SYM S50 R50 SR50 Service Manual

SERVICE MANUAL S50/R50/SR50 Forward How to use this manual Contents Model illustration Downloaded from www.Manualslib.com manuals search engine

Forward This service manual contains the technical data of each component inspection and repair for the SANYANG Jet Sport X S50 / R50 / SR50 series scooters. 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 scooters, Jet Sport X S50 / R50 / SR50 series, 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. Home page Contents Downloaded from www.Manualslib.com manuals search engine

How to Use This Manual This service manual describes basic information of different system parts and system inspection & service for SANYANG Jet Sport X S50 / R50 / SR50 series scooters. 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. The 3rd to the 10th chapters covers engine and driving systems. The 11th to the 14th chapters is contained the parts set of frame body. The 15th chapter is electrical equipment. The 16th chapter is wiring diagram. Please see index of content for quick having the special parts and system information. 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 SANYANG can not copy any part of this manual. There are 4 buttons, "Forward", "How to use this manual", "Mechanism Illustrations", and "Contents" 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 main contents can reach to each chapter. There are two buttons, Back to homepage and Main 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 main 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 "This chapter contents" button at the top line of each page so that clicking the button can back to the contents of this chapter. Home page Contents Downloaded from www.Manualslib.com manuals search engine

Contents Page Content Index 1-1 ~ 1-18 General Information 1 2-1 ~ 2-14 Service Maintenance Information 2 3-1 ~ 3-6 Lubrication System 3 4-1 ~ 4-10 Fuel System 4 5-1 ~ 5-6 Engine Removal 5 6-1 ~ 6-4 Cylinder Head / Cylinder / Piston 6 7-1 ~ 7-14 A.C. Generator 7 8-1 ~ 8-6 "V" Type Belt Driving System / Kick-Starter 8 9-1 ~ 9-6 Final Driving Mechanism 9 10-1 ~ 10-10 Crankcase / Crankshaft 10 11-1 ~ 11-12 Body Cover 11 12-1 ~ 12-12 Brake System 12 13-1 ~ 13-10 Steering / Front Wheel / Shock absorber 13 14-1 ~ 14-4 Rear Wheel / Shock absorber 14 15-1 ~ 15-22 Electrical Equipment 15 16-1 ~ 16-4 Electrical Diagram 16 Home page Downloaded from www.Manualslib.com manuals search engine

Model illustration Jet Sport X S50 / R50 / SR50 Series Headlight Front brake lever Rear brake lever Taillight Helmet hook Fuel tank cap Engine number Luggage box Muffler Battery / Fuses / C.D.I. / Eng. Oil tank cap ENG. Stop / Starter switch High & Low beam / Passing / Turn signal / Horn switch Air cleaner Frame number Front turn signal Ignition switch Rear turn signal Seat lock Rear turn signal Home page Contents Downloaded from www.Manualslib.com manuals search engine

1. General Information 1-1 Symbols and Marks ····················· 1-1 General Safety······························ 1-2 Service Precautions····················· 1-3 Specifications······························· 1-6 Torque values······························· 1-7 Cables and Harness Routing ······ 1-9 Troubleshooting··························· 1-13 Lubrication Points ······················· 1-20 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. O Correct Meaning correct installation. X 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 Downloaded from www.Manualslib.com manuals search engine

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. Keeps 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 dust 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. This chapter Contents Downloaded from www.Manualslib.com manuals search engine

1. General Information 1-3 Service Precautions • Always use with SANYANG genuine parts and recommended oils. Using non-designed parts for SANYANG scooter may damage the scooter. • 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 scooter, 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 scooter. Otherwise, dirt and deposit accumulated on the part's surface may fall into the engine, chassis, or brake system to cause 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. Caution In addition to damaging paint finish, brake oil can also damage the structural integration of plastic or rubber parts. Downloaded from www.Manualslib.com manuals search engine

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. Boots Manufacturer's name Downloaded from www.Manualslib.com manuals search engine

1. General Information 1-5 Downloaded from www.Manualslib.com manuals search engine

SYM S50 R50 SR50 Service Manual

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