SANYANG Euro 100 Service manual

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SERVICE MANUAL

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This service manual contains the technical data of each component inspection and repair for the SANYANG JET 50/100 and JET Euro 50/100 series 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, 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. Specifications are subject to change without notice.

Service Department

Sanyang Industry Co., LTD.

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Contents

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.

The first chapter covers general information and trouble diagnosis.

The second chapter covers service maintenance information.

Th third to the tenth nine chapters covers engine and driving systems.

The tenth to the fourteenth is contained the parts set of assembly body.

The fifteenth chapter is electrical equipment.

The sixteenth 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.

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CONTENTS

Page Content Index

1-1 ~ 1-18 GENERAL INFORMATION

2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION

1

2

3 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 CRANKCASE/CRANKSHAFT

4

5

6

7

8

9

10-1 ~ 10-10 FUEL SYSTEM

11-1 ~ 11-12 BRAKE SYSTEM

12-1 ~ 12-12 BODY COVER

13-1 ~ 13-10 STEERING/FRONT WHEEL/SUSPENSION

14-1 ~ 14-4 REAR WHEEL/SUSPENSION

15-1 ~ 15-22 ELECTRICAL EQUIPMENT

16-1 ~ 16-4 ELECTRICAL DIAGRAM

10

11

12

13

14

15

16

MODEL ILLUSTRATION

JET 50 / 100 Series

Home page

Front turn signal

Contents

Frame number

Light / Starter switch

Fuel tank cap

Rear turn signal

Seat lock


Helmet hook

High & Low beam /

Turn signal / Horn switch

Battery / Fuses / C.D.I. /

Eng. Oil tank cap

Head light

Tail light

Storage box

Air cleaner

Front brake lever Rear brake lever

Ignition switch

Engine number

Muffler

JET Euro Series

Front turn signal

Head light

Home page

Contents

MODEL ILLUSTRATION

Light / Starter switch

Fuel tank cap


Seat lock


Helmet hook

High & Low beam /

Turn signal / Horn switch

Battery / Fuses / C.D.I. /

Eng. Oil tank cap

Frame number

Tail light

Storage box

Air cleaner

Front brake lever Rear brake lever

Ignition switch

Engine number

Muffler

Contents

1. GENERAL INFORMATION

Symbols and Marks···························1-1

General Safety ···································1-2

Service Precautions ··························1-3

Specifications ····································1-5

Torque values ·································· 1-7

Cables and Harness Routing·········· 1-9

Troubleshooting ······························ 1-13

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.

Warning

Means that serious injury or even death may result if procedures are not followed.

Caution

Engine oil

Means that equipment damages may result if procedures are not followed.

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)

1

King Mate G-3 is recommended.

Grease

Home page

Gear oil

Locking sealant

King Mate gear oil serials are recommended. (Bramax HYPOID GEAR

OIL # 140)

Apply sealant, medium strength sealant should be used unless otherwise specified.

Oil seal

Apply with lubricant.

Renew

Brake fluid

Replace with a new part before installation.

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.

Indicates position and operation directions. Directions

Components assembly directions each other.

Indicates where the bolt installation direction, --- means that bolt cross through the component (invisibility).

1-1

This chapter Contents


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 y Battery emits explosive gases; flame is strictly prohibited. Keep the place well ventilated when charging the battery. y 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. y y

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.

1-2



Service Precautions

z Always use with Sanyang genuine parts and recommended oils. Using non-designed parts for Sanyang motorcycle may damage the motorcycle. z 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. z z

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. z 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. z 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. z Store complex components such as transmission parts in the proper assemble order and tie them together with a wire for ease of installation later. z 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. z Never bend or twist a control cable to prevent stiff control and premature worn out. z Note the reassemble position of the important components before disassembling them to ensure they will be reassembled in correct dimensions (depth, distance or position). z 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.

1-3


1. GENERAL INFORMATION z 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. z 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. z Rubber and plastic boots should be properly reinstalled to the original correct positions as designed. z 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.

