SANYANG SYM Service Manual

SERVICE MANUAL FORWARD HOW TO USE THIS MANUAL CONTENTS

1. GENERAL INFORMATION 1-5 Specifications Make SANYANG MODEL LA12W Overall Length 2010 mm Front TELESCOPIC FORK Overall Width 760 mm Suspensio

9. FINAL DRIVING MECHANISM 9-5 Remove oil seal, and then remove final shaft bearing from left crankcase. Install new final shaft bearing. Press the

9. FINAL DRIVING MECHANISM 9-6 Install a new final shaft bearing onto gear box cover. Tool: Bearing (6203/6004UZ) driver Press the bearing in with

9. FINAL DRIVING MECHANISM 9-7 Install dowel pin and new gasket. Install gear box cover and bolts, and tighten. Torque value: 1.0~1.4 k

9. FINAL DRIVING MECHANISM 9-8 NOTES To this chapter contents

10. ALTERNATOR/STARTING CLUTCH 10-1 Precautions in Operation... 10-2 Starting Clutch ...10-4 Right Crankcas

10. ALTERNATOR/STARTING CLUTCH 10-2 Precautions in Operation General information • Refer to chapter 5: Engine removal and installation • Refer to c

10. ALTERNATOR/STARTING CLUTCH 10-3 Right Crankcase Cover Removal Remove 7 bolts from the right crankcase cover. Remove the right crankcase cover.

10. ALTERNATOR/STARTING CLUTCH 10-4 Hold flywheel with flywheel holder, and then remove flywheel nut. Tool: Multi-functional holder Pull ou

10. ALTERNATOR/STARTING CLUTCH 10-5 Starting Clutch Inspection Check the starting clutch gear for wear or damage. Measure the ID and OD of the star

10. ALTERNATOR/STARTING CLUTCH 10-6 Remove the rollers, spring caps, and springs of clutch on the one way clutch that located on the back of flywhe

1. GENERAL INFORMATION 1-6 Specifications Make SANYANG MODEL LA15W Overall Length 2010 mm Front TELESCOPIC FORK Overall Width 760 mm Suspensio

10. ALTERNATOR/STARTING CLUTCH 10-7 Flywheel Installation Insert the pin onto crankshaft. Make sure that there is no other material stock on it. If

10. ALTERNATOR/STARTING CLUTCH 10-8 NTOES To this chapter contents

11. CRANKSHAFT/CRANKCASE 11-1 General information ...11-2 Crankshaft...11-5

11. CRANKSHAFT/CRANKCASE 11-2 General information Operational precautions • This Section concerns disassembly of the crankcase for repair purpos

11. CRANKSHAFT/CRANKCASE 11-3 Disassembly of crankcase Remove the cam chain. Loosen the bolt and remove the tensioner. Loosen seven bolts o

11. CRANKSHAFT/CRANKCASE 11-4 Remove crankshaft from right crankcase. Remove gasket and dowel pins. Scrape gasket residues o

11. CRANKSHAFT/CRANKCASE 11-5 Crankshaft Use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit: 0.6

11. CRANKSHAFT/CRANKCASE 11-6 Assembly of crankcase Install a new bearing onto the left crankcase. Special tool : left crank shaft bearing driver

11. CRANKSHAFT/CRANKCASE 11-7 Install new dowel pin and new gasket. Install the right crankcase onto the left crankcase.

11. CRANKSHAFT/CRANKCASE 11-8 Install the new oil seal. Apply a layer of grease on the lip of oil seal. Clean the crankshaft with clean solvent. Sp

1. GENERAL INFORMATION 1-7 Specifications Make SANYANG MODEL LA18W Overall Length 2010 mm Front TELESCOPIC FORK Overall Width 760 mm Suspensio

12. COOLING SYSTEM 12-1 General Information ... 12-2 Radiator...12-5 Trouble Diagnosis...

12. COOLING SYSTEM 12-2 General Information General Warning: zRefill the radiator with distilled water or specified additives. zAdd coola

12. COOLING SYSTEM 12-3 Trouble Diagnosis The engine temperature is too high zThe water thermometer and the temperature sensor do not work properly

12. COOLING SYSTEM 12-4 System Test Test on the filler cap Hermetically seal the filler cap, apply water and pressure to the filler cap. Replace i

