SERVICE MANUAL Symply² 50 - 49ccScoot
SERVICE MANUALSymply² 50
SYMFORWARDThis service manual contains the technical data of each componentinspection and repair for the SYM series motorcycle. The manual is shownwith illustrations and focused on 「Service Procedures」, 「Operation KeyPoints」, and 「Inspection Adjustment」 so that provides technician with serviceguidelines.If the style and construction of the motorcycle are different from that of thephotos, 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 specificationsis based on current production information. SYM reserves the right to makechanges at any time without notice and without incurring any obligationwhatever. No part of this manual can be duplicated by any means withoutwritten permission of SANYANG.SERVICE DEPARTMENTSAN YANG INDUSTRY CO., LTD.
HOW TO USE THIS MANUALSYMThis service manual describes basic information of different system parts andsystem inspection & service for SYM series motorcycles. In addition, pleaserefer to the manual contents in detailed for the model you serviced ininspection and adjustment.The first chapter covers general information and trouble diagnosis.The second chapter covers service maintenance.The third to the eleventh chapters cover engine and driving systems.The twelfth to fifteenth chapters are contained the parts set of assemblybody.The sixteenth chapter is electrical equipment.The seventh chapter is for wiring diagram.Please see index of content for quick having the special parts and systeminformation.
SYMCONTENTSCONTENTSGENERAL INFORMATION/TROUBLE DIAGNOSIS .1MAINTENANCE INFORMATION .2LUBRICATION SYSTEM.3FUEL SYSTEM .4ENGINE REMOVAL.5CYLINDER HEAD/VALVE.6CYLINDER/PISTON.7"V" TYPE BELT DRIVING SYSTEM/KICK STARTER ARM/ STARTER CLUTCH .8FINAL DRIVING MECHANISM.9A.C. GENERATOR/STARTING CLUTCH .10CRANKCASE/CRANKSHAFT .11BODY COVER .12BRAKE SYSTEM.13STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER .14REAR WHEEL/SUSPENSION.15ELECTRICAL EQUIPMENT .16ELECTRICAL DIAGRAM .17
MECHANISM ILLUSTRATIONSMeterSYMHigh& Low beam/Seatopen/turn signal/hornRear brake leverStart magnetic switchFront turnsignal lightFuel tank / Fuel unitHorn/REG.RECFrame numberTail lightHead light/Position lightRR. turningsignal lightAir cleanerGear oil filling boltGear oil draining boltFront disk brakeEngine numberLight/starter switchEngine controlswitchBattery/Fuse/CDIEngine oil draining boltWinker relayFront brake leverFront turnsignal lightTail lightRear turnsignal lightIgnition switchExhaust mufflerIgnition coilOil levelA.C. Generator
SPECIAL TOOLITEM: OUTER BEARING PULLERITEM: ACG FLYWHEEL PULLERNO：SYM-6204010PURPOSE: REMOVE THE BEARINGNO：SYM-3110A00PURPOSE: REMOVE ACG FLYWHEELITEM: LOCK NUT PULLERITEM: UNIVERSAL HOLDERNO：SYM-9020100PURPOSE: REMOVE THE LOCK NUTNO：SYM-2210100PURPOSE:HOLD THE MDF/CLUTCH OUTERITEM: CLUTCHSPRING COMPRESSORITEM: CLUTCH NUT WRENCHNO：SYM-2301000PURPOSE:DISASSEMBLE THE CLUTCHNO：SYM-9020200PURPOSE:LOOSE THE CLUTCH NUT1
SPECIAL TOOLITEM: GY6 STARTER GEAR PULLERNO：SYM-2822100-GY6PURPOSE:REMOVE THE STARTER GEAR2
