SANYANG INDUSTRY CO. SYM Series Scooter Manuals

Manuals and User Guides for SANYANG INDUSTRY CO. SYM Series Scooter. We have 1 SANYANG INDUSTRY CO. SYM Series Scooter manual available for free PDF download: Service Manual

SANYANG INDUSTRY CO. SYM Series Service Manual

SANYANG INDUSTRY CO. SYM Series Service Manual (177 pages)

Brand: SANYANG INDUSTRY CO. | Category: Scooter | Size: 4 MB

Table of Contents

Vehicle View
1
How to Use the Manual
3
Table of Contents
4
Mechanism Illustrations
5
General Information/Trouble Diagnosis
6
Maintenance Information
22
- Periodical Maintenance Schedule
  23
- Lubrication System Maintenance
  24
- Engine Oil Capacity
  24
- Oil Change
  24
- Cleaning the Oil Strainer
  24
- Fuel System
  25
- Gear Oil
  25
- Fuel Pipe
  25
- Fuel Filter
  25
- Air Cleaner
  26
- Throttle Valve Operation
  26
- Valve Clearance Adjustment
  27
- Crankcase Ventilation
  27
- Carburetor Idle Speed Adjustment
  28
- Spark Plug
  29
- Ignition System
  29
- Ignition Timing
  29
- Cylinder Compression Pressure
  30
- Driving System Maintenance
  30
- Driving Belt
  30
- Clutch Pad
  30
- Steering System
  31
- Suspension System
  31
- Front Shock Absorber
  31
- Rear Shock Absorber
  31
- Air Bleed Operation
  32
- Front Disc Brake System
  32
- Brake Fluid
  32
- Brake System Hose
  32
- Added Brake Fluid
  33
- Brake Lining Wear
  33
- Drum Brake System
  34
- Rear Brake Free Play
  34
- Brake Confirmation
  34
- Brake Light Switch
  35
- Wheel/Tire
  35
- Appointed Tire Pressure
  35
- Battery Removal
  36
- Headlight Adjustment
  36
- Lubrication System Overview
  37
- Lubrication System Trouble Diagnosis
  38
- Engine Oil Replacement
  39
- Oil Pump Removal
  40
- Oil Pump Inspection
  40
- Oil Pump Re-Assembly
  41
- Gear Oil Inspection
  42
- Gear Oil Replacement
  42
- Fuel System Overview
  43
- Mechanism Illustration
  43
- Fuel System Trouble Diagnosis
  45
- Poor Engine Start
  45
- Stall after Started
  45
- Rough Idle
  45
- Carburetor Removal
  46
- Vacuum Chamber
  46
- Carburetor Installation
  47
- Accelerate Pump Removal and Installation
  48
- Auto By-Starter Inspection, Removal and Installation
  49
- Float Chamber
  50
- Installation of Carburetor
  51
- Idle Speed Adjustment
  51
- Fuel Tank Removal
  52
- Air Cleaner Removal and Installation
  53
- Air Cleaner Element Cleaning
  53
- Removal of Engine
  54
- Engine Mechanism Diagram
  54
Engine Removal
56
Cylinder Head/Valve
62
- White Smoke
  64
- Cylinder Head/Valve Troubleshooting
  64
- Low Compression Pressure
  64
- High Compression Pressure
  64
- Cylinder Head Removal
  65
- Cylinder Head Disassembly
  67
- Camshaft Inspection
  68
- Valve Rocker Arm/Shaft Inspection
  69
- Cylinder Head Inspection
  69
- Valve Stem
  70
- Valve Guide
  70
- Valve Seat Inspection and Service
  71
- Cylinder Head Reassembly
  73
- Cylinder Head Installation
  74
- Valve Clearance Adjustment
  75
Cylinder/Piston
76
V" Type Belt Driving System/Kick Starter Arm/ Starter Clutch
86
- Kick Starter Arm Reassembly
  87
- Installation of the Left Crankcase Cover
  87
- Driving Belt Removal
  88
- Driving Belt Installation
  89
- Install the Starter Clutch
  89
- Sliding Pulley Removal
  90
- Sliding Pulley Inspection
  91
- Sliding Pulley Installation
  91
- Driving Pulley Install
  92
- Clutch/Driven Pulley Disassembly
  93
- Clutch Block Replacement
  95
- Installation of Clutch/Driven Pulley
  97
- Final Driving Mechanism Overview
  98
- Final Driving Mechanism Trouble Diagnosis
  99
- Final Driving Mechanism Disassembly
  100
- Final Driving Mechanism Inspection
  100
- Bearing Replacement