12. COOLING SYSTEM 12-5 Removing the reserve tank filler cap. ˙Check the liquid level in the reservoir. Add coolant to proper level if too low. ˙Rei

12. COOLING SYSTEM 12-6 Loosen the hose clamp and remove the upper water hose. Disconnect the connectors for the thermostat and fan motor. Loosen

12. COOLING SYSTEM 12-7 Removal of water pump Remove the water hose. Loosen three bolts and remove the pump cover. Loosen 9 bolts and remove the rig

12. COOLING SYSTEM 12-8 Replacement of Mechanical Seal Drive the mechanical seal and inner seal out of the right crankcase. Tools required Water pu

12. COOLING SYSTEM 12-9 Mount the water pump shaft and the inner bearing to the right crankcase cover. Install the circlip to hold the inner bearing.

12. COOLING SYSTEM 12-10 Install the right crankcase cover.(bolt × 9) Install the dowel pin and new gasket. Install the water pump co

1. GENERAL INFORMATION 1-8 Torque values Item Q’ty Thread Dia. (mm) Torque Value (Kgf-m) Remarks Cylinder head bolt 4 8 2.0-2.4 Valve clearance

12. COOLING SYSTEM 12-11 Thermostat Removal Remove the rear cover. Drain out the coolant. Disconnect the cable from the thermostat. Remove the water

12. COOLING SYSTEM 12-12 Technical Data Valve begins to open 71 ~ 80℃ Valve stroke 3.5 ~ 4.5 mm at 80℃ Installation Install in reverse o

13. BODY COVERS 13-1 Mechanical Illustration... 13-1 Maintenance... 13-2 Steering Handlebar Guard...

13. BODY COVERS 13-2 Maintenance Body covers disassemble sequence: zBe careful not to damage various

13. BODY COVERS 13-3 Steering Handle Cover Disassembly Loosen 5 screws from both sides and rear. Disengage the buckle from the slot, take

13. BODY COVERS 13-4 Front Cover Disassembly Loosen two lock bolts. Loosen four screws on the lower part of the front cover.

13. BODY COVERS 13-5 Front Under Spoiler Disassembly Loosen six screws that hold the front inner box. Loosen two screws that lock up the f

13. BODY COVERS 13-6 Luggage Box Disassembly Lift up the seat saddle Loosen six bolts inside the luggage box. (Bolt x 6) Loosen one hook scr

13. BODY COVERS 13-7 Side Covers Disassembly Loosen four screws and take of the rear center cover. (Screw x 4). Loosen six screws and remove

13. BODY COVERS 13-8 Body Cover Disassembly Loosen three bolts and remove the rear grip. (Bolt x 3). Loosen two bolts from the rear frame. (

1. GENERAL INFORMATION 1-9 Standard Torque Values for Reference Type Torque value kgf-m 5 mm Bolt, Nut 0.45 - 0.6 6 mm Bolt, Nut

13. BODY COVERS 13-9 Center Cover Disassembly Remove the hook and screw from the center cover (Screw x 1). Loosen four screws and take off

13. BODY COVERS 13-10 Floor Panel Disassembly Loosen four screws (Screw x 4). Loosen four front bolts (Bolt x 4). Loosen two bolts under th

13. BODY COVERS 13-11 Inner cover Disassembly Take off four screws from the speedometer cover (Screw x 4). Disconnect the cable and connector of the

13. BODY COVERS 13-12 Front Fender Disassembly Loosen four screws from the front fender (Screw x 4). Lift the front fender upward and disengage the

14. BRAKE 14-1 Illustration - Front Disc Brake System ...14-1 Illustration - Rear Disc Brake Sys

14. BRAKE 14-2 Rear Disk Brake System 4.5 kgf-m 0.55 kgf-m 3.5 kgf-m To this chapter contents

14. BRAKE 14-3 Maintenance Description Operational precautions Caution zThe brake calliper can be removed without removing the hydraulic syste

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

14. BRAKE 14-5 Hydraulic Disc Brake zClose the drain valve of the hydraulic disc brake. zReplace the brake fluid. Before the brake fluid reservoir

14. BRAKE 14-6 Air Bleed 1. Tightly hold the brake lever and open the drain valve around 1/4 turns, and then close the valve. CAUTION 2. Slowly

1. GENERAL INFORMATION 1-10 Cables and harness routing Note the following when routing cables and wire harnesses: • A loose wire, cable or harness

14. BRAKE 14-7 Brake Disc Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replac

14. BRAKE 14-8 Master Cylinder Inspection Check the master cylinder for damage or scratch. Replace it if necessary. Measure the cylinder inner diame

14. BRAKE 14-9 Install the rubber cap into the groove correctly. Place the master cylinder onto handlebar, and install the master cylinder seat and

14. BRAKE 14-10 Notes To this chapter contents

15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION 15-1 Mechanical Illustration... 15-1 Front Wheel...