SYM1. GENERAL INFORMATION/TROUBLE DIAGNOSISSYMBOLS AND MARKS .1-1GENERAL SAFETY.1-2SERVICE PRECAUTIONS .1-3SPECIFICATIONS.1-9TORQUE VALUES (ENGINE) . 1-10TORQUE VALUES (FRAME) . 1-11TROUBLES DIAGNOSIS . 1-12LUBRICATION POINTS . 1-16SYMBOLS AND MARKSSymbols and marks are used in this manual to indicate what and where the special service areneeded, 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.WarningMeans that serious injury or even death may result if procedures are notfollowed.CautionMeans that equipment damages may result if procedures are not followed.Engine oilGreaseLocking sealantOil sealRenewLimits to use SAE 10W-30 API SH/CD class oil. Warranty will not cover thedamage that caused by not apply with the limited engine oil.King Mate G-3 is recommended.Apply sealant, medium strength sealant should be used unless otherwisespecified.Apply with lubricant.Replace with a new part before installation.Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid.Special toolsSpecial service tools.CorrectMeaning correct installation.WrongMeaning wrong installation.Indication Indication of components.DirectionsIndicates position and operation directions.Components assembly directions each other.Indicates where the bolt installation direction, --- means that bolt crossthrough the component (invisibility).1-1
1. GENERAL INFORMATION/TROUBLE DIAGNOSISSYMGENERAL SAFETYCarbon monoxideIf you must run your engine, ensure the place iswell ventilated. Never run your engine in aclosed area. Run your engine in an open area, ifyou have to run your engine in a closed area, besure to use an extractor.CautionExhaust contains toxic gas which may causeone to lose consciousness and even result indeath.GasolineGasoline is a low ignition point and explosivematerial. Work in a well-ventilated place, noflame or spark should be allowed in the workplace or where gasoline is being stored.CautionGasoline is highly flammable, and may explodeunder some conditions, keep it away fromchildren.BatteryCautionBattery emits explosive gases; flame isstrictly prohibited. Keep the place wellventilated when charging the battery.Battery contains sulfuric acid (electrolyte)which can cause serious burns so be carefuldo not be spray on your eyes or skin. If youget battery acid on your skin, flush it offimmediately with water. If you get batteryacid in your eyes, flush it off immediatelywith water, then go to hospital to see anophthalmologist.If you swallow it by mistake, drink a lot ofwater or milk, and take some laxative suchas castor oil or vegetable oil, and then go tosee a doctor.Keep electrolyte beyond reach of children.Brake shoeUsed engine oilCautionProlonged contact with used engine oil (ortransmission oil) may cause skin canceralthough it might not be verdict.Do not use an compressed air or a dry brush toclean components of the brake system, use avacuum cleaner or the equivalent to avoidasbestos dust flying.CautionInhaling asbestos dust may cause disordersand cancer of the breathing system.Hot componentsCautionComponents of the engine and exhaust systemcan become extremely hot after engine running.They remain very hot even after the engine hasbeen stopped for some time. When performingservice work on these parts, wear insulatedgloves and wait until cooling off.1-2Brake fluidCautionSpilling brake fluid on painted, plastic, or rubberparts may cause damage to the parts. Place aclean towel on the above-mentioned parts forprotection when servicing the brake system.Keep brake fluid beyond reach of children.
