Forward Contents How To Use This Manual Mechanism Illustrations 50/100 50/100 SERVICE MANUAL...
Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. If the style and construction of the motorcycle, JET 50/100 and JET Euro 50/100 series, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.
How to Use This Manual This service manual describes basic information of different system parts and system inspection & service for Sanyang JET 50/100 and JET Euro 50/100 series motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
Home page CONTENTS Page Content Index 1-1 ~ 1-18 GENERAL INFORMATION 2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION 3-1 ~ 3-6 LUBRICATION SYSTEM 4-1 ~ 4-4 ENGINE REMOVAL 5-1 ~ 5-8 CYLINDER HEAD/CYLINDER/PISTON 6-1 ~ 6-4 ALTERNATOR 7-1 ~ 7-14 “V” TYPE BELT DRIVING SYSTEM/KICK-STARTER 8-1 ~ 8-6 FINAL DRIVING MECHANISM 9-1 ~ 9-6...
Home page Contents MODEL ILLUSTRATION JET 50 / 100 Series Light / Starter switch Fuel tank cap Rear turn signal Seat lock Front turn signal Rear turn signal Helmet hook High & Low beam / Turn signal / Horn switch Battery / Fuses / C.D.I.
Home page Contents MODEL ILLUSTRATION JET Euro Series Light / Starter switch Fuel tank cap Rear turn signal Seat lock Front turn signal Rear turn signal Helmet hook High & Low beam / Turn signal / Horn switch Battery / Fuses / C.D.I. / Eng.
Home page Contents 1. GENERAL INFORMATION Symbols and Marks···························1-1 Torque values ·································· 1-7 General Safety ···································1-2 Cables and Harness Routing·········· 1-9 Service Precautions ··························1-3 Troubleshooting ······························ 1-13 Specifications····································1-5 Lubrication Points··························· 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.
This chapter Contents 1. GENERAL INFORMATION General Safety Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a Battery emits explosive gases; flame is closed area. Run your engine in an open area, if strictly prohibited.
This chapter Contents 1. GENERAL INFORMATION Service Precautions Always use with Sanyang genuine parts and Rubber parts may become deteriorated when recommended oils. Using non-designed parts old, and prone to be damaged by solvent and for Sanyang motorcycle may damage the oil.
This chapter Contents 1. GENERAL INFORMATION The ends of rubber hoses (for fuel, vacuum, or The length of bolts and screws for assemblies, coolant) should be pushed as far as they can cover plates or boxes is different from one go to their connections so that there is enough another, be sure they are correctly installed.
This chapter Contents 1. GENERAL INFORMATION Specifications Make SANYANG MODEL JET 50 SERIES Overall Length 1785 mm Front TELESCOPIC Suspension System Overall Width 630 mm Rear UNlT SWING Overall Height 1115 mm Front 120 / 70 – 12 Tire Specifications...
This chapter Contents 1. GENERAL INFORMATION Specifications Make SANYANG MODEL JET 100 SERIES Overall Length 1785 mm Front TELESCOPIC Suspension System Overall Width 630 mm Rear UNlT SWING Overall Height 1115 mm Front 120 / 70 – 12 Tire Specifications Wheel Base 1275 mm Rear...
This chapter Contents 1. GENERAL INFORMATION Torque values Standard Torque Values for Reference Type Torque value Type Torque value 5 mm Bolt, nut 0.45 - 0.6 kg-m 5 mm Bolt 0.35 - 0.5 kg-m 6 mm Bolt, nut 0.8 - 1.2 kg-m 6 mm Bolt, SH nut 0.7 - 1.1 kg-m 8 mm Bolt, nut...
This chapter Contents 1. GENERAL INFORMATION Frame Thread Dia. Torque Value Item Q’ty Remarks (mm) (Kgf-m) Bolt for engine suspension Bolt for engine suspension bracket Upper bolt for rear shock absorber Lower bolt for rear shock absorber Mounting screws for exhaust pipe connection Nut for exhaust Brake hose bolts...
This chapter Contents 1. GENERAL INFORMATION Cables and Harness Routing Note the following when routing cables and wire harnesses: • A loose wire, cable or harness may cause safety hazard. After clamping, check each wire to make sure it is secured. •...
This chapter Contents 1. GENERAL INFORMATION Headlight switch Winker switch Speedometer High/low beam switch Starter switch Horn switch Front brake Rear brake lamp switch lamp switch Throttle cable Speedometer cable Front brake cable Rear brake cable Headlight Throttle cable Winker relay Main switch Regulator Horn...
This chapter Contents 1. GENERAL INFORMATION Speedometer cable Front brake hose Rear brake cable Throttle cable Winker relay Fuel unit Rear brake cable Throttle cable Front brake hose Rear brake cable Throttle cable Fuel unit cord Front brake hose Fuel pump Speedometer cable Fuel filter 1-11...