15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION 15-2 Operational Precautions General Please refer to the Maintenance Manual of tubeless tire in

15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION 15-3 Steering Handlebar Removal Remove the front handle cover. (Screw ×4) Remove the r

15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION 15-4 Remove the left switch assembly by loosening two screws. Loosen the lock bolt f

15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION 15-5 Loosen nuts and locating sleeve from the handlebar. Remove the handlebar. Instal

15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION 15-6 Front Wheel Removal Loosen two screws from the front brake calliper. Remove the front brake

1. GENERAL INFORMATION 1-11 Troubleshooting A. Engine hard to start or can not be started Check and adjustment Faul

15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION 15-7 Wheel rim Place the wheel rim on a rotary rack. Rotate the wheel rim and measure the runout

15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION 15-8 Assembly Assemble in reverse order of disassembly. Apply a coat of grease on the i

15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION 15-9 Install the speedometer cable. Press the brake pad to open. Install the brake cal

15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION 15-10 Front Shock Absorber Removal of front shock absorber Loosen two bolts from the front brake

15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION 15-11 Front Fork/Steering Removal of the front fork Remove the following parts: - The instrument

15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION 15-12 Use the punch and the drive to press the ball race into the steering shaft end. Tools Dri

16. REAR WHEEL/REAR BRAKE/REAR CUSHION 16-1 Mechanical Illustration... 16-1 Muffler... 16-3

16. REAR WHEEL/REAR BRAKE/REAR CUSHION 16-2 Operational Precaution General Please refer to the Maintenance Manual for tubeless tire in respect to t

16. REAR WHEEL/REAR BRAKE/REAR CUSHION 16-3 Muffler Removal Loosen the front lock nuts of the muffler (nut x2). Loosen the lock bolts (bolt x 3). R

16. REAR WHEEL/REAR BRAKE/REAR CUSHION 16-4 Check any deformation and warping of the brake disc. Allowable limit: 0.3 mm Warning Inspect

1. GENERAL INFORMATION 1-12 B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fa

16. REAR WHEEL/REAR BRAKE/REAR CUSHION 16-5 Align the rear shock absorber with the rocker arms hole; tighten the cushion with bolts. Install the br

16. REAR WHEEL/REAR BRAKE/REAR CUSHION 16-6 Remove an upper bolt from the shock absorber (bolt x 1). Remove the rear shock absorber. I

17. ELECTRICAL SYSTEM 17-1 Mechanical Illustration... 17-1 Maintenance Data... 17-2 Trouble Diagnosis...

17. ELECTRICAL SYSTEM 17-2 Maintenance Data Operational Precaution z When remove the battery, the disconnection sequence of cable terminals shall b

17. ELECTRICAL SYSTEM 17-3 Trouble Diagnosis No voltage z Battery discharged z The cable disconnected z The fuse is blown z Improper operation o

17.ELECTRICAL SYSTEM 17-4 Battery Removal Loosen four screws and remove the rear cover (screw x 4). Loosen three screws and remove the right body c

17.ELECTRICAL SYSTEM 17-5 Charging System Charging Circuit Current Leakage Test Current Leakage Inspection Turn the main swi

17.ELECTRICAL SYSTEM 17-6 Inspection on Charging Voltage Caution After the engine is warmed up, replace original battery with a fully charge

17.ELECTRICAL SYSTEM 17-7 Inspection on SCR Remove the bumper by loosening four screws (screw x 4). Remove the right side cover by loosening three s

17.ELECTRICAL SYSTEM 17-8 Ignition System Ignition circuit diagram C.D.I Assembly Disconnect connectors of the C.D.I assembly.