Boots z 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. z 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.

Manufacturer's name z Remove residues of the old gasket or sealant before reinstallation, grind with a grindstone if the contact surface has any damage.

Both of these examples can result in bearing damage. z Lubricate the rotation face as assembling.

Check if positions and operation for installed parts is in correct and properly.

1-4

Specifications

Make

Overall Length

Overall Width

Overall Height

Wheel Base


SANYANG

1785 mm

630 mm

1115 mm

1275 mm

Tire


MODEL

Suspension

System

Specifications

Front

Front

Rear

Front

JET 50 SERIES

TELESCOPIC

120 / 70 – 12

130 / 70 – 12

DlSK (ψ190mm)

Rear DRUM (ψ110mm)

Passengers /

Weight

Two /110 kg Max. Speed 50 km/hr Below

Front

Rear

Type

Installation and arrangement

Fuel Used

Cycle/Cooling

Bore

84 kg Climb Ability 22° Below

120 kg Primary Reduction

Secondary

Reduction

Clutch

BELT

GEAR

Gasoline

Horizontal, below center, incline

Unleaded (92/95)

Transmission C.V.T.

Speedometer

Centrifugal, dry type

0 ~ 90 km/hr

2-stroke/forced air cooled

39 mm

Horn 80 ~ 112 dB/A

Muffler Expansion & Pulse Type

Exhaust Pipe Position mm and Direction

Right side, and Backward

Cylinder Number/Arran gement

Single Cylinder Lubrication System Separated-lubrication

Displacement

Compression

Ratio

7.2 : 1 CO 8.0 g/km

↓

Max. HP 3.2 kw / 7000 rpm HC

Max. Torque 4.6 Nm / 6500 rpm E.E.C.

Ignition C.D.I. P.C.V.

5.0 g/km

↓

Below 2g / test

X

Starting System

49.4 cc

Electrical & kick

Solid Particulate

Catalytic reaction control system

○

1-5



Specifications

Make

Overall Length

Overall Width

Overall Height

Wheel Base

SANYANG

1785 mm

630 mm

1115 mm

1275 mm

MODEL

Front

Suspension

System

Tire

Specifications

Front

Rear

Front

JET 100 SERIES

TELESCOPIC

120 / 70 – 12

130 / 70 – 12

DlSK (ψ190mm)

Rear DRUM (ψ110mm)

Passengers /

Weight

Front

Rear

Type

Installation and arrangement

Fuel Used

Cycle/Cooling

Two /110 kg

84.5 kg

122.5 kg

Gasoline

Horizontal, below center, incline

Unleaded (92/95)

2-stroke/forced air cooled

51 mm

Max. Speed

Climb Ability

Primary Reduction

Secondary

Reduction

Clutch

Speedometer

Horn

50 km/hr Below

22° Below

BELT

GEAR

Centrifugal, dry type

Transmission C.V.T.

0 ~ 120 km/hr

80 ~ 90 dB/A

Bore Muffler Expansion & Pulse Type

Right side, and Backward and Direction

Cylinder Number/Arran gement

Displacement

Single Cylinder Lubrication System Separated-lubrication

Compression

Ratio

6.3 : 1 CO 4.5 %

↓

Max. HP 7.0 ps / 6500 rpm HC

Max. Torque 0.89 kg-m / 5500 rpm E.E.C.

Ignition C.D.I. P.C.V.

7000 ppm

↓

Below 2g / test

X

Starting System

101.3 cc

Electrical & kick

Solid Particulate

Catalytic reaction control system

X

1-6



Torque values

Standard Torque Values for Reference value value

5 mm Bolt, nut

6 mm Bolt, nut

8 mm Bolt, nut

10 mm Bolt, nut

0.45 - 0.6 kg-m

0.8 - 1.2 kg-m

1.8 - 2.5 kg-m

3.0 - 4.0 kg-m

5 mm Bolt

6 mm Bolt, SH nut

6 mm Flange bolt, nut

8 mm Flange bolt, nut

0.35 - 0.5 kg-m

0.7 - 1.1 kg-m

1.0 - 1.4 kg-m

2.4 - 3.0 kg-m

12 mm Bolt, nut 5.0 - 6.0 kg-m 10 mm Flange bolt, nut 3.5 - 4.5 kg-m

The torque values listed in below table are for more important tighten torque values. Please see above standard values for not listed in the table.