This chapter Contents 1. GENERAL INFORMATION Battery Fuse Purge control valve Oil control cable C.D.I. UNIT Fuel hose Fuel pump Carburetor Fuel filter Rear brake cable Oil hose Vacuum hose Oil lever switch 1-12...
This chapter Contents 1. GENERAL INFORMATION Troubleshooting A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline 1. No fuel in fuel tank inside the carburetor 2.
This chapter Contents 1. GENERAL INFORMATION Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed 1. Air cleaner clogged Engine speed can be Engine speed can not be 2.
This chapter Contents 1. GENERAL INFORMATION Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Normal Abnormal 1. Incorrect ignition timing (malfunction of CDI or AC generator) Adjust the air screw of carburetor Good...
This chapter Contents 1. GENERAL INFORMATION . CLUTCH, DRIVING AND DRIVING PULLEY FAULT CONDITION PROBABLE CAUSES 1. Driving belt worn out or deformation 2. Driving disk damaged 3. Driving pulley spring broken Engine can be started but 4. Clutch ling broken motorcycle can not be driving 5.
This chapter Contents 1. GENERAL INFORMATION Lubrication Points Throttle cable/ Front & rear brake lever pivot Seat lock Engine suspension bushing Steering shaft bearing Rear wheel bearing Speedometer gear/ front Main stand shaft Side stand shaft wheel bearing 1-17...
This chapter Contents 1. GENERAL INFORMATION Note: 1-18...
25. Carbon cleaning for cylinder ¡ ¸ head, cylinder, piston head, and exhaust system. Have your scooter checked, adjusted periodically by your SYM Authorized Dealer to maintain the scooter at the optimum condition Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement...
¡ E Limit to use SAE 20 JASO FC class engine Soap Clean oil, otherwise, SYM is no responsible for the warranty. ¡ E Recommended engine oil: MAX-2 serial oils. Squeeze out remaining oil Squeeze oil out...
This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Fuel Filter Remove the luggage box. Remove the fuel line from the fuel filter. Replace the fuel filter with new one. Install the fuel filter. The arrow indicates the fuel flowing direction. Check the fuel line for leaking. Fuel filter Engine Oil Line Remove the body cover.
This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Oil Pump Control Cable Mounting nut Caution To adjust the oil pump control cable after adjusted the throttle grip play. Remove the body cover. Wide open the throttle valve, and check if the calibration point aligns on the oil pump lever with the mark of pump body.
This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Tire Caution Tire pressure should be checked when cold. Check tire for cracks, damage, nail, or other object stuck in tread. Recommended tire and tire pressure Front: Rear: Tire size 120 / 90 - 10 130 / 90 - 10 Tire pressure 1.75...
This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Rear Brake Free Play: (Drum 10¡ ã 20mm Brake Type) (3/8¡ ã 3/4 in) Measure the free play of the rear brake lever at the end of the lever. Free play: 10-20 mm (3/8-3/4 in) Adjust the free play by turning the front brake adjustment nut if necessary.
This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Brake System Hose: (Front Disc Brake Type) Lower limit Make sure that the brake hose is corrosion or damage, and also check the system for leaking. Brake Fluid: Check brake fluid level in the brake fluid reservoir.
This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Remove the pin bolt cap. Loosen the bolt. Remove the front wheel shaft bolt. Take out the front wheel. Pin bolt cap Remove brake caliper mounting bolt and then remove the brake caliper. Caution Mounting bolt Do not operate the brake lever after the...
This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Steering System Caution The control cables can not interfere with the rotation of steering handle. Lift the front wheel out of ground, and check if the steering handle turning is smoothly. If handle turning is uneven and bending, stuck, or the handle can be operated in vertical direction, then adjust the handle top bearing by adjusting the steering nut.
This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Transmission Oil Leak Oil level check bolt Draining bolt Check if the transmission is leak. Check Caution Park the scooter on flat ground with its main stand. Remove the oil level check bolt, and check if the oil level is placed on the hole of check bolt.
This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Control Cable Lubrication Remove the throttle control and the brake cables periodically, and lubricate the moving parts of Tooth face Belt width the cables thoroughly. Driver Belt Remove left crankcase cover. Check if the belt is crack or worn out. Replace the belt if necessary.
This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Headlight Adjustment Loosen headlight mounting bolt. Move the headlight for adjustment its light beam. Tighten the headlight mounting bolt after adjusted. Caution Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting for safety distance.
This chapter Contents 3. LUBRICATION SYSTEM Precautions In Operation Be careful not let dirt enter into engine or oil hoses when removing or installing the oil pump. If air is found in the oil tube (from oil tank to oil pump) or oil tube is removed, the oil pump should be conducted air-bleeding operation.
This chapter Contents 3. LUBRICATION SYSTEM Oil Pump Removal Oil tube Oil output tube Caution Before removing the oil pump, clean the oil pump and crankcase. Remove the luggage box and seat. Loosen the mounting nut of the oil pump control cable, and remove the control cable.