1. GENERAL INFORMATION 1-13 C. Engine runs sluggish (especially in low speed and idling) D. Engine runs sluggish (High speed)

17.ELECTRICAL SYSTEM 17-9 Inspection on Ignition Coil Remove the luggage box. Disengage the connector of the ignition coil and the spark plug cap. M

17.ELECTRICAL SYSTEM 17-10 Starting System Starting Circuit Diagram Inspection on Starter Relay Remove the luggage box assemb

17.ELECTRICAL SYSTEM 17-11 Removal of Starter motor Remove the rear cover (screw x 4). Remove the right body cover (screw x 3). Remove the battery c

17.ELECTRICAL SYSTEM 17-12 Lamp/Bulb Replacing Bulb for Headlamp Loosen the front cover (bolt x 2, screw x 8). Disconnect the terminal co

17.ELECTRICAL SYSTEM 17-13 Replacing Bulb of Number Plate Lamp Remove the rear cover (screw x 4). Remove the lamp lens (screw x 2). Repla

17.ELECTRICAL SYSTEM 17-14 Replacement of Main Switch Disconnect the connector of the main switch and loosen the lock bolts (bolt x 2). Remove the

17.ELECTRICAL SYSTEM 17-15 Winker light R WR L R ● ● PUSH OFF N L ● ● Wire Color Light blueGray Orange Horn switch BAT3 HO FREE ● ●

17.ELECTRICAL SYSTEM 17-16 Fuel Gauge Open the seat. Remove the luggage box (bolt x 6, screw x 1). Remove the rear carrier (bolt x 3). Remove the r

17.ELECTRICAL SYSTEM 17-17 Thermal Switch The thermal switch mounted on the radiator controls the operation of the cooling fan motor. In case that t

17.ELECTRICAL SYSTEM 17-18 Sensor Remove the sensor. Hang the sensor in an oil heater, heat the oil and measure the resistance at each temperature.

1. GENERAL INFORMATION 1-14 E. CLUTCH, DRIVING AND DRIVING PULLEY 1. Clutch lining spring broken 2. Clutch outer stuck with c

17.ELECTRICAL SYSTEM 17-19 Gauges Digital meters trouble diagnosis 1. The meter doesn’t indicate

17.ELECTRICAL SYSTEM 17-20 NOTES: To this chapter contents

18. SPECIAL TOOLS 18-1 Special tools list ... 18-1 How to use special tools... 18-4 R/L. Crank case disassem

18. SPECIAL TOOLS 18-2 10 11 12 NAME WATER PUMP MECHANICL SEAL DRIVER NAME AC.G. FLYWHEEL PULLER NAME OIL SEAL DRIVER NO. SYM-1721700-H9A NO.

18. SPECIAL TOOLS 18-3 19 20 21 NAME VALVE SPRING COMPRESSOR NAME VALVE COTTER REMOVE & ASSEMBLY TOOL NAME UNIVERSAL HOLDER NO. SYM-147110

18. SPECIAL TOOLS 18-4 How to use special tools: Disassemble thecrankcase Install the left crankcase bearing Install the

18. SPECIAL TOOLS 18-5 BEARING DRIVER To this chapter contents

18. SPECIAL TOOLS 18-6 WATER PUMP OIL SEAL DRIVER INNER OIL SEAL MECHANICL SEAL BEARING (6901) WATER PUMP BEARING DR

18. SPECIAL TOOLS 18-7 OIL SEAL (25*42*7) OIL SEAL (20*32*6) OIL SEAL (25*40*8) (Seal from transmission side install) CRANK CASE

18. SPECIAL TOOLS 18-8 AC.G. FLYWHEEL PULLER VALVE COTTER REMOVE / INSTALL DRIVER To this chapter contents

FORWARD This service manual contains the technical data of each component inspection and repair for the Sanyang JOYRIDE 125/150/200 motorcycle. T

1. GENERAL INFORMATION 1-15 LUBRICATION POINTS Engine suspension bushing Seat lock Rear wheel bearing Steering shaft bearing Speedometer

