the drain valve on the calipers and delay val

1. General Information 1-12 Troubles Diagnosis A. Engine hard to start or can not be started To this chapter contents

14. Brake System 14-7 Front Brake Caliper Removal Place a container under the brake caliper, and loosen the brake hose bolts and finally remove the

14. Brake System 14-8 Rear Brake Caliper Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the b

14. Brake System 14-9 Brake Disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places.

14. Brake System 14-10 Remove the rubber pad. Remove the cir clip. Remove the piston and the spring. Clean the master cylinder with recommended bra

14. Brake System 14-11 Master Cylinder Install Install the rubber pad into the groove correctly. Place the master cylinder onto handlebar, and insta

14. Brake System 14-12 Note: To this chapter contents

15. Steering / Front Wheel / Front Cushion 15-1 Mechanism Diagram···························· 15-1 Operational Precautions ····················· 15-

15. Steering / Front Wheel / Front Cushion 15-2 Operational Precautions General Please refer to the Maintenance Manual of tubeless tire in respect t

15. Steering / Front Wheel / Front Cushion 15-3 Steering Handle Remove Remove the right and left handle side cover, handle upper cover and front cov

15. Steering / Front Wheel / Front Cushion 15-4 Loosen 2 bolts from the master cylinder of the rear brake. Remove holder and master cylinder.

1. General Information 1-13 B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fau

15. Steering / Front Wheel / Front Cushion 15-5 Front Wheel Loosen 2 bolts from the front brake caliper and remove it Caution y Care shall be take

15. Steering / Front Wheel / Front Cushion 15-6 Inspection Wheel axle Place the wheel axle on a V block, measure its run out. Service limit: 0.2 mm

15. Steering / Front Wheel / Front Cushion 15-7 Assembly Fill out the block of bearing by grease. Drive the left bearing, dust seal and install the

15. Steering / Front Wheel / Front Cushion 15-8 Front Cushion Remove Remove front cover, front under spoiler and front fender. Remove front wheel.

15. Steering / Front Wheel / Front Cushion 15-9 Steering Stem Remove Remove handle, front wheel and front cushion. Remove the steering stem mountin

15. Steering / Front Wheel / Front Cushion 15-10 Lubricate the top cone race seat with grease. Screw the cone race in to top ball bearing seat till

16. Rear Wheel / Rear Fork / Rear Cushion 16-1 Mechanism Diagram···························16-1 Operational Precaution ······················16-2 Tr

16. Rear Wheel / Rear Fork / Rear Cushion 16-2 Operational Precaution General Please refer to the Maintenance Manual for tubeless tire in respect t

16. Rear Wheel / Rear Fork / Rear Cushion 16-3 Muffler Removal Loosen the 2 nuts from exhaust muffler front side. Loosen the 3 mounting bo

16. Rear Wheel / Rear Fork / Rear Cushion 16-4 Remove rear wheel axle nut. Remove rear fork and both side collars. Remove the rear wh

1. General Information 1-14 C. Engine runs sluggish (especially in low speed and idling) D. Engine runs sluggish (High speed)

16. Rear Wheel / Rear Fork / Rear Cushion 16-5 Rear Fork Inspection rear fork bearing Rotate the inner ring of the bearing with a finger. The bearin

16. Rear Wheel / Rear Fork / Rear Cushion 16-6 Install the bearing lock cir clip. Rear Cushion Removal Remove the luggage box, rear ca

17. Electrical System 17-1 Mechanism Diagram ··························· 17-1 Maintenance Data································ 17-2 Technical Specif

17. Electrical System 17-2 Maintenance Data Operational precaution y When remove the battery, the disconnection sequence of cable terminals shall b

17. Electrical System 17-3 Trouble Diagnosis No voltage y Battery discharged y The cable disconnected y The fuse is blown y Improper operation of

17. Electrical System 17-4 Battery Removal Loosen 1 screw and remove the battery cover. Disconnect the negative cable terminal first, then the posit

17. Electrical System 17-5 Fuse Fuse circuit diagram Main switch(Luggage box & Outlet) Fuse 20A Battery (Foggy & Fan) Fuse 15A (Meter

17. Electrical System 17-6 Charging System Charging circuit Regulator rectifier Inspection (KΩ)

17. Electrical System 17-7 Inspection on AC. Generator coil Remove the luggage box, rear carrier and body covers. Disconnect 3 pin couplers of the g

17. Electrical System 17-8 Inspection on Charging Voltage Caution y Before conducting the inspection, be sure that the battery is fully charged.