This chapter Contents 3. LUBRICATION SYSTEM Oil Pump/Oil Tube Air Bleeding Oil tube Caution The oil tube system has to be conducted air bleeding operation because air will clog or restraint oil flowing so that cause serious Oil output tube engine damage.
This chapter Contents 3. LUBRICATION SYSTEM Oil Tank Mounting bolt Removal/Installation Remove the luggage box and seat. Remove the battery and battery box. Remove the R/L. side cover, rear center cover, rear carrier and body cover. Remove the rear fender. Remove the oil input tube from oil pump, and then drain oil to a clean container.
This chapter Contents 3. LUBRICATION SYSTEM NOTES:...
Home page Contents 4. ENGINE REMOVAL Maintenance Information ················ 4-1 Engine installation···························· 4-4 Engine removal ································ 4-2 Maintenance Information There are parts that require removal of engine for maintenance. Crankcase Crankshaft Related bolts tightening torque for removal of engine: Engine hanger bolt 5.0kgf-m Engine bracket bolt 6.0kgf-m...
This chapter Contents 4. ENGINE REMOVAL Engine removal Spark plug Remove body cover. Remove the spark plug cap from the spark plug section. Fuel output tube Oil tube Remove the fuel output and the vacuum tubes from fuel pump. Remove the oil control cable from oil pump. Remove the oil tube from oil pump and then clip the tube.
This chapter Contents 4. ENGINE REMOVAL Remove rear brake cable from engine rear-lower side. Brake cable Remove air cleaner mounting bolts. (2 bolts) Mounting bolt Support the engine and then remove shock absorber lower mounting bolt. Shock absorber lower mounting bolt Remove two exhaust pipe connection nuts.
Home page Contents 5. CYLINDER HEAD/CYLINDER/PISTON Maintenance Information·················· 5-2 Cylinder Head ·····································5-3 Troubleshooting································ 5-2 Cylinder/Piston···································5-5...
Be careful do not damage cylinder head, cylinder and piston when removing. Inspect the removed & cleaned parts thoroughly, and apply with oil onto the rotation surfaces before installation. Specification JET 50 series JET 100 series Item Standard value Standard value...
This chapter Contents 5. CYLINDER HEAD/CYLINDER/PISTON Tightening bolt Cylinder Head Cylinder Removal Removal body covers. Remove spark plug cap. Remove fan cover. Remove engine shield. Tightening bolt Engine shield Remove two connection nuts of the exhaust Tightening bolt x 2 pipe.
This chapter Contents 5. CYLINDER HEAD/CYLINDER/PISTON Cylinder Head Inspection Use a straight edge and a feeler gauge to measure the cylinder head for warp. Service limit: 0.10 mm Tightening bolts Cylinder Head Installation Replace the cylinder head gasket with new one, and place the cylinder head onto cylinder.
This chapter Contents 5. CYLINDER HEAD/CYLINDER/PISTON Cylinder/Piston Cylinder Removal Be careful to pull the cylinder up and prevent piston from damage. Caution Do not have pry out operation between cylinder and crankcase. Or let radiation fan be knocked seriously. Piston Removal Place a clean rag onto crankshaft to cover the piston.
JET 100 : 51.050mm Measure the OD of piston at the 7 mm from the bottom of the piston. Service limit JET 50 : 38.935 mm JET 100 : 50.935 mm Calculate the clearance between piston and cylinder. Service limit: 0.100 mm Measure the ID of piston pin hole.
This chapter Contents 5. CYLINDER HEAD/CYLINDER/PISTON Piston Ring Inspection Measure the end gap of each piston ring. Service limit: 0.40 mm Caution With the piston, push each piston ring into cylinder correctly. Connecting Rod Inspection Install bearing and piston pin onto connecting rod small end, and then check its clearance.
Home page Contents 6. ALTERNATOR Maintenance Information ················ 6-2 Alternator Installation······················· 6-4 Alternator Removal·························· 6-3 3.8 kgf-m...
Please refer to Chapter 15 for the relative alternator inspection. Torque value: Flywheel 3.8 kgf-m Tool General tool Rotor puller Universal holder Coil resistance value for the A.C. alternator JET 50/100 series Earth Earth 50~200Ω 0.2~0.8Ω 0.2~1.0Ω 400~800Ω JET EURO 50/100 series Earth 50~200Ω...
This chapter Contents 6. ALTERNATOR Alternator Removal Cooling fan cover Remove the body cover. Remove two bolts and then take out cooling fan cover. Bolt Remove four bolts, and then take out the cooling fan. Cooling fan 10mm flanged nut Hold flywheel with universal holder.
This chapter Contents 6. ALTERNATOR Disconnect alternator wire connector and pulse Wire harness connector generator connector. Remove the pulse generator and alternator four (4) bolts, and then take out the alternator assembly. Caution Care to be taken for not damaging the alternator coil.