18. SPECIAL TOOLS 18-9 OUTER BEARING PULLER INNER BEARING PULLER To this chapter cont

18. SPECIAL TOOLS 18-10 CRANK CASE BUSH PULLER / DRIVER (ψψψψ 22mm) (ψψψψ 30mm) REMOVER INSTALL To this chapter contents

19. WIRING DIAGRAM 19-1 LA12W / LA15W SERIER WIRING DIAGRAM Homepage Contents 19

19. WIRING DIAGRAM 19-2 LA18W SERIER WIRING DIAGRAM Homepage Contents

1. GENERAL INFORMATION 1-16 NOTES: To this chapter contents

2. MAINTENANCE INFORMATION 2-1 Precautions in operation ... 2-1 Periodical maintenance schedule...

2. MAINTENANCE INFORMATION 2-2 Periodical Maintenance Schedule Maintenance Code item Every 300KM 1 Month every 1000KM 3 month every 3000KM 6 month e

2. MAINTENANCE INFORMATION 2-3 FUEL LINES Remove trunk. Remove side cover. Remove central cover. Remove body frame cover. Remove pedal. Remove front

2. MAINTENANCE INFORMATION 2-4 AIR CLEANER Remove trunk. Remove side cover. Remove 8 screws from the air cleaner cover and then remove the cover.

2. MAINTENANCE INFORMATION 2-5 VALVE CLEARANCE Caution Checks and adjustment must be performed when the engine temperature is below 35℃. Remove tr

2. MAINTENANCE INFORMATION 2-6 CARBURETOR IDLING SPEED ADJUSTMENT Caution Inspection & adjustment for idle speed have to be performed after all

2. MAINTENANCE INFORMATION 2-7 CYLINDER COPMRESSION PRESSURE Warm up engine. Turn off the engine. Remove the trunk. Remove the central cover. Remove

2. MAINTENANCE INFORMATION 2-8 BRAKE SYSTEM (FRONT/REAR DISK BRAKE) Free play of front/rear brake: 10~20 mm BRAKE SYSTEM HOSE Make sure the

How to Use This Manual This service manual describes basic information of different system parts and system inspection & service for Sanyang JOY

2. MAINTENANCE INFORMATION 2-9 AIR BLEED OPERATION Connect a transparent hose to draining valve. Hold the brake lever and open air bleeding valve. P

2. MAINTENANCE INFORMATION 2-10 Remove brake lining bolt. Take out the lining. Caution In order to maintain brake power balance, the brake lining

2. MAINTENANCE INFORMATION 2-11 SIDE STAND Check side stand spring for damage or looseness. Press down side stand and pull it with spring gauge. If

2. MAINTENANCE INFORMATION 2-12 WHEEL/TIRE Caution Tire pressure check should be done as cold engine. Check if tire surface is ticked with nails,

3. LUBRICATION SYSTEM 3-1 Precautions in operation ... 3-2 Oil pump disassembly ... 3-4 Troubleshooting...

3. LUBRICATION SYSTEM 3-2 PRECAUTIONS IN OPERATION General Information: • 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 motorcycle in flat surface with main stand. Check oil level with oil dipstick So

3. LUBRICATION SYSTEM 3-4 Oil Pump Removal Remove generator and starting gear. Remove snap ring and take out oil pump driving chain and

3. LUBRICATION SYSTEM 3-5 Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance b

3. LUBRICATION SYSTEM 3-6 Install the oil pump cover and fixing pin properly Tighten screw Make sure that oil pump shaft can be rotate

CONTENTS Page Content Index 1-1 ~ 1-16 GENERAL INFORMATION 1 2-1 ~ 2-12 MAINTENANCE INFORMATION 2 3-1 ~ 3-6 LUBRICATION SYSTEM 3 4-1 ~ 4

3. LUBRICATION SYSTEM 3-7 Gear Oil Oil level inspection Park the motorcycle on flat surface with main stand. Turn off engine and remove oil inspect

3. LUBRICATION SYSTEM 3-8 NOTES To this chapter contents

4. FUEL SYSTEM 4-1 Precautions in operation ... 4-2 Trouble diagnosis ... 4-3 Air cut-off valve ...

4. FUEL SYSTEM 4-2 PRECAUTIONS IN OPERATION General Information Warning Cautions Specification Item LA12W LA15W LA18W Carburetor diame

4. FUEL SYSTEM 4-3 TROUBLE DIAGNOSIS Poor engine start zNo fuel in fuel tank zClogged fuel tube zToo much fuel in cylinder zNo spark from spark

4. FUEL SYSTEM 4-4 AIR CUT-OFF VALVE Inspection Disconnect vacuum hose and air vent hose from the air cut-off valve. Connect a hose from vacuum hos