Forward This service manual contains the technical data of each component inspection and repair for the SANYANG LM25W series scooter. The manual

1. General Information 1-15 E. Clutch, Driving And Driving Pulley 1. Clutch ling spring broken 2. Clutch outer cover stickled

17. Electrical System 17-9 Ignition System Ignition circuit diagram Transistor ignition coupler Inspection on transistor ignition

17. Electrical System 17-10 Inspection on ignition coil Remove the luggage box. Disengage the connector of the ignition coil and the spark plug cap.

17. Electrical System 17-11 Starting System Starting circuit diagram Inspection on starter relay Open the main switch. Press the brake. Push down t

17. Electrical System 17-12 Disconnect the positive cable of the starter motor. Disconnect the coupler of the relay. Connect an ohmmeter to the larg

17. Electrical System 17-13 Meters Meter circuit diagram Meter coupler Wire harness coupler Wire harness coupler Red Black Green G

17. Electrical System 17-14 Removal of meter Remove wind screen garnish, wind screen, meter visor, front cover, meter visor. (Refer chapter 13)

17. Electrical System 17-15 Light / Bulb Headlight and foggy light circuit diagram Winker light circuit diagram Lo-beam relay R Main switc

17. Electrical System 17-16 Replacement headlight bulbs Remove wind screen garnish, wind screen, meter visor, front cover. (Refer chapter 13) Discon

17. Electrical System 17-17 Replacement the front winker light and foggy light bulb Remove wind screen garnish, wind screen, meter visor, front cove

17. Electrical System 17-18 Replacement the meter bulbs Remove the meter board waterproofing rubber. Uses the “-“ screw driver turn the

1. General Information 1-16 Lubrication Points Steering shaft bearing Seat lockerClutch bearing Main stand shaft Side stand shaft Sp

17. Electrical System 17-19 Switch / Horn Main switch Inspection Remove the front cover. Disconnect the main switch coupler. Check the continuity be

17. Electrical System 17-20 Left handle switch Remove the handle cover and front cover. Disconnect the coupler of left handle switch. Check the cont

17. Electrical System 17-21 Fuel Unit Open the seat. Remove the luggage box. Remove the rear carrier. Remove right & left side cover. Remove the

17. Electrical System 17-22 Cooling Fan Thermo Switch The thermo switch mounted on the radiator controls the operation of the cooling fan motor. I

17. Electrical System 17-23 Thermo Sensor Remove the thermo unit. Hang the thermo unit in an oil heater, heat the oil and measure the resistance at

17. Electrical System 17-24 Note: To this chapter contents

18. Emission Control System 18-1 Names of Mechanisms in the Emission Control System······································ 18-1Function of Mechanism

18. Emission Control System 18-2 Fuel Evaporative Emission Control System (E.E.C.) 1. Construction: y Reduce HC to pollute air. y To absorber fue

18. Emission Control System 18-3 Evaporative Emission Control System (EEC) 1. Visual check: 1) Check the outside of canister for damage. 2) Check

18. Emission Control System 18-4 Catalytic Converting System (CATA) 1. Construction: 2. Description: 1) The function of the catalytic converter

2. Maintenance Information 2-1 Precautions in Operation······················ 2-1 Periodical Maintenance Schedule ······· 2-2 Engine Oil ···········

18. Emission Control System 18-5 Secondary Air Introduction System 4. Construction This system contained AICV (air Injection Cut Valve), R/V