Home page Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Maintenance Information ················ 7-2 Drive Belt··········································· 7-5 Trouble Shooting ····························· 7-2 Movable Driven Pulley ····················· 7-6 Left Crankcase Cover ······················ 7-3 Clutch/Driven Pulley························· 7-10 Reassembly Of Kick Starter ············ 7-4 Installation Of The Left Crankcase Cover·················································...
This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Maintenance Information Precautions In Operation The surfaces of drive belt and driven pulley must be free of grease. Specification Item Standard value(mm) Limit(mm) Drive belt width 18.0 16.5 ID of movable drive face 20.035~20.085 20.120 OD of movable drive face boss...
This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Left crankcase cover Left Crankcase Cover Left crankcase cover removal Remove left body side cover. Remove air cleaner. Remove kick start arm. Remove left crankcase cover. Kick start arm Disassembly of Kick Starter Return spring Remove snap clip and thrust washer from left crankcase cover.
This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Reassembly Of Kick Starter Kick starter spindle Install bush, return spring and starter spindle as diagram shown. Install thrust washer and snap clip onto starter spindle. Install Kick starter lever temporary. Slightly rotate the lever and then align driven gear with width-tooth on the starter spindle.
This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Drive Belt Removal Remove left crankcase cover. Hold clutch outer with universal holder, and remove nut and clutch outer. Caution Using special tools for tightening or loosening the nut. Fixed rear wheel or rear brake will damage reduction gear system.
This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Install the driven pulley that has installed the belt Drive shaft Drive face Drive belt onto drive shaft. Clutch/driven pulley Install the clutch with universal holder, and then Clutch outer tighten nut to specified torque value. Torque value: 3.8 kgf-m Universal holder Movable Drive Face...
This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Removal Drive face boss Movable drive face Remove movable drive face set and drive belt from crankshaft. Crankshaft Remove ramp plate. Ramp plate Remove weight rollers from movable face. Movable drive face Weight roller Inspection Weight roller...
This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Check if movable drive face boss is worn or damage and replace it if necessary. Movable drive face Measure the outer diameter of drive face boss, and replace it if it exceed service limit. Service limit: 19.98 mm Measure the inner diameter of drive face, and replace it if it exceed service limit.
This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Install movable drive face assembly onto Drive face boss Movable drive face crankshaft. Crankshaft Drive Face Installation Drive belt Press down Press drive belt into pulley groove, and then pull the belt on to crank shaft. Install drive face, washer and nut.
This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Clutch/Driven Pulley Clutch nut wrench Disassembly Remove drive belt and clutch/driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let nut be installed more easily. Caution Do not press the compressor too much.
This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Clutch weight Clutch weight Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 2.0 mm Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 82.5 mm Free length Driven pulley...
This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Clutch Block Replacement Spring Drive plate Remove clip and washer, and then remove clutch weight and spring from drive plate. Caution Some of models are equipped with one mounting plate instead of 3 snap clips. Check if spring is damage or insufficient elasticity.
This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Install snap clip and mounting plate onto lock pin. Snap clip Replacement of Driven Pulley Bearing Remove inner bearing. Outer bearing Clip Caution If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly.
This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Installation of Clutch/Driven Pulley Oil seal Assembly Install new oil seal and O-ring onto sliding pulley. Apply with specified grease to lubricate the inside of sliding pulley. O-ring Specified grease Install sliding pulley onto driven pulley. Sliding pulley Oil seal Install guide pin and guide pin roller.
Home page Contents 8. FINAL DRIVING MECHANISM Maintenance Information ················· 8-2 Inspection of Final Driving Mechanism ···························································· 8-4 Troubleshooting ······························· 8-2 Bearing Replacement ······················· 8-4 Disassembly of Final Driving Mechanism········································ 8-3 Re-Assembly of Final Driving Mechanism ········································ 8-4...
This chapter Contents 8. FINAL DRIVING MECHANISM Disassembly of Final Driving Oil filling hole Mechanism Remove driven pulley Drain gear oil out from gearbox. Remove rear wheel. Remove gearbox cover mounting bolts from the clutch side and then remove the cover from the rear wheel side.
Special tool: Gear Box Cover Final shaft bearing: Punch guide Bearing driver 6203/6004UZ (SYM-9620000) Bearing driver 6201 (SYM-9610001) Final shaft oil seal installer (SYM-9125500) Adapter Left Crankcase Drive shaft bearing: Drive shaft Bearing driver 6203/6004UZ (SYM-9620000) Bearing driver 6201 (SYM-9610001) L.
This chapter Contents 8. FINAL DRIVING MECHANISM Install countershaft, final driven gear and thrust Final driven gear & shaft washer. Counter gear & shaft Install new gasket and lock pin. Install gearbox cover. Install clutch/driven pulley assembly. Install driven pulley, drive belt, and left crankcase side cover.
This chapter Contents 8. FINAL DRIVING MECHANISM Notes:...