4. FUEL SYSTEM 4-5 AUTO BY-STARTER Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminal

4. FUEL SYSTEM 4-6 Carburetor removal Remove the luggage box. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the ca

4. FUEL SYSTEM 4-7 Installation Install needle, spring and needle seat to vacuum piston. Install vacuum piston to carburetor body and a

4. FUEL SYSTEM 4-8 FLOAT CHAMBER Disassembly Remove 4 mounting screws and remove float chamber cover. Remove the float pin and float. Checking Che

MODEL ILLUSTRATION Winker relay Radiator Fuel tank cap Spark plug Front brake disk Engine number ENG. Oil drain plug Kick starter pedal Engine s

4. FUEL SYSTEM 4-9 Assembly Install main jet, fuel needle jet holder, fuel needle jet slow jet and pilot screw. Caution Set the pilot screw in ac

4. FUEL SYSTEM 4-10 Adjustment of pilot screw Caution ˙Pilot screw was set at factory, so no adjustment is needed. Note the number of turns it ta

4. FUEL SYSTEM 4-11 FUEL TANK Fuel unit removal Open the seat. Remove the luggage box (6 bolts and 1 screw). Remove rear carrier (3 bolts). Remove

4. FUEL SYSTEM 4-12 AIR CLEANER Open the seat. Loosen the clamp strip of air cleaner. Remove left cover (2 screws). Remove mounting bolts for crank

5. ENGINE REMOVAL 5-1 Precautions in Operation... 5-1 Removal of Engine... 5-2 Removal of Engine Mounting Bracket

5. ENGINE REMOVAL 5-2 Removal of Engine Open seat cushion. Remove the luggage box (6 bolts and 1 screw). Remove rear carrier (3 bolts). Remove rear

5. ENGINE REMOVAL 5-3 Remove fuel pipe, vacuum tube and throttle valve wire from carburetor. Loosen the screw of air cleaner duct strip, and then r

5. ENGINE REMOVAL 5-4 Remove brake hose bracket (1 bolt). Remove rear brake callipper (2 bolts). Caution Remove the mounting bolt of rig

5. ENGINE REMOVAL 5-5 Loosen the mounting screw of left crankcase duct, and then remove the duct. . Remove the mounting bolts (2 bolts)

5. ENGINE REMOVAL 5-6 Check if engine mounting bracket bushing and cushion rubber for damage. Engine Mounting Bracket Installation Inst

1. GENERAL INFORMATION 1-1 Symbols and marks………………….1-1 Torque values……………………….1-8 General safety…………………………1-2 Cables and harness routing………1-10

6. CYLINDER HEAD/VALVE 6-1 Mechanism Diagram ... 6-1 Valve stem replacement ...6-8 Precautions in Operation...

6. CYLINDER HEAD/VALVE 6-2 PRECAUTIONS IN OPERATION General Information zThis chapter is contained maintenance and service for cylinder head, valv

6. CYLINDER HEAD/VALVE 6-3 TOOLS Special service tools Valve reamer: 5.0mm Valve guide driver: 5.0mm Valve spring compressor Troubleshooting Engi

6. CYLINDER HEAD/VALVE 6-4 CYLINDER HEAD REMOVAL Remove cushion and body center cover. Remove the clamp strip bolt of carburetor, and disconnect

6. CYLINDER HEAD/VALVE 6-5 Remove the 2 cylinder head mounting bolts from cylinder head side cover, and then remove 4 nuts and washers from cylinde

6. CYLINDER HEAD/VALVE 6-6 CYLINDER HEAD DISASSEMBLY Remove the hole cap of intake & exhaust valve clearance adjustment. There are 6 bolts.

6. CYLINDER HEAD/VALVE 6-7 INSPECTION CYLINDER HEAD Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge

6. CYLINDER HEAD/VALVE 6-8 Caution Correct it with reamer after replacement. If clearance still exceeds service limit after replaced valve g

6. CYLINDER HEAD/VALVE 6-9 VALVE SEAT INSPECTION AND SERVICE Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly

6. CYLINDER HEAD/VALVE 6-10 Use 60° cutter to cut a quarter lower part out. Remove the cutter and check new valve seat. Use 45° cutter

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 i

6. CYLINDER HEAD/VALVE 6-11 After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up al

6. CYLINDER HEAD/VALVE 6-12 CYLINDER HEAD INSTALLATION Install a new O-ring into the indent of carburetor insulator, and then install the insulator