SYM1. GENERAL INFORMATION/TROUBLE DIAGNOSISSERVICE PRECAUTIONSAlways use with SANYANG genuine partsand recommended oils. Using non-designedparts for SANYANG motorcycle may damagethe motorcycle.Special tools are designed for remove andinstall of components without damaging theparts being worked on. Using wrong toolsmay result in parts damaged.When servicing this motorcycle, use onlymetric tools. Metric bolts, nuts, and screwsare not interchangeable with the Englishsystem, using wrong tools and fasteners maydamage this vehicle.Clean the outside of the parts or the coverbefore removing it from the motorcycle.Otherwise, dirt and deposit accumulated onthe part's surface may fall into the engine,chassis, or brake system to cause a damage.Wash and clean parts with high ignition pointsolvent, and blow dry with compressed air.Pay special attention to O-rings or oil sealsbecause most cleaning agents have anadverse effect on them.Never bend or twist a control cable to preventstiff control and premature worn out.Rubber parts may become deteriorated whenold, and prone to be damaged by solvent andoil. Check these parts before installation tomake sure that they are in good condition,replace if necessary.When loosening a component which hasdifferent sized fasteners, operate with adiagonal pattern and work from inside out.Loosen the small fasteners first. If the biggerones are loosen first, small fasteners mayreceive too much stress.Store complex components such astransmission parts in the proper assembleorder and tie them together with a wire forease of installation later.Note the reassemble position of the importantcomponents before disassembling them toensure they will be reassembled in correctdimensions (depth, distance or position).Components not to be reused should bereplaced when disassembled includinggaskets metal seal rings, O-rings, oil seals,snap rings, and split pins.1-3
1. GENERAL INFORMATION/TROUBLE DIAGNOSISThe length of bolts and screws forassemblies, cover plates or boxes is differentfrom one another, be sure they are correctlyinstalled. In case of confusion, Insert the boltinto the hole to compare its length with otherbolts, if its length out side the hole is thesame with other bolts, it is a correct bolt.Bolts for the same assembly should have thesame length.SYMRemove residues of the old gasket or sealantbefore reinstallation, grind with a grindstone ifthe contact surface has any damage.The ends of rubber hoses (for fuel, vacuum,or coolant) should be pushed as far as theycan go to their connections so that there isenough room below the enlarged ends fortightening the clamps.GrooveTighten assemblies with different dimensionfasteners as follows:Tighten all the fasteners with fingers, thentighten the big ones with special tool firstdiagonally from inside toward outside,important components should be tightened 2to 3 times with appropriate increments toavoid warp unless otherwise indicated. Boltsand fasteners should be kept clean and dry.Do not apply oil to the threads.ClampConnectorRubber and plastic boots should be properlyreinstalled to the original correct positions asdesigned.BootsWhen oil seal is installed, fill the groove withgrease, install the oil seal with the name ofthe manufacturer facing outside, check theshaft on which the oil seal is to be installedfor smoothness and for burrs that maydamage the oil seal.The tool should be pressed against two (innerand outer) bearing races when removing aball bearing. Damage may result if the tool ispressed against only one race (either innerrace or outer race). In this case, the bearingshould be replaced. To avoid damaging thebearing, use equal force on both races.Manufacturer'snameBoth of these examples can result in bearing damage.1-4