18. Emission Control System 18-6 3. Service Points/Trouble Diagnosis: Diesel a. Malfunction of air inject cut valve (AICV). b. System hose leakage

18. Emission Control System 18-7 1. Warm-up test: y Start engine. y Remove the air injection filter. y Check the air inlet if there is air-sucki

18. Emission Control System 18-8 Positive Crankcase Ventilation System (P.C.V.) 1. Construction 2. Principle of operation: y Install a separated

18. Emission Control System 18-9 Inspection Items Secondary air injection system 1. Visual inspect the reed valve, air injection cut valve, and se

18. Emission Control System 18-10 Countermeasure for Emission Pollutants Not Within Standard as In Idle Speed (4-Stroke Engine)

19. Electrical Diagram 19-1 18Home pageContents LA25W 電路圖

19. Electrical Diagram 19-2 Note: Home pageContents

2. Maintenance Information 2-2 Periodical Maintenance Schedule No item Every 300KM1 Monthevery 1,000KM3 month every 3,000KM 6 month every 6,000KM

2. Maintenance Information 2-3 Engine Oil Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstic

2. Maintenance Information 2-4 Gear Oil Oil level inspection Park the motorcycle on flat surface with main stand. Turn off the engine. Gear Oil C

2. Maintenance Information 2-5 Primary adjustment is conducted from bottom side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighte

2. Maintenance Information 2-6 P.C.V. system Draws out the plug from lower of the breather chamber hose. Releases the dry internal deposit. Ever

2. Maintenance Information 2-7 Carburetor Idle Speed Adjustment Caution ● Inspection & adjustment for idle speed have to be performed after al

2. Maintenance Information 2-8 Ignition System Caution ● C.D.I ignition system is set by manufacturer so it can not be adjusted. ● Ignition tim

How To Use This Manual This service manual describes basic information of different system parts and system inspection & service for SANYANG L

2. Maintenance Information 2-9 Cylinder Compression Pressure Warm up engine. Turn off the engine. Remove luggage box and central cover Remove spark

2. Maintenance Information 2-10 Steering Handle Top Bearing Caution ● Check all wires and cables if they are interfered with the rotation of ste

2. Maintenance Information 2-11 Disk Brake System Brake System Hose Make sure the brake hoses for corrosion or leaking oil. Brake Fluid Check br

2. Maintenance Information 2-12 Brake Lining Wear The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear lim

2. Maintenance Information 2-13 Brake Light Switch/Starting Inhibitor Switch The brake lamp switch is to light up brake lamp as brake applied. Make

2. Maintenance Information 2-14 Battery Open the inner box lid. Loosen screw & remove the battery cover Battery cable remove： 1. Disconne

2. Maintenance Information 2-15 Special Tools List NAME Left crank bearing puller NAME R/L. crank case disassemble tool NAMEValve cotter remove &am

2. Maintenance Information 2-16 NAME Inner bearing puller NAME Outer bearing puller NAMEHandle stand nut wrench NO SYM-6204022 NO SYM-6204001 NO

2. Maintenance Information 2-17 NAME Bearing driver 6205 NAME Drive shaft & oil seal (25*40*8) socket NAMEBearing puller 6303 NO SYM-961500

2. Maintenance Information 2-18 Note: To this chapter contents

Contents Page Content Index 1-1 ~ 1-16 General Information 1 2-1 ~ 2-18 Service Maintenance Information 2 3-1 ~ 3-8 Lubrication System 3 4-1 ~

3. Lubrication System 3-1 Mechanism Diagram······························ 3-1 Precautions in Operation ······················ 3-2 Troubleshooting ··

3. Lubrication System 3-2 Precautions in Operation General Information: z This chapter contains maintenance operation for the engine oil pump and g

3. Lubrication System 3-3 Engine Oil Turn off engine, and park the scooter in flat surface with main stand. Check oil level with oil dipstick. So no

3. Lubrication System 3-4 Oil Pump Oil Pump Removal Remove generator and starting gear. (Refer to chapter 10) 。 Remove cir clip and take ou