This chapter Contents 9. CRANKCASE/CRANKSHAFT Crankcase Disassembly Remove the crankcase bolts. Bolts Install the crankcase puller onto the right Crankcase puller crankcase with two (2) bolts, 6mm, as the diagram shown. Disassemble the right crankcase. Right crankcase Crankcase puller Crankshaft Removal As the diagram show with 3 special bolts to install the specified service tool onto the left crankcase.
This chapter Contents 9. CRANKCASE/CRANKSHAFT Crankshaft Inspection Measure the clearance of connecting rod big end. Service limit: 0.60 mm Measure the radial clearance of connecting rod big end at X-Y directions as diagram show. Service limit: 0.04 mm Place the crankshaft on a V-block, measure run-out points A and B of the crankshaft with dial gauge.
This chapter Contents 9. CRANKCASE/CRANKSHAFT Crankcase Installation Clean the crankshaft with solvent and blow it Bearing driver 6204 with compressed air. Then, check for damage or other foreign materials attached. Install new bearing into right crankcase. Caution All rotation and sliding surfaces have to be applied with clean engine oil.
This chapter Contents 9. CRANKCASE/CRANKSHAFT Assemble the right crankcase with assembly tools. R. Crank shaft puller Install right crankcase onto the crankshaft. R. Crank shaft Install right crankshaft puller and install bush install bush onto crankshaft. Screw the right crankshaft puller onto crankshaft.
When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly It has to conduct air bleeding operation as removed the oil tube. Idle speed adjustment. Specification Item JET 50 JET 100 Venturi diameter 15 mm 16 mm Fuel level 8.8¡...
This chapter Contents 10. FUEL SYSTEM Carburetor Throttle Valve upper part Removal Remove the body cover. Remove the carburetor upper part, throttle valve spring and sealed cap. Remove the throttle valve cable from the throttle valve. Remove needle clamp and fuel needle. Oil hose Inspection Throttle valve spring...
This chapter Contents 10. FUEL SYSTEM Carburetor Remove Remove the body cover. Auto by-starter Disconnect the auto by-starter connector. Loosen draining screw and then drain out fuel Carburetor Fuel hose inside the carburetor. upper part Loosen carburetor upper part and remove carburetor upper part.
This chapter Contents 10. FUEL SYSTEM Remove carburetor, and allow it to cool off for 30 minutes. Connect fuel rich circuit with a hose and pump compressed air to the hose. Air should flow into fuel rich circuit. Replace the auto by-starter if the circuit clogged. Connect battery to starter’s connectors and wait for several minutes.
This chapter Contents 10. FUEL SYSTEM Float/Float Valve/Jet Removal Remove the float from carburetor body. Remove the float pin and then remove float and float valve. Check the valve seat for worn out or damage. Check float for bend and if fuel inside the float. Before removing both the throttle valve stopper and air screws, record their original turns for close to their original set up position as...
This chapter Contents 10. FUEL SYSTEM Flaot Level Inspection Measure float fuel level to have the upper end of float just contact with the float. Float fuel level: 8.8 mm Carefully bend the float arm for adjustment. Check the float operation and the install it. Carburetor Carburetor Installation Fuel hose...
This chapter Contents 10. FUEL SYSTEM Inspection Reed valve Check the reed valve for damage and its reed strength. Reed stopper Check the reed valve seat for crack, damage and the clearance between the seat and the valve. Replace reed valve if necessary. Caution Do not bend the reed valve stopper.
This chapter Contents 10. FUEL SYSTEM Hose clamp Air Cleaner Removal/Installation Loosen connection hose clamp. Remove 2 bolts and then remove the air cleaner. Install in the reverse order of removal procedures. Bolts 10-9...
This chapter Contents 10. FUEL SYSTEM Notes: 10-10...
This chapter Contents 11. BRAKE SYSTEM Maintenance Information Precautions in Operation Caution Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake caliper can be removed without removing the hydraulic system.
This chapter Contents 11. BRAKE SYSTEM Troubleshooting Disc Brake Soft brake lever Hard operation of brake Tight brake lever 1. Air inside the hydraulic 1. Dirty brake lining/disc system 2. Poor wheel alignment 1. Blocked brake system 2. Hydraulic system leaking 3.
This chapter Contents 11. BRAKE SYSTEM Hydraulic Disc Brake Close the drain valve of the hydraulic disc brake. Replace the brake fluid. Lower level Before the brake fluid reservoir is removed, turn Cap plate the handle so that the brake fluid reservoir Diaphragm becomes horizontal, then remove the brake fluid reservoir.
This chapter Contents 11. BRAKE SYSTEM Drain valve Disc Brake -Air Bleed Air bubble 1. Tightly hold the brake lever and open the drain valve around 1/4 turns, and then close the valve. Caution Do not release the brake lever before the drain valve is closed.
This chapter Contents 11. BRAKE SYSTEM Brake Disc Brake disc Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. Allowable limit: 2.0 mm Micrometer Remove the brake disc from wheel.