SYM1. GENERAL INFORMATION/TROUBLE DIAGNOSISLubricate the rotation face with specifiedlubricant on the lubrication points beforeassembling.Before battery removal operation, it has toremove the battery negative (-) cable firstly.Notre tools like open-end wrench do notcontact with body to prevent from circuit shortand create spark.Check if positions and operation for installedparts is in correct and properly.After service completed, make sure allconnection points is secured. Batterypositive ( ) cable should be connected firstly.And the two posts of battery have to begreased after connected the cables.Make sure service safety each other whenconducting by two persons.Make sure that the battery post caps arelocated in properly after the battery posts hadbeen serviced.Note that do not let parts fall downIf fuse burned, it has to find out the causeand solved it. And then replace withspecified capacity fuse.capacityverification1-5
1. GENERAL INFORMATION/TROUBLE DIAGNOSISWhen separating a connector, it locker has tobe unlocked firstly. Then, conduct theservice operation.SYMBefore terminal connection, check if the bootis crack or the terminal is loose.Insert the terminal completely. Check if theterminal is covered by the boot. Do not letboot open facing up.Do not pull the wires as removing aconnector or wires. Hold the connectorbody.Make sure if the connector pins are bent,extruded or loosen.Secure wires and wire harnesses to theframe with respective wire bands at thedesignated locations. Tighten the bands sothat only the insulated surfaces contact thewires or wire harnesses.Insert the connector completely. If there aretwo lockers on two connector sides, makesure the lockers are locked in properly.Check if any wire loose.Wire band and wire harness have to beclamped secured properly.Check if the connector is covered by the twinconnector boot completely and securedproperly.Do not squeeze wires against the weld or itsclamp.1-6
SYM1. GENERAL INFORMATION/TROUBLE DIAGNOSISDo not let the wire harness contact withrotating, moving or vibrating components asrouting the harness.Keep wire harnesses far away from the hotparts.Protect wires or wire harnesses with electricaltape or tube if they contact a sharp edge orcorner. Thoroughly clean the surface wheretape is to be applied.Secure the rubber boot firmly as applying iton wire harness.Do not touch it.Route wire harness to avoid sharp edges orcorners and also avoid the projected ends ofbolts and screws.Never use wires or harnesses whichinsulation has been broken. Wrap electricaltape around the damaged parts or replacethem.Route harnesses so that they neither pull tootight nor have excessive slack.Never clamp or squeeze the wire harness asinstalling other components.Please do not clip orsqueeze the wire.Do not extendit too much.1-7
1. GENERAL INFORMATION/TROUBLE DIAGNOSISDo not let the wire harness been twisted asinstallation.With sand paper to clean rust on connectorpins/terminals if found. And then conductconnection operation later.Clean rust.Wire harnesses routed along the handlebarshould not be pulled too tight or haveexcessive slack, be rubbed against orinterfere with adjacent or surrounding parts inall steering positions.Before operating a test instrument, operatorshould read the operation manual of theinstrument. And then, conduct test inaccordance with the instruction.Do you know how to set theinstrument to its measurementposition and the insert locationsof its two probes?1-8SYM
SYM1. GENERAL INFORMATION/TROUBLE l99kgPassengers/WeightTwo men/150 kgFront84kgRear125kgTotal209kgType4-STROKE ENGINEInstallation andarrangementFuel UsedVertical, below center,incline 80 Petrol4-stroke/forced aircooledCylinderSuspensionSystemWheel BaseRearSingle swing armTireSpecifications1138 mmTelescopic emOverall HeightAAA(AV05W-6)FrontFrontDISK (ø 190 mm)RearDRUM (ø 110 mm)Performance694mmMODELMax. Speed45km/hClimb Ability20 BelowPrimary al, dry typeTransmissionC.V.T.DecelerationequipmentOverall WidthCurb Weight1906mmCycle/CoolingSpeedometer0 80 km/hrHorn95 115dB(A)Boreφ39.0 mmMufflerExpansion & Pulse TypeStroke41.5 mmExhaust Pipe Positionand DirectionNumber/ArrangementSingle Cylinder/horizontalLubrication SystemRight side, t49.5 ccCompressionRatio11.8:1Max. HP2.35KW/8500 rpmMax. Torque2.91N.m /6500 rpmAir FiltrationPaper filterIgnitionC.D.I. 70dBStarting SystemElectrical & foot typeNoise EmissionEngine ll LengthTotal WeightWEIGHTDIMENSIONMAKERCO 12.0 g/kmHC 1.0 g/km23kg1-9