3. Lubrication System 3-5 Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance betw

3. Lubrication System 3-6 Tighten the oil pump screw. Oil Pump Installation Install the oil pump, and then tighten screws. Torque value：0

3. Lubrication System 3-7 Gear Oil Gear Oil Change Remove oil join bolt. Remove drain bolt and drain gear oil out. Install the drain bolt after drai

3. Lubrication System 3-8 Notes: To this chapter contents

4. Fuel System 4-1 Mechanism Diagram ...4-1 Precautions in Operation...4-2 Trouble Diagnosis...

4. Fuel System 4-2 Precautions in Operation General Information Warning Gasoline is a low ignition point and explosive materials, so always work in

Serial Number Home pageContents

4. Fuel System 4-3 Trouble Diagnosis Poor engine start y No fuel in fuel tank y Clogged fuel tube y Too much fuel in cylinder y No spark

4. Fuel System 4-4 Carburetor Remove / Install Removal Remove luggage box. Drain out fuel in the float chamber. Disconnect the fuel hose,

4. Fuel System 4-5 Remove fuel needle seat, spring, and injector needle. Inspection Check if the vacuum piston and needle for wear out, crack or oth

4. Fuel System 4-6 Air Cut-off Valve Removal Removal the throttle cable seat (2 screws) Remove the screws (2 screws) of the air cut-off valv

4. Fuel System 4-7 Automatic by-starter Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two term

4. Fuel System 4-8 Float Chamber Disassembly Remove 3 mounting screws and remove float chamber cover. Remove the fuel level plate, float pi

4. Fuel System 4-9 Assembly Install main jet, needle jet holder, needle jet, slow jet and air adjustment screw. Caution Set the air adjustment scre

4. Fuel System 4-10 Adjustment of Idle Speed Caution y Air screw was set at factory, so no adjustment is needed. Note the number of turns it takes

4. Fuel System 4-11 Fuel Tank Fuel unit removal Remove the left and right side covers. Open seat and remove the luggage box. Remove rear carrier. Re

4. Fuel System 4-12 Remove fuel tank upper bolts (2 bolts). Remove fuel tank under bolt (1 bolt). Remove fuel tank. Ins

1. General Information 1-1 Symbols and Marks····························1-1 General Safety ····································1-2 Service Precautio

4. Fuel System 4-13 Fuel Pump Inspection Remove the left side cover and floor panel side cover. Warm up the engine and adjust idle speed. Remove fue

4. Fuel System 4-14 Air Cleaner Removal Loosen the clamp strip of air cleaner and carburetor, and then remove the vapor hose. Remove the a

5. Removal & Installation of Engine 5-1 Operational Precautions····················· 5-1 Engine Removal ·································· 5-2 E

5. Removal & Installation of Engine 5-2 Engine Removal Open inner box cover. Remove battery cover (1 screw). Remove the battery negative (-) cab

5. Removal & Installation of Engine 5-3 Remove the generator power wire and pulse generator connector. Remove the starter motor wire.

5. Removal & Installation of Engine 5-4 Remove the air cleaner connection bolts (2 bolts). Remove the air cleaner. Remove the exhaus

5. Removal & Installation of Engine 5-5 Remove rear brake hose clamp and rear brake caliper. Remove the right rear cushion lower bo

5. Removal & Installation of Engine 5-6 With a bracket to support the engine to prevent from it damage by falling down as removing the engine. R

5. Removal & Installation of Engine 5-7 Rear Fork Bearing Inspection Check bearings on rear fork. Rotate bearing inner ring with fingers. Chec

5. Removal & Installation of Engine 5-8 Install assembly directs puller bearing puller. Special Service Tools: Assembly directs puller SYM-23411

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

5. Removal & Installation of Engine 5-9 Removal of Engine Bush If engine hanger frame and the cushion rubber of rear cushion bush damaged. Then,

5. Removal & Installation of Engine 5-10 Installation of Engine Install the engine according to the reversing order of removal. Caution z Note