Engine

Thread Dia.

Item Q’ty

(mm)

Cylinder head bolt

Spark plug

Flywheel nut

Sliding driving disc nut

Sliding driving disc nut

Clutch outer cover nut

4 6

Torque Value

1 10

1 10 3.8

1 28

(Kg-m)

1.0

3.8

5.5

1 10 3.8

Remarks

When engine cooled

1 14 1.4

Drain bolts

Crankcase bolts

1 8 1.3

6 6 1.0

1-7



Frame

Thread Dia.

Item Q’ty

(mm)

Bolt for engine suspension

1

Torque Value

(Kgf-m)

Remarks

10 5.0

Bolt for engine suspension bracket

1 12 6.0

Upper bolt for rear shock absorber

1 10 4.0

Lower bolt for rear shock absorber

1 8 2.7

Mounting screws for exhaust pipe connection

Nut for exhaust

2 6 1.2

2 8 3.3

Brake hose bolts

2 10 3.5

Brake caliper mounting bolts

2 8 3.1

Brake cushion guide bolts

2 6 1.8

Brake cushion guide bolts cap

2 6 1.0

Brake drain valve

1 6 0.6

Rear brake arm bolts

1 5 0.55

Tightening nut for steering rod

1 25.4 7.0

Front shaft nut

1 12 6.0

Mounting bolt for handle

1 10 5.0

Mounting nut for front hub

4 8 2.5

Mounting bolt for front brake disc

3 8 4.5

Rear shaft nut

1 14 11.0

Nut for rear hub

4 8 2.5

1-8



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.

Do not squeeze wires against the weld or its clamp.

Secure wires and wire harnesses to the frame with respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses.

Route harnesses so that they neither pull too tight nor have excessive slack.

Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner.

Route wire harnesses to avoid sharp edges or corners.

Avoid the projected ends of bolts and screws.

Keep wire harnesses far away from the exhaust pipes and other hot parts.

Be sure grommets are seated in their groves properly.

After clamping, check each harness to be certain that it is not interfered with any moving or sliding parts.

After routing, check that the wire harnesses are not twisted or kink.

Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering positions.

Thoroughly clean the surface where tape is to be applied.

Wrap electrical tape around the damaged parts or replace them.

O：Correct

X：Wrong

1-9



Headlight switch

Speedometer

Starter switch

Winker switch

High/low beam switch

Horn switch

Front brake lamp switch

Rear brake lamp switch

Throttle cable

Headlight

Throttle cable

Main switch

Regulator

Horn

Front brake cable

Speedometer cable

Rear brake cable

Winker relay

Resistor


Front brake hose

1-10






Throttle cable

Winker relay

Fuel unit


Throttle cable





Throttle cable

Fuel unit cord

Fuel pump

Fuel filter

1-11



Battery

Fuse

Purge control valve

Oil control cable

Fuel hose

Fuel pump

Fuel filter

C.D.I. UNIT

Carburetor

Vacuum hose

Oil hose


Oil lever switch

1-12



Troubleshooting

A. Engine hard to start or can not be started

Check and adjustment Fault condition

Loosen carburetor drain bolt to check if there is gasoline inside the carburetor

Fuel supplied tom carburetor sufficient

No fuel is supplied to carburetor

Remove spark plug, install it into spark plug cap, and perform a spark test against engine ground.

Check if sparks

Perform cylinder compression pressure test. cylinder compression pressure normal

Re-start by following the starting procedures

No ignition

Remove the spark plug again and check it.