This chapter Contents 11. BRAKE SYSTEM Master Cylinder Inspection Cylinder gauge Check the master cylinder for damage or scratch. Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit.
This chapter Contents 11. BRAKE SYSTEM Install the rubber pad into the groove correctly. Master cylinder Place the master cylinder onto handlebar, and install the bolts. Install the brake lever, and connect leads to brake lamp switch. Brake lamp switch Connect brake hoses with 2 new washers.
This chapter Contents 11. BRAKE SYSTEM Rear Drum Brake To use vacuum cleaner or other alternatives to avoid danger caused from dusts. Caution Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use compressed air or dry brush to clean brake parts.
This chapter Contents 11. BRAKE SYSTEM Installation Bolt Apply with a thin coat of grease to the brake cam and the anchor pin. Install brake cam. Never allow brake linings to be contaminated by oil or grease. Wipe off the excessive grease from brake cam and the anchor pin.
This chapter Contents 11. BRAKE SYSTEM Notes: 11-12...
Home page Contents 12. BODY COVER Body Overview ······························· 12-1 Front Under Spoiler ························ 12-7 Maintenance Information ··············· 12-2 Front Inner Box······························· 12-8 Side Covers····································· 12-3 Floor Panel ······································ 12-9 Luggage Box··································· 12-3 Front Fender ··································· 12-9 Body Cover ····································· 12-4 Steering Handle Cover ···················...
This chapter Contents 12. BODY COVER Maintenance Information Body covers disassemble sequence: Handlebar Front Cover Front Cover Luggage Box/Seat Handlebar Rear Cover Center Cover Front Spoiler Left/Right Side Cover Front InnerCover Front Fender Body Cover Rear Mudguard Rear Fender Floor Panel Under Cover Be careful not to damage various covers in disassembly or re-assembly operation.
This chapter Contents 12. BODY COVER Side Covers 1. Removal: Remove 3 screw (front/middle) from two side covers. Slide the side cover backward so that their hooks are out of slots. Take out the side cover end part and then remove the cover. Screws 2.
This chapter Contents 12. BODY COVER Body Cover Bolts 1. Removal: Remove 4 bolts from rear carrier, and then remove rear carrier. Remove 1 screw and 2 nuts and 1bolt from luggage box, and then remove luggage box. Remove 3 screws from the tail cover,.and then remove the tail cover.
This chapter Contents 12. BODY COVER Front Cover 1. Removal: Remove 2 bolts from the front side reflector, and then remove front side reflector. Screws Remove 2 screws from the front inner box and front cover. Screws Remove 1 screw from the front cover. Screws Remove electric cord coupler from the head light.
This chapter Contents 12. BODY COVER Front Under Spoiler Removal: Remove right and left side cover. (6 screws) Screw Remove 4 screws from the front inner box. Screws Remove 2 screws from the front upper part of the front spoiler and the front inner box.
This chapter Contents 12. BODY COVER Front Inner Box Key set cover 1. Removal: Remove the front cover. Remove the front under spoiler. Remove hook and 1 screw. Remove key set cover. Hook & 1 screw Remove 2 bolts from the floor panel. Bolts Remove the front inner box.
This chapter Contents 12. BODY COVER Floor Panel 1. Removal: Remove 6 screws and the side cover. Remove 6 screws and the body cover. Bolts Remove the floor panel. (4 bolts) 2. Installation: Install in reverse order of removal procedures. Bolt Front Fender Removal:...
This chapter Contents 12. BODY COVER Steering Handle Cover Screws 1. Removal: Remove 6 screws from the handle rear cover. Remove handle front cover. Screw Remove front winker electric cord Electric cord coupler coupler Remove 1 screw from rear side by handle rear cover.
This chapter Contents 12. BODY COVER Under Cover 1. Removal: Remove 2 bolts from the under cover. Remove under cover. 2 bolts 2 nuts 2. Installation: Install in reverse order of removal procedures. 12-11...
This chapter Contents 12. BODY COVER Note: 12-12...
Home page Contents 13. STEERING/FRONT WHEEL/SUSPENSION Maintenance Information ················· 13-2 Front Wheel ······································· 13-4 Troubleshooting ······························· 13-2 Front Shock Absorber ······················ 13-8 Steering Handle ································ 13-3 Front Fork·········································· 13-9 4.5 kgf-m 1.5 kgf-m 0.25 kgf-m 3.3 kgf-m 2.7 kgf-m 6.0 kgf-m 13-1...
This chapter Contents 13. STEERING/FRONT WHEEL/SUSPENSION Maintenance Information Specification Item Standard value (mm) Limit (mm) ¢ w Shaft bending 0.2 (0.01 in) ¢ w Radial 2.0 (0.08 in) Rim wobbling ¢ w Axial 2.0 (0.08 in) Torque Value Steering handle nut 4.5 kgf-m Front brake caliper bolt 3.3 kgf-m Front wheel axle...