6. CYLINDER HEAD/VALVE 6-13 Install cylinder head. Tighten 4 nuts and washers on the cylinder head upper side, and then tighten 2 cyli

6. CYLINDER HEAD/VALVE 6-14 Install carburetor insulator onto carburetor and tighten clamp strip bolt. Install the vacuum hose of carburet

7. CYLINDER/PISTON 7-1 Mechanism Diagram ... 7-1 Piston Removal...7-4 Precautions in Operation...

7. CYLINDER/PISTON 7-2 PRECAUTIONS IN OPERATION General Information zBoth cylinder and piston service can be carried out when engine mounted on fr

7. CYLINDER/PISTON 7-3 CYLINDER REMOVAL Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder head. Remove cylinder.

7. CYLINDER/PISTON 7-4 Check cylinder if warp. Service limit: 0.05 mm PISTON REMOVAL Plug crankcase opening with a cleaning cloth to pr

7. CYLINDER/PISTON 7-5 Place piston rings respective into cylinder below 20 mm of cylinder top. In order to keep the piston rings in horizontal lev

7. CYLINDER/PISTON 7-6 Measure piston outer diameter. Caution Service limit: LA12W & LA15W: 56.9 mm LA18W: 60.9 mm Compare measured value

1. GENERAL INFORMATION 1-3 Service Precautions zAlways use with Sanyang genuine parts and recommended oils. Using non-designed parts for Sanyang m

7. CYLINDER/PISTON 7-7 PISTON INSTALLATION Install piston and piston pin, and place the IN marks on the piston top side forward to intake valve. In

7. CYLINDER/PISTON 7-8 NOTES To this chapter contents

8. V-BELT DRIVING SYSTEM/KICK STARTER 8-1 Mechanism Diagram ... 8-1 Kick starter ...8-3 Mainten

8. V-BELT DRIVING SYSTEM/KICK STARTER 8-2 MAINTENANCE DESCRIPTION Precautions in Operation General Information zDrive face, clutch outer, and drive

8. V-BELT DRIVING SYSTEM/KICK STARTER 8-3 LEFT CRANKCASE COVER Left crankcase cover removal Remove body cover. Remove air cleaner (2 bolts). Remove

8. V-BELT DRIVING SYSTEM/KICK STARTER 8-4 Reassembly of Kick Starter Install socket, return spring and starter spindle as diagram shown. Install thr

8. V-BELT DRIVING SYSTEM/KICK STARTER 8-5 DRIVING BELT Removal Remove left crankcase cover Hold clutch outer with universal holder, and remove nut a

8. V-BELT DRIVING SYSTEM/KICK STARTER 8-6 Install the clutch with universal holder, and then tighten nut to specified torque value. Torque

8. V-BELT DRIVING SYSTEM/KICK STARTER 8-7 Removal Remove movable drive face comp. and driving belt from crankshaft. Remove ramp plate.

8. V-BELT DRIVING SYSTEM/KICK STARTER 8-8 Check if drive face boss is worn or damaged and replace it if necessary. Measure the outer diameter of mov

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 c

8. V-BELT DRIVING SYSTEM/KICK STARTER 8-9 Install movable drive face comp. onto crankshaft. Driven pulley installation Press driving be

8. V-BELT DRIVING SYSTEM/KICK STARTER 8-10 CLUTCH OUTER/DRIVEN PULLEY Disassembly Remove driving belt and clutch outer/driven pulley. Install clutch

8. V-BELT DRIVING SYSTEM/KICK STARTER 8-11 Clutch lining Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit:

8. V-BELT DRIVING SYSTEM/KICK STARTER 8-12 Clutch weight Replacement Remove snap and washer, and then remove clutch weight and spring from driving p

8. V-BELT DRIVING SYSTEM/KICK STARTER 8-13 Install snap ring and mounting plate onto setting pin. Replacement of Driven Pulley Bearing R

8. V-BELT DRIVING SYSTEM/KICK STARTER 8-14 Installation of Clutch OUTER/Driven Pulley Assembly Install new oil seal and O-ring onto movable driven f

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 driven pulley. Drain gear oil out from gear box. Remove gear box cover

9. FINAL DRIVING MECHANISM 9-4 Check bearings on gear box. Rotate each bearing’s inner ring with fingers. Check if bearings can be turned in smooth