Dry spark plug

Remove carburetor after 30 minutes and connect a hose onto fuel supplement circuit.

Then blow the hose with air

Blowing in normal

Week sparks or no spark at all

Low compression pressure or no pressure

There are some signs of ignition, but engine can not be started

Wet spark plug

Blowing clogged

Probable causes

1. No fuel in fuel tank

2. Check if the pipes, fuel tank to carburetor and intake vacuum, are clogged.

3. Float valve clogged

4. Lines in fuel tank evaporation system clogged

5. Malfunction of fuel pump

6. Loosen or damaged fuel pump vacuum hose

7. Fuel filter clogged

1. Malfunction of spark plug

2. Spark plug foul

3. Malfunction of CDI set

4. Malfunction of AC generator

5. Ignition coil is in open or short circuit

6. Ignition coil leads open or short circuit

7. Malfunction of main switch

1. Piston ring seized

2. Malfunction of cylinder valves

3. Worn cylinder and piston ring

4. Cylinder gasket leak

5. Sand hole in compression parts

6. Crankcase leakage for pre-compression

1. Malfunction of throttle valve operation

2. Air sucked into intake manifold

3. Incorrect ignition timing

1. Fuel level in carburetor too high

2. Malfunction of throttle valve operation

3. Throttle valve opening too wide

1. Malfunction of auto-starter

1-13



B.

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

Engine speed can be increased.

Check ignition timing

(Using ignition lamp)

Ignition timing correct

Check cylinder compression pressure (using compression pressure gauge)

Compression pressure correct

Check if carburetor is clogged

Remove spark plug

Normal

No foul or discoloration

Check if engine over heat

Normal

Continually drive in acceleration or high speed

No knock

Engine speed can not be increased.

Incorrect ignition timing

No compression pressure

Clogged

Fouled and discoloration

Engine overheat

Knock

1. Air cleaner clogged

2. Poor fuel supply

3. Lines in fuel tank evaporation system clogged

4. Exhaust pipe clogged

1. Malfunction of CDI


1. Cylinder & piston ring worn out

2. Cylinder gasket leaked

3. Sand hole in compression parts

5. Crankcase leakage for pre-compression

2. Incorrect spark plug heat range

1. Piston and cylinder worn out

3. Poor fuel quality

4. Too much carbon deposited in combustion chamber

5. Ignition timing too advanced

1. Too much carbon deposited in combustion chamber

3. Poor fuel quality

1-14



C.

Engine runs sluggish (especially in low speed and idling)

Check and adjustment Fault condition Probable causes


(using ignition lamp)

Normal

Adjust the air screw of carburetor

Good

Air sucked through carburetor gasket

No air sucked

Remove spark plug, install spark plug into spark plug cap and perform spark test against engine ground

Good spark

Abnormal

Poor

Air sucked

Poor

D.

Engine runs sluggish (High speed)

CHECK AND ADJUSTMENT FAULT CONDITION


Normal

Check for fuel supplying system in automatic fuel cup

Good

Check if carburetor clogged

Abnormal

Poor

1. Incorrect ignition timing (malfunction of CDI or AC generator)

1. Rich mixture (loosen the screw)

2. Lean mixture (tighten the screw)

1. Poor heat insulation gasket

2. Carburetor lock loose

3. Poor intake gasket

4. Poor carburetor O-ring

1. Spark plug fouled



4. Malfunction of ignition coil

5. Open or short circuit in spark plug leads

6. Malfunction of main switch

PROBABLE CAUSES



1. Insufficient fuel in fuel tank

2. Fuel filter clogged

3. Restricted fuel tank vent

Normal Clogged 1. Cleaning

1-15



E

. CLUTCH, DRIVING AND DRIVING PULLEY

FAULT CONDITION

Engine can be started but motorcycle can not be driving

Engine running and misfire as motorcycle initial forward moving or jumping sudden (rear wheel rotating as engine in running)

Poor initial driving (Poor climbing performance)