6. Cylinder Head / Valve 6-1 Mechanism Diagram··························· 6-1 Precautions in Operation ··················· 6-2 Troubleshooting······

6. Cylinder Head / Valve 6-2 Precautions in Operation General Information y This chapter is contained maintenance and service for cylinder head, va

6. Cylinder Head / Valve 6-3 Troubleshooting Engine performance will be affected by troubles on engine top parts. The trouble usually can be determi

6. Cylinder Head / Valve 6-4 Cylinder Head Removal Remove engine. (Refer to chapter 5) Remove 2 bolts of thermostat and then remove the

6. Cylinder Head / Valve 6-5 Remove the side cover mounting blots of cylinder head, and then take out the side cover. Remove left crankc

6. Cylinder Head / Valve 6-6 Cylinder Head Disassembly Remove cam shaft setting plate (1 bolt). Remove rocker arm shafts and rocker ar

6. Cylinder Head / Valve 6-7 Remove valve cotters, spring retainers, springs and valves. Remove valve stem seals. Clean ca

6. Cylinder Head / Valve 6-8 Cylinder Head Inspection Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedg

1. General Information 1-3 Service Precautions y Always use with SANYANG genuine parts and recommended oils. Using non-designed parts for SANYANG A

6. Cylinder Head / Valve 6-9 Valve spring free length Measure the free length of intake and exhaust valve springs. Service limit: Inner spring

6. Cylinder Head / Valve 6-10 Valve Stem Replacement Heat up cylinder head to 100~150 ℃ with heated plate or toaster. Caution y Do not let torch

6. Cylinder Head / Valve 6-11 Valve Seat Inspection and Service Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slight

6. Cylinder Head / Valve 6-12 Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Use 45° cutte

6. Cylinder Head / Valve 6-6 Cylinder Head Disassembly Remove cam shaft setting plate (1 bolt). Remove rocker arm shafts and rocker ar

6. Cylinder Head / Valve 6-14 Install camshaft into cylinder head. Install valve rocker arm, rocker arm shaft and cam shaft setting plate.

6. Cylinder Head / Valve 6-15 Install cylinder head side cover (3 bolts). Install thermostat (2 bolts). Loosen auto tensioner adjustme

6. Cylinder Head / Valve 6-16 Valve Clearance Adjustment Loosen Air Injection system (AI) pipe upper side bolt (2 bolts). Remove cylinder head cover

7. Cylinder / Piston 7-1 Mechanism Diagram···························· 7-1 Precautions in Operation ···················· 7-2 Trouble Diagnosis·····

7. Cylinder / Piston 7-2 Precautions in Operation General Information y Both cylinder and piston service cannot be carried out when engine mounted

1. General Information 1-4 y The length of bolts and screws for assemblies, cover plates or boxes is different from one another, be sure they are c

7. Cylinder / Piston 7-3 Cylinder and Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder.

7. Cylinder / Piston 7-4 Check cylinder if warp. Service limit: 0.05 mm Measure clearance between piston rings and grooves. Service Limit:

7. Cylinder / Piston 7-5 Measure the outer diameter of piston pin. Service Limit: 16.96 mm Measure the inner diameter of connecting rod sm

7. Cylinder / Piston 7-6 Piston Ring Installation Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston careful

7. Cylinder / Piston 7-7 Piston Installation Install piston and piston pin, and place the IN marks on the piston top side forward to inlet valve.

7. Cylinder / Piston 7-8 Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder

8. V-Belt Driving System 8-1 Mechanism Diagram ··························· 8-1 Maintenance Description···················· 8-2 Trouble Diagnosis····

8. V-Belt Driving System 8-2 Maintenance Description Precautions in Operation General Information y Drive face, clutch outer, and driven pulley can

8. V-Belt Driving System 8-3 Left Crankcase Cover Left crankcase cover removal Loosen 4 bolts from left side crank out cover & remove it. Remove

8. V-Belt Driving System 8-4 Left crankcase cover inspection Remove 2 bolts to remove left crankcase cover bearing setting plate. Check bea