1. GENERAL INFORMATION/TROUBLE DIAGNOSISSYMTORQUE VALUES (ENGINE)ITEMQ'TYTHREAD DIATORQUE(mm)VALUE(Kg-m)REMARKSCylinder head bolts460.8 1.2Cylinder head nuts481.8 2.2Apply oil to threadCylinder/cylinder head two-ends bolts470.7 1.1Tighten to crankcaseCam holder nut471.0 1.4Right crank case cover bolts1060.8 1.2Pulse generator bolts250.35 0.5Valve adjustment fixing nuts250.7 1.1Spark plug1101.0 1.4Engine oil strainer cap1301.0 2.0Gear oil draining plug181.0 1.5Gear oil filling bolt181.0 1.5Oil pump bolts360.8 1.2Oil pump drive sprocket nuts160.8 1.2Left crankcase cover bolts1060.8 1.2Cylinder head cover bolts460.8 1.2Camshaft chain tensioner pivot160.8 1.2Camshaft chain adjuster bolts261.0 1.4Cooling fan bolts460.8 1.2Shroud A/B260.8 1.2RR. brake fixing nut181.5 2.0Flywheel nut1103.5 4.5Transmission(Gear box) bolts782.6 3.0RR. brake arm bolt160.7 1.1Drive face nut1125.0 6.0Drive pulley nut1103.5 4.5A.C. generator flange bolt260.8 1.2Air/C connect bracket bolts260.8 1.2Start motor bolts260.8 1.2Brake arm bolt160.7 1.1Kick starter arm bolt160.8 1.2Carburetor nut260.8 1.2A.I. fixing hex cap nut260.8 1.2Crankcase bolts160.8 1.2Exhaust pipe bolts283.0 3.6Exhaust pipe connecting nuts261.0 1.41-10Apply oil to threadHex socket bolt
SYM1. GENERAL INFORMATION/TROUBLE DIAGNOSISTORQUE VALUES (FRAME)Q'TYTHREAD DIA(mm)TORQUEVALUE(Kg-m)Mounting bolt for steeringhandlebar1104.0 5.0Mounting nut for steering rod125.41.0 2.0Cone seat for steering rod125.40.2 0.3Front wheel shaft nut1125.0 7.0Rear wheel shaft nutWheel hub/rim mountingnutsSpeedometer cable lockingscrewFront shock absorbermounting boltsRear shock absorber upperconnection boltRear shock absorber upperconnection boltBrake lever bolts11611.0 13.0882.8 3.2150.15 0.3482.4 3.01103.5 4.5182.4 3.0260.8 1.22103.3 3.7160.8 1.04104.0 4.52103.1 3.5260.8 1.2ITEMFront brake hose boltsFront brake air-bleedingvalveFront brake disc mountingboltsFront brake clipper mountingboltsDrum brake arm bolts(front/rear)REMARKSEngine suspension bracketboltsEngine connection bolt2104.5 5.5On frame side1104.5 5.5On engine sideMain standard nut1103.5 4.5Foot-starting lever bolt161.6 1.8Air cleaner bolts261.0 1.4The torque values listed in above table are for more important tighten torque values. Please seestandard values for not listed in the table.Standard Torque Values for ReferenceTYPETIGHTEN TORQUETYPETIGHTEN TORQUE5mm bolt、nut6mm bolt、nut8mm bolt、nut10mm bolt、nut12mm bolt、nut0.45 0.60kgf-m3mm screw4mm screw5mm screw6mm screw、SH nut6mm bolt、nut0.05 0.08kgf-m0.10 0.15kgf-m0.35 0.50kgf-m0.70 1.10kgf-m1.00 1.40kgf-m8mm bolt、nut2.40 3.00kgf-m10mm bolt、nut3.50 4.50kgf-m0.80 1.20kgf-m1.80 2.50kgf-m3.00 4.00kgf-m5.00 6.00kgf-m1-11
1. GENERAL INFORMATION/TROUBLE DIAGNOSISSYMTROUBLES DIAGNOSISA. Engine hard to start or can not be startedCheck and adjustmentFault conditionLoosen carburetor drainbolt to check if there isgasoline inside thecarburetorFuel supplied tomcarburetor sufficientNo fuel is supplied tocarburetorRemove spark plug, installit into spark plug cap, andperform a spark testagainst engine ground.Check if sparks1. No fuel in fuel tank2. Check if the pipes, fuel tank tocarburetor and intake vacuum,are clogged.3. Float valve clogged4. Lines in fuel tank evaporationsystem clogged5. Malfunction of fuel pump6. Loosen or damaged fuel pumpvacuum hose7. Fuel filter cloggedWeak sparks, no sparkat all
HOW TO USE THIS MANUAL SYM. This service manual describes basic information of different system parts and system inspection & service for SYM series 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
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Annual Day. Since that year, we have raised money to subsidize our conference claims which support many missions of the Christian Methodist Episcopal Church. Among them are our institu- tions of higher learning: Lane College Miles College Paine College Phillips School of Theology Thank you for your continuous support! We are proud to be CME! Sister Patricia McKinney Lewis 17 Sis. Hattie Hicks .