This chapter Contents 13. STEERING/FRONT WHEEL/SUSPENSION Master cylinder Steering Handle Removal Rear brake lever seat Remove handle cover, front cover and inner box. Remove throttle grip after mounting screw removed. Remove master cylinder (disc brake) after 2 bolts removed. Remove rear brake lever bracket after mounting Bolt bolt removed.
This chapter Contents 13. STEERING/FRONT WHEEL/SUSPENSION Place master cylinder onto handle and align its Master cylinder connection surface with bolt hole on the handle (disc brake). Install the mounting seat. Tighten the upper part bolt, and then tighten lower bolt. Install all components in reverse order of removal procedures.
This chapter Contents 13. STEERING/FRONT WHEEL/SUSPENSION Inspection Place the axle onto a V-block to measure its run-out with a dial gauge. The dial gauge indicated 1/2 run-out. Service limit: 0.20 mm Wheel axle Place the wheel on to a rotation seat, and turn Free play the wheel to check its bearing free play.
This chapter Contents 13. STEERING/FRONT WHEEL/SUSPENSION Remove dust seal, bearing and side collar. Special tools Inner bearing puller (SYM-6204020) Installation Fill out the block of bearing by grease. Dist. collar Drive the left bearing and install the dist. collar. Install the right bearing.
This chapter Contents 13. STEERING/FRONT WHEEL/SUSPENSION Lubricate the speedometer gear with grease and install the gear into the wheel hub. Align the flange part on the speedometer gear with the slot of wheel hub. Caution Contaminated brake lining will reduce brake performance so the brake lining, brake drum and disc must be free of grease.
This chapter Contents 13. STEERING/FRONT WHEEL/SUSPENSION Front Shock Absorber Removal Front cover Front under spoiler Front fender Front wheel Disc Brake Bolts Remove the caliper mounting bolt and the Hose clamp caliper. Take out the hose from hose clamp. Brake caliper Bolts Remove the front shock absorber upper bolt and the shock absorber.
This chapter Contents 13. STEERING/FRONT WHEEL/SUSPENSION Front Fork Steering stem mounting nut Removal Handle Front wheel Front shock absorber Remove the steering stem mounting nut. Remove top cone race and front fork. Caution Place the steel ball onto a parts container to prevent from missing.
This chapter Contents 13. STEERING/FRONT WHEEL/SUSPENSION Install the steering stem mounting nut and Steering stem mounting nut tighten the nut by means of holding the top cone race body. Torque value: 1.5 kgf-m Install in reverse order of removal procedures. Top cone race 13-10...
This chapter Contents 14. REAR WHEEL/SUSPENSION Maintenance Information Specification Item Standard value (mm) Limit (mm) Rear wheel rim run out 2.0 (0.08 in) Torque Value Rear shock absorber upper mounting bolt: 4.0 kgf-m Rear shock absorber lower mounting bolt: 2.7 kgf-m Rear wheel nut: 11.0 kgf-m Rear wheel hub: 2.5 kgf-m Exhaust muffler nut: 1.2kgf-m...
This chapter Contents 14. REAR WHEEL/SUSPENSION Rear Wheel Remove Remove exhaust pipe nut. (2 connection nuts) Connection nuts Bolts Remove exhaust muffler bolt (3 bolts), then remove the muffler. Muffler Remove rear wheel shaft nut and then remove the rear wheel. Shaft nut Inspection As the diagram shown, measure wheel rim...
This chapter Contents 14. REAR WHEEL/SUSPENSION Brake Hub Replacement Remove 4 nuts of cover and wheel rim, and then remove the wheel hub. Install the wheel hub and tighten the nuts. Tighten torque: 2.5 kgf-m Installation Install the rear wheel and tighten the nut. Tighten torque: 11.0 kgf-m Install exhaust pipe &...
Charging current 1.2 A / 5000 rpm Control voltage in charging 14.0 - 15.0 V / 5000 rpm Control voltage in headlight 12.6 - 13.6 V / 5000 rpm (JET 50/100) Ignition System Item Specification JET 50 series JET 100 series...
This chapter Contents 15. ELECTRICAL EQUIPMENT Troubleshooting No voltage Charging system does not operate properly Battery discharged The cable disconnected Burnt fuse The fuse is blown Poor contact, open or short circuit Improper operation of the main switch Poor regulator Poor ACG Low voltage Engine does not crank smoothly...
This chapter Contents 15. ELECTRICAL EQUIPMENT Battery Negative terminal Positive terminal Battery Removal/Installation Turn off main switch. Open seat. Remove screw and the open battery cover. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery from the scooter. Install the battery in reverse order of removal.
This chapter Contents 15. ELECTRICAL EQUIPMENT Charging System JET 50 / JET 100 Green White Yellow Pink Green/ Black AC. Generator JET EURO 50 / JET EURO 100 Main Switch Auto by- starter Green Yellow Black Fuse 15A Yellow Yellow...