PROBABLE CAUSES

1. Driving belt worn out or deformation

2. Driving disk damaged

3. Driving pulley spring broken

4. Clutch ling broken

5. Driving slide-shaft gear groove broken

6. Transmission gear damage

7. Transmission gear worn out or burned

1. Clutch ling spring broken

2. Clutch outer cover stuck with clutch balance weights

3. Connection parts in clutch and shaft worn out or burned

1. Driving belt worn out or deformation

2. Balance weight roller worn out

3. Driving sliding gear shaft worn out

4. Driving disk spring deformation

5. Driving sliding gear shaft worn out

6. Greased in driving belt and sliding gear.

1-16



Lubrication Points

Throttle cable/

Front & rear brake lever pivot

Engine suspension bushing Seat lock

Steering shaft bearing

Speedometer gear/ front wheel bearing

Side stand shaft Main stand shaft

Rear wheel bearing

1-17


Note:


1-18

Home page

Contents

2. SERVICE MAINTENANCE INFORMATION

General Information ························· 2-1

Periodical Maintenance Schedule··· 2-2

Air Cleaner ········································ 2-3

Fuel Lines ········································· 2-3

Fuel Filter ·········································· 2-4

Engine Oil Line ································· 2-4

Oil Pump Control Cable ··················· 2-5

Tire····················································· 2-6

Battery··············································· 2-6

Rear Brake Free Play: (Drum Brake Type)

···························································· 2-7

Brake System Hose: (Front Disc Brake

Type)·················································· 2-8

Steering System ······························· 2-10

General Information

Specification

Suspension ····································· 2-10

Transmission Oil ···························· 2-11

Spark Plug ······································ 2-11

Control Cable Lubrication ············· 2-12

Driver Belt ······································· 2-12

Ignition Timing ······························· 2-12

Throttle Valve Operation················ 2-12

Carburetor Idle Speed Adjustment 2-13

Carbon Removing For Exhaust Pipe &

Muffle··············································· 2-13

Cylinder Compression Pressure Test

2-13

Headlight Adjustment ···················· 2-14

2

Model

Item

JET 50 JET 100

Tire dimension Front: 120 / 70 – 12, Rear: 130 / 70 - 12

Tire pressure at cold Only rider

Rear brake lever free play

Front: 1.75kg/cm

2

Rear: 2.0 kg/cm

10~20 mm

2

Transmission oil / Recommendation

Type: HYPOID GEAR OIL

Oil: SAE #140 Quantity: 0.12 L Replacement: 0.11L

Spark plug / Recommendation

Driving belt width

Ignition timing F mark

Acceleration operation

Idle speed

Cylinder compression pressure

Type: NGK BR8 HSA

Plug gap: 0.6-0.7mm

Type: NGK BR6 HSA

Plug gap: 0.6-0.7mm

Standard 18.0mm

Allowable limit: replace it if below 16.5mm

17 °, BTDC/1500 rpm

2~6 mm

2000 ±100 rpm

7 ±1 kgf/cm²

2100 ±100 rpm

10 ±2 kgf/cm²

2-1



Periodical Maintenance Schedule

Check item

Maintenance kilometer

Maintenance interval

300KM

New

Every

1000KM

Every

3000KM

Every

6000KM

1 month 3 month 6 month

Every

12000KM

Reference

1 year

I C R

C

C C ☆ 3. Engine oil filter cleaning

☆

4. Oil pump linkage operation check

I I

7. Brake & free play check

8. Steering handle check

9. Cushion operation check

10. Every screw tightening check

11. Gear oil check for leaking

☆ 12. Spark plug check or change

☆ 13. Gear oil change

☆ 16. Carburetor

17. Driving belt check

☆ 18. Ignition timing

☆ 19. Emission check in Idling

☆ 20. Idle speed check

I I

I I

I I

I I

I I

I I

I I

I R

R Replacement for every 5000km

L

I I

I I

I

I I

I I

I I

I I

I I

I I

I

☆ 22. Throttle operation

☆ 23. Engine bolt tightening

☆ 24. Engine screw torque

☆

25. Carbon cleaning for cylinder head, cylinder, piston head, and exhaust system.

I

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

C ~ Cleaning (replaced if necessary) L ~ Lubrication

The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.

