SYM Scooter Service Repair Workshop Manual

SERVICE MANUAL FORWARD HOW TO USE THIS MANUAL CONTENTS

FORWARD This service manual contains the technical data of each component inspection and repair for the Sanyang JOYRIDE 125/150/200 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, JOYRIDE 125/150/200, 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 JOYRIDE 125/150/200 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. Th third to the tenth chapters cover engine and driving systems. The eleventh to the fourteenth is contained the parts set of assembly body. The fifteenth chapter is electrical equipment. The sixteenth chapter is emission control system. The seventeenth chapter is wiring diagram Please see index of content for quick having the special parts and system information. There are link devices in the “H9A CONTENTS” file. Just only click on the icon and it will link to the article what you want to see. All information, illustration, directions and specifications included in this manual are current as at the time of publication. Sanyang reserves the rights to make changes at any time without prior notice and without incurring any obligation whatever. Without written consent by Sangang can not copy any part of this manual. Homepage Contents

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 ~ 4-9 FUEL SYSTEM 4 5-1 ~ 5-6 ENGINE REMOVAL 5 6-1 ~ 6-14 CYLINDER HEAD/VALVE 6 7-1 ~ 7-8 CYLINDER/PISTON 7 8-1 ~ 8-14 V-BELT DRIVING SYSTEM/FOOT STARTER 8 9-1 ~ 9-8 FINAL DRIVING MECHANISM 9 10-1 ~ 10-6 ALTERNATOR/STARTING CLUTCH 10 11-1 ~ 11-8 CRANKSHAFT/CRANKCASE 11 12-1 ~ 12-11 COOLING SYSTEM 12 13-1 ~ 13-13 BODY COVERS 13 14-1 ~ 14-10 BRAKE 14 15-1 ~ 15-12 STEERING/FRONT WHEEL/FRONT BRAKE/ FRONT CUSHION 15 16-1 ~ 16-5 REAR WHEEL/REAR BRAKE/REAR CUSHION 16 17-1 ~ 17-18 ELECTRICAL SYSTEM 17 18-1 ~ 18-10 SPECIL TOOLS 18 19-1 ~ 19-2 WIRING DIAGRAM 18 Homepage Contents

MODEL ILLUSTRATION Winker relay Radiator Fuel tank cap Spark plug Front brake disk Engine number ENG. Oil drain plug Kick starter pedal Engine stop /Light / Starter switch High & Low beam / Passing / Turn signal / Horn switch Muffler Reserved tank cap Coolant filler cap Ignition / Seat open switch Fuses / C.D.I. Gear oil drain plug REG/REC. Start MAG. switch Battery IG. coil Horn Fuel tank Fuel pump Frame number Oil level Oil strainer Water pump Seat catch A Seat catch B Front brake caliper Rear brake disk Rear brake caliper Front brake Rear brake Homepage Contents

1. GENERAL INFORMATION 1-1 Symbols and marks………………….1-1 Torque values……………………….1-8 General safety…………………………1-2 Cables and harness routing………1-10 Service precautions………………….1-3 Troubleshooting…………………….1-11 Specifications…………………………1-5 Lubrication points…………………..1-15 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 20 JASO FC class oil. Warranty will not cover the damage that caused by not apply with the limited engine oil. (Recommended oil: MAX-2 serial oils) 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 To this chapter 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 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 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 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 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. 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 verified. We recommend that you wash your hands with soap and water right after contacting. Keep the used oil beyond reach of children. Inhaling brake shoe or pad ash 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 the 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. 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. Caution In addition to damaging paint finish, brake oil can also damage the structural integration of plastic or rubber parts. 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. Lubricate the rotation face as assembling. Check if positions and operation for installed parts is in correct and properly. Manufacturer's name Groove Clamp Connection Boots To this chapter contents

1. GENERAL INFORMATION 1-5 Specifications Make SANYANG MODEL LA12W Overall Length 2010 mm Front TELESCOPIC FORK Overall Width 760 mm Suspension System Rear UnlT SWING Overall Height 1155 mm Front 110 / 80-12 61L Wheel Base 1440 mm Tire Specifications Rear 130 / 70-12 64L Front 55 kg Front DlSK (ψ273mm) Rear 89 kg Brake System Rear DlSK (ψ200mm) Curb Weight Total 144 kg Passengers/ Weight Two /110 kg Max. Speed 99 km/hr Above Front 79 kg Climb Ability 28° above Rear 175 kg Primary Reduction BELT WEIGHT DIMENSION Total Weight Total 254 kg Secondary Reduction GEAR Type Gasoline Clutch 3-piece centrifugal, dry type Position and arrangement Horizontal, below center, CYL incline 80° PERFORMANCE Transmission C.V.T. Fuel Used >92 Unleaded gasoline Speed meter 0 ~ 140 km/hr Cycle/Cooling 4-stroke/water cooled Horn 93 – 112 dB/A Bore Ø 57 mm Muffler Expansion & Pulse Type Stroke 48.8 mm Exhaust Pipe Position and Direction Right side, and Backward Cylinder Number/Arra ngement Single Cylinder Lubrication System Forced pressure and wet sump Displacement 124.5 cc Solid Particulate Compression Ratio 10.5 : 1 CO 3.5 % ↓ Max. HP 11.4 / 8500 ps/rpm Exhaust Concentration HC Below 2000 ppm Max. Torque 1.01 / 7000 kg-m/rpm E.E.C. Non-equipped Ignition C.D.I. P.C.V. Equipped ENGINE Starting System Power & Foot Catalytic reaction control system Non-equipped Remark: To this chapter contents

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SYM Scooter Service Repair Workshop Manual

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