This chapter Contents 15. ELECTRICAL EQUIPMENT Current Leakage Inspection Ammeter Turn the main switch to OFF position, and remove the negative cable terminal (-) from the Battery (-) terminal battery. Connect an ammeter between the negative Ground circuit cable terminal and the battery negative terminal. Caution In the current leakage test, set the current range at larger scale, then gradually...
(3) The charging current is normal, but the voltage is not. The fuse of the voltmeter is blown. Headlight Voltage Inspection Front cover JET 50/100 series Connect a tachometer. Do not disconnect the headlight harness connector after engine started. Turn the headlight ON and to high beam position.
This chapter Contents 15. ELECTRICAL EQUIPMENT Voltage Regulator Inspection – Voltage regulator JET 50/100 Check the each pins of connector on the voltage regulator. Voltage regulator connector Inspection Probable cause Check voltage between battery terminal (red) and ground Blown fuse or poor main switch (green).
This chapter Contents 15. ELECTRICAL EQUIPMENT Inspection on SCR – JET EURO 50/100 Remove the front cover. Disconnect 4P connectors to remove the SCR. Item Check Points Standard Value Main switch R – B Battery voltage connection (ON) Battery R – G Battery voltage connection Charging coil...
This chapter Contents 15. ELECTRICAL EQUIPMENT Ignition System JET 50/100 series Green Blue/Yellow Black/Red Black/Yellow Black/White JET EURO 50/100 series Black/Yellow Green Blue/Yellow Black/Blue Black 15-10...
This chapter Contents 15. ELECTRICAL EQUIPMENT Ignition Coil Inspection Remove body cover. Ignition coil Measure the primary coil resistance Resistance :0.19~0.23K£ [ (A)¡ ÷ (B) Measure the secondary coil resistance Resistance : 8.2~9.3K£ [ (A)¡ ÷ (C) Remove the high voltage coil cap, and measure its negative (-) terminal for the secondary coil resistance.
Standard (at 20¢ J ) ITEM Measure at: Main Switch (compatible Black/white-green Continuity as main switch OFF with JET 50/100) Main Switch (compatible Continuity (battery voltage) as Black/ Blue -green with JET EURO 50/100) master switch ON Exciter Coil (compatible Black/Red-Green 400 ~800Ω...
This chapter Contents 15. ELECTRICAL EQUIPMENT Starting System Starter relay Starter Relay Inspection Remove luggage box. Connect both the green/yellow (-) and the Starter relay yellow/red (+) pins to battery posts directly. If the red and red/white pins are also in continuity, it means it is in normal.
This chapter Contents 15. ELECTRICAL EQUIPMENT Starter Motor Removal/Disassembly Remove body cover. Remove bolt and oil pump control cable. Disconnect starter motor harness connector. Remove 2 bolts for separation starter motor and Starter motor gasket. Remove 2 bolts for disassembly the starter motor.
This chapter Contents 15. ELECTRICAL EQUIPMENT Oil Level Switch Troubleshooting Fuse Main switch If the oil level in oil tank is in specified level, but the oil level indicator still goes on. 1. Remove body cover. 2. Disconnect oil gauge wire, and turn the Indicator main switch to ON position.
This chapter Contents 15. ELECTRICAL EQUIPMENT Fuel Unit Fuel unit Removal/Installation Remove 4 bolts and floor panel. Disconnect fuel unit connector. Remove the fuel unit plastic cap. Turn the snap ring in CCW direction and then remove the fuel unit. Caution Do not bend the float arm.
This chapter Contents 15. ELECTRICAL EQUIPMENT Switch / Horn Remove handle covers and front cover. Remove front inner box. Check continuity on each switch. The connected circles with a line are that they should be in continuity. Main Switch Wire Black / Black Green...
This chapter Contents 15. ELECTRICAL EQUIPMENT Light Switch Light switch Wire color Brown Yellow Pink Mark ● ● ● ● Start Switch Wire color Yellow / Red Green Mark Start switch FREE ● ● PUSH Light switch Start switch Front / Rear Brake Light Switch If the switch is in continuity as braking, it is in normal.
Remove front cover. Remove bulb seat and replace the bulb. Install the all removed parts. Headlight Position light JET 50/100 Remove front cover. Loosen the headlight bulb stop plate and replace the bulb. Remove the position light bulb seat and replace the bulb.
This chapter Contents 15. ELECTRICAL EQUIPMENT Rear winker light Remove rear winker lens. Replace winker light bulb. 6 Screws Front winker light Remove 6 screws and then remove handle front cover 1 Screw Replace winker light bulb 15-20...
This chapter Contents 15. ELECTRICAL EQUIPMENT Clock unit – JET EURO 50/100 Remove 6 screws and then remove handle front cover Remove 2 screws and then remove clock unit. Handle rear cover Clock Meter Remove handlebar front cover. Take out the bulb seat from the bottom of instrument panel.
This chapter Contents 15. ELECTRICAL EQUIPMENT Notes: 15-22...