Remarks:

1. Clean or replace the air cleaner element more often for pro-long engine life-span when the scooter is operated on dusty roads or in the Heavily- polluted environment.

2. Maintenance should be performed more often if the scooter is frequently operated in high speed and after the scooter has accumulated a higher mileage.

2-2



Mounting screw X 7

Air Cleaner

• Remove the mounting screw from the air cleaner cover

• Remove the air cleaner cover

Remove the air cleaner element

Clean the element with non-flammable or high-flash point solvent and then squeeze it for dry.

Air cleaner element

Caution

Never use gasoline or acid organized solvent to clean the element.

Soap the element into cleaning engine oil and then squeeze it out. Install the element onto the element seat and then install the air cleaner cover.

• Limit to use SAE 20 JASO FC class engine oil, otherwise, SYM is no responsible for the warranty.

• Recommended engine oil: MAX-2 serial oils.

Fuel Lines

Remove the body cover

Check fuel lines and replace damaged lines if found.

Install the body cover.

Clean

Squeeze oil out

Fuel pump

Soap

Squeeze out remaining oil

Carburetor

Fuel line

2-3



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.

Check the engine oil line and replace damaged parts.

Remove the filling pipe from the oil pump, and drain oil into a cleaning container.

Loosen the clamp under the engine oil tank, and then remove the oil pipe.

Bleed the air inside the oil pump and oil pipe if air found.


Oil pump

Oil filling pipe

Engine oil pipe

2-4


Oil Pump Control Cable


Caution

To adjust the oil pump control cable after adjusted the throttle grip play.


Wide open the throttle valve, and check if the calibration point aligns on the oil pump lever with the mark of pump body.

Loosen the adjustment nut of the oil pump control cable.

Turn the adjustment nut and align with the point, then tighten the nut.

Mounting nut

Adjustment nut

2-5



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

Tire size

Front:

120 / 90 - 10

Rear:

130 / 90 - 10

Tire pressure

(cold) kg/cm

2

1.75 2.0

Check if the tire tread and wall rubber for crack or damage, and replace if necessary.

Check if foreign materials such as nail, metal pieces, and stones stuck on tire.

The thread depth can be checked by visual inspection or by a depth gauge.

• If the tread bend too much, replace the tire.

• If tire wear exceeds limitation, replace the tire, and check it for un-even wear.

Caution

Wear indicator “△” is distributed on average along the wall rubber for check.

Battery

Open the seat.

Loosen two screws of battery cap and then remove the cap. Check if the battery terminals are loosen. Remove the battery if its terminals are corroded obviously.

Battery Removal

1. Remove the Negative (-) battery cable at first.

2. Then, remove the Positive (+) battery cable.

3. Remove the battery.

Clean the rust with steel brush.

Install the battery in reverse order of removal, and apply with grease onto two terminals.

Caution

The electrolyte is contained sulfuric acid so be careful not to let it touch to eyes, skin, or clothes. If touched by accident, flush them with clean water immediately. However, if the electrolyte sprays to eyes, medical care should be done quickly.

Wear indicator

2-6

△ Mark



Rear Brake Free Play: (Drum

Brake Type)

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.

Brake Confirmation

10∼20mm

(3/8∼3/4 in)

Adjustment nut

Caution

After brake adjustment, it has to check the brake operation to make sure the front and rear wheel can be braked.

Decreasing free play

Increasing free play

2-7



Brake System Hose: (Front Disc

Brake Type)

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. If the level is lower than the LOWER limit, add brake fluid DOT-3 to UPPER limit. Also check brake system for leaking if low brake level found.

Caution z In order to maintain brake fluid in the reservoir in horizontal position, