SYM SHARK 150 OPTI SH Full Service & Repair Manual

SERVICE MANUAL FORWARD CONTENTS HOW TO USE THIS MANUAL MECHANISM ILLUSTRATIONS

Forward This service manual contains the technical data of each component inspection and repair for the SANYANG ATTILA RS-21 EFi 150 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 are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to change without notice. This manual that contains all data, illustration, indication and specifications is based on current production information. SANYANG reserves the right to make changes at any time without notice and without incurring any obligation whatever. No part of this manual can be duplicated by any means without written permission of SANYANG. Service Department SANYANG Industry Co., LTD. Home page Contents

How to Use This Manual This service manual describes basic information of different system parts and system inspection & service for SANYANG ATTILA RS-21 EFi 150 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 and special service tools information. The third to the eleventh chapters cover engine, fuel injection and driving systems. The twelfth to fifteenth chapters are contained the parts set of assembly body. The sixteenth chapter is electrical equipment. The seventh chapter is exhaust emission control system. The eighteenth chapter is for wiring diagram Please see index of content for quick having the special parts and system information. Home page Contents

Contents Page Content Index 1-1 ~ 1-16 General Information / Trouble Diagnosis 1 2-1 ~ 2-16 Service Maintenance Information 2 3-1 ~ 3-8 Lubrication System 3 4-1 ~ 4-38 Fuel System 4 5-1 ~ 5-10 Engine Removal 5 6-1 ~ 6-16 Cylinder Head / Valve 6 7-1 ~ 7-8 Cylinder / Piston 7 8-1 ~ 8-14 “V” Type Belt Driving System / Foot-Starter 8 9-1 ~ 9-6 Final Driving Mechanism 9 10-1 ~ 10-10 Alternator / Starting Clutch 10 11-1 ~ 11-6 Crankcase/Crankshaft 11 12-1 ~ 12-14 Body Cover 12 13-1 ~ 13-10 Brake System 13 14-1 ~ 14-8 Steering/Front Wheel/Suspension 14 15-1 ~ 15-6 Rear Wheel/Suspension 15 16-1 ~ 16-18 Electrical Equipment 16 17-1 ~ 17-8 Exhaust Emission Control System 17 18-1 ~ 18-2 Electrical Diagram 18 Home page

Model illustration Seat lock Horn Spark plug Engine number Engine oil drain plug Light / Starter switch High & Low beam / Passing / Turn signal / Horn switch Exhaust muffler Ignition switch Gear oil drain plug Battery / fuse IG. Coil / Start relay / Fuel pump relay Fuel tank / Fuel pump Oil level Oil strainer Front brake lever Rear brake lever Air cleaner Gear oil Inspection plug Headlight Front winker light Tail light / Rear winker light Engine control unit (ECU) Winker relay Engine temperature sensor Crankshaft position sensor Intake temperature & MAP sensor (T-MAP) Throttle position sensor (TPS) / Air by-pass valve / Fuel injector / Home page Contents

1. General Information/Trouble Diagnosis 1-1 Symbols And Marks .................. 1-1 General safety ........................... 1-2 Service Precautions.................. 1-3 Specifications............................ 1-9 Torque Values (Engine) .......... 1-10 Torque Values (Frame) ........... 1-11 Standard Torque Values for Reference ................................. 1-11 Troubles Diagnosis ................. 1-12 Parts To Be Greased ............... 1-16 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. (KING MATE G-3) Gear oil King Mate gear oil (SYM HYPOID GEAR OIL ) is recommended. (SAE 85W-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 service 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 Home page Contents

1. General Information/Trouble Diagnosis 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 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 Used engine oil Caution Hot components Caution Battery Caution Brake shoe Do not use an compressed air or a dry brush to clean components of the brake system, use a vacuum cleaner or the equivalent to avoid asbestos dust flying. Caution Brake fluid Caution Exhaust contains toxic gas which may cause one to lose consciousness and even result in death. • 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, 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. Gasoline is highly flammable, and may explode under some conditions, keep it away from children. Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although it might not be verdict. We recommend that you wash your hands with soap and water right after contacting. Keep the used oil beyond reach of children. Inhaling asbestos dust may cause disorders and cancer of the breathing system. 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 brake fluid beyond reach of children. 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. This chapter Contents

1. General Information/Trouble Diagnosis 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 stiff 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. This chapter Contents

1. General Information/Trouble Diagnosis 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 This chapter Contents

1. General Information/Trouble Diagnosis 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 This chapter Contents

SYM SHARK 150 OPTI SH Full Service & Repair Manual

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