  101
- Final Driving Mechanism Re-Assembly
  103
- AC Generator
  104
Generator/Starting Clutch
105
- Right Crankcase Cover Removal
  106
- Right Crankcase Cover Installation
  107
- Mounted Coil Set Installation
  107
- Flywheel Installation
  107
- Crankcase/Crankshaft Diagram
  109
- Crankcase/Crankshaft Specification
  110
- Crankcase/Crankshaft Trouble Diagnosis
  110
- Engine Noise
  110
- Crankcase Disassembly
  111
- Crankshaft Instpection
  113
- Crankcase Assembly
  114
- Body Cover Diagram
  116
- Body Covers Disassembly Sequence
  117
- Handle Cover
  118
- Front Cover
  119
- Front Inner Box
  120
- Body Cover/Rear Center Cover/Rear Fender
  121
- Front Center Cover
  123
- Luggage Box
  123
- Floor Panel
  123
- Side Cover
  124
- Under Cover
  125
- Brake Diagram
  126
- Rear Drum Brake System Diagram
  127
- Brake Specifications
  128
- Hard Operation of Brake Lever
  129
- Brake Trouble Diagnosis
  129
- Uneven Brake
  129
- Soft Brake Lever
  129
- Hydraulic Brake System Inspection
  130
- Brake Fluid Add
  130
- Brake Fluid Replacement/Air-Bleed
  131
Brake System
131
- Brake Caliper Removal and Installation
  132
- Brake Disc Inspection
  133
- Brake Master Cylinder
  133
- Master Cylinder Installation
  135
- Brake Lining
  136
- Drum Brake-Drum
  136
- Brake Panel
  137
- Steering/Front Wheel/Front Shock Absorber Diagram
  139
- Front Suspension Noise
  140
- Front Wheel Wobbling
  140
- Hard Steering Stem
  140
- Steering Stem off Center
  140
- Steering Handle Removal
  141
- Front Wheel Removal
  142
- Front Wheel Disassembly
  143
- Front Wheel Inspection
  143
- Disc Brake
  145
- Front Shock Absorber Removal and Installation
  147
- Mechanism Diagram
  149
- Rear Wheel/Rear Shock Absorber Diagram
  149
- Braking Noise
  150
- Poor Brake Performance
  150
- Rear Wheel Wobbling
  150
- Shock Absorber too Soft
  150
- Exhaust Muffler
  151
- Rear Wheel Inspection
  151
- Rear Wheel Removal
  151
- Rear Shock Absorber Removal and Installation
  152
- Electrical Equipment Diagram
  153
- Charging System - Precautions
  154
- Ignition System - Precautions
  154
- Precautions in Operation
  154
  - Starting System - Precautions
    154
  - Electrical Equipment Specification
    155
  - Engine Does Not Crank Smoothly
    156
  - No Power Supply
    156
  - No Spark Produced by Spark Plug
    156
  - Starter Motor Does Not Work
    156
- Trouble Diagnosis
  156
- Charging System
  157
  - Charging Wire Diagram
    157
  - Current Leakage Inspection
    157
  - Battery
    158
  - Battery Charging
    159
  - Voltage Check
    159
  - Charging Voltage/Current Inspection
    160
  - Voltage Regulator Inspection
    161
  - Alternator Charging Coil Check
    162
  - Alternator Lighting Coil Check
    162
  - Resistor Check
    162
  - CDI Unit Check
    163
  - Ignition System Circuit
    163
  - Ignition Coil Removal
    164
  - Primary Coil Check
    164
  - Spark Plug Confirmation
    164
  - Pulse Generator Check
    165
  - Secondary Coil
    165
  - Remove the Luggage Box
    166
  - Starter Magnetic Switch Inspection
    166
  - Starting Circuit
    166
- Starting System
  166
  - Meter Removal
    167
  - Starting Motor Removal
    167
  - Headlight Bulb Replacement
    169
  - The Headlight Beam Adjustment
    169
  - Front Turn Signal Lamp Bulb Replacement
    170
  - Main Switch Check
    171
  - Main Switch Replacement
    171
  - Handle Switch
    172
  - Horn
    173
  - Turn Signal Light Switch
    173
- Fuel Unit
  174
- Wiring Diagram
  175
- Special Tools
  176

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