SYM HD200 HD 200 Scooter Bike Service & Repair Manual

HD125 / 200 SERVICE MANUAL FORWARD HOW TO USE THIS MANUAL CONTENTS MECHANISM ILLUSTRATIONS

FORWARD This service manual contains the technical data of each component inspection and repair for the SANYANG HD 125 / 200 motorcycle. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. If the style and construction of the motorcycle, HD 125 / 200, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to change without notice. Service Department SANYANG INDUSTRY CO., LTD. Homepage Contents

HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for SANYANG HD 125/200 motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment. The first chapter covers general information and trouble diagnosis. The second chapter covers service maintenance information and special tools manual. The third to the 11th chapters cover engine and driving systems. The 12th chapter is cooling system. The 13th to the 16th chapter is contained the parts set of assembly frame body. The 17th chapter is electrical equipment. The 18th chapter is wiring diagram. Please see index of content for quick having the special parts and system information. There are 4 buttons, “Forward”, “Contents”, “How to use this manual” and “Mechanism Illustrations” on the CD-R version, and can be access to these items by click the mouse. If user wants to look for the content of each chapter, selecting the words of each chapter on the 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 content so that clicking the button can back to the contents of this chapter. Homepage Contents

CONTENTS Page Content Index 1-1 ~ 1-18 GENERAL INFORMATION 1 2-1 ~ 2-16 SERVICE MAINTENANCE INFORMATION 2 3-1 ~ 3-8 LUBRICATION SYSTEM 3 4-1 ~ 4-12 FUEL SYSTEM 4 5-1 ~ 5-8 ENGINE REMOVAL 5 6-1 ~ 6-14 CYLINDER HEAD/VALVE 6 7-1 ~ 7-8 CYLINDER/PISTON 7 8-1 ~ 8-14 “V” TYPE BELT DRIVING SYSTEM/KICK-STARTER 8 9-1 ~ 9-10 FINAL DRIVING MECHANISM 9 10-1 ~ 10-8 ALTERNATOR 10 11-1 ~ 11-8 CRANKSHAFT/ CRANKCASE 11 12-1 ~ 12-14 COOLING SYSTEM 12 13-1 ~ 13-16 BODY COVER 13 14-1 ~ 14-14 BRAKE SYSTEM 14 15-1 ~ 15-10 STEERING/FRONT WHEEL/SUSPENSION 15 16-1 ~ 16-6 REAR WHEEL/SUSPENSION 16 17-1 ~ 17-20 ELECTRICAL EQUIPMENT 17 18-1 ~ 18-2 ELECTRICAL DIAGRAM 18 Homepage

MECHANISM ILLUSTRATIONS LH12W / LH18W Winker relay Radiator Spark plug Engine number Engine oil drain bolt Reserve tank cap Radiator filler cap Ignition coil Horn Fuel unit Tail light/ Rear winker light Fuel tank cap Battery/CDI Exhaust muffler Oil lever / Oil filter Water pump AC. Generator Rear brake lever Front brake lever Winker light / Horn / Dimmer & Passing switches Headlight/Start switches Main switch Gear oil drain bolt Air cleaner Luggage box Front winker light Headlight Fuse box / Regulator rectifier Starter relay Headlight relay Home page Contents

1. GENERAL INFORMATION 1-1 Symbols and Marks............................... 1-1 General safety........................................ 1-2 Service Precautions .............................. 1-3 Specifications ........................................ 1-9 Specifications ..................................... 1-10 Torque Values .................................... 1-11 Troubles Diagnosis ............................ 1-13 Parts to Be Greased ........................... 1-17 Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks. Warning Means that serious injury or even death may result if procedures are not followed. Caution Means that equipment damages may result if procedures are not followed. Engine oil Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the damage that caused by not apply with the limited engine oil. (Recommended oil: KING MATE G-3 oil) Grease King Mate G-3 is recommended. Gear oil King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL # 140) Locking sealant Apply sealant, medium strength sealant should be used unless otherwise specified. Oil seal Apply with lubricant.。 Renew Replace with a new part before installation. Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid. Special tools Special tools Correct Meaning correct installation. Wrong Meaning wrong installation. Indication Indication of components. Directions Indicates position and operation directions Components assembly directions each other. Indicates where the bolt installation direction, --- means that bolt cross through the component (invisibility). 1 Homepage Contents

1. GENERAL INFORMATION 1-2 General safety Carbon monoxide If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor. Caution Exhaust contains toxic gas which may cause one to lose consciousness and even result in death. Gasoline Gasoline is a low ignition point and explosive material. Work in a well-ventilated place, no flame or spark should be allowed in the work place or where gasoline is being stored. Caution Gasoline is highly flammable, and may explode under some conditions, keep it away from children. Used engine oil Caution Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although it might not be verified. We recommend that you wash your hands with soap and water right after contacting. Keep the used oil beyond reach of children. Hot components Caution Components of the engine and exhaust system can become extremely hot after engine running. They remain very hot even after the engine has been stopped for some time. When performing service work on these parts, wear insulated gloves and wait until cooling off. Battery Caution ‧ Battery emits explosive gases; flame is strictly prohibited. Keep the place well ventilated when charging the battery. ‧ Battery contains sulfuric acid (electrolyte) which can cause serious burns so be careful do not be spray on your eyes or skin. If you get battery acid on your skin, flush it off immediately with water. If you get battery acid in your eyes, flush it off immediately with water and then go to hospital to see an ophthalmologist. ‧ If you swallow it by mistake, drink a lot of water or milk, and take some laxative such as castor oil or vegetable oil and then go to see a doctor. ‧ Keep electrolyte beyond reach of children. Brake shoe Do not use an air hose or a dry brush to clean components of the brake system, use a vacuum cleaner or the equivalent to avoid dust flying. Caution Inhaling brake shoe or pad ash may cause disorders and cancer of the breathing system Brake fluid Caution Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the parts. Place a clean towel on the above-mentioned parts for protection when servicing the brake system. Keep the brake fluid beyond reach of children. To this chapter contents

1. GENERAL INFORMATION 1-3 Service Precautions Always use with Sanyang genuine parts and recommended oils. Using non-designed parts for Sanyang motorcycle may damage the motorcycle. Special tools are designed for remove and install of components without damaging the parts being worked on. Using wrong tools may result in parts damaged. When servicing this motorcycle, use only metric tools. Metric bolts, nuts, and screws are not interchangeable with the English system, using wrong tools and fasteners may damage this vehicle. Clean the outside of the parts or the cover before removing it from the motorcycle. Otherwise, dirt and deposit accumulated on the part's surface may fall into the engine, chassis, or brake system to cause a damage. Wash and clean parts with high ignition point solvent, and blow dry with compressed air. Pay special attention to O-rings or oil seals because most cleaning agents have an adverse effect on them. Never bend or twist a control cable to prevent unsmooth control and premature worn out. Rubber parts may become deteriorated when old, and prone to be damaged by solvent and oil. Check these parts before installation to make sure that they are in good condition, replace if necessary. 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. Store complex components such as transmission parts in the proper assemble order and tie them together with a wire for ease of installation later. Note the reassemble position of the important components before disassembling them to ensure they will be reassembled in correct dimensions (depth, distance or position). Components not to be reused should be replaced when disassembled including gaskets metal seal rings, O-rings, oil seals, snap rings, and split pins. To this chapter contents

1. GENERAL INFORMATION 1-4 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. 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. When oil seal is installed, fill the groove with grease, install the oil seal with the name of the manufacturer facing outside, check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal. Remove residues of the old gasket or sealant before reinstallation, grind with a grindstone if the contact surface has any damage. 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. Rubber and plastic boots should be properly reinstalled to the original correct positions as designed. 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. Manufacturer's name Groove Clamp Connector Boots To this chapter contents

1. GENERAL INFORMATION 1-5 Lubricate the rotation face with specified lubricant on the lubrication points before assembling. Check if positions and operation for installed parts is in correct and properly. Make sure service safety each other when conducting by two persons. Note that do not let parts fall down. 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. After service completed, make sure all connection points is secured. Battery positive (+) cable should be connected firstly. And the two posts of battery have to be greased after connected the cables. Make sure that the battery post caps are located in properly after the battery posts had been serviced. If fuse burned, it has to find out the cause and solved it. And then replace with specified capacity fuse. Capacity verification To this chapter contents

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SYM HD200 HD 200 Scooter Bike Service & Repair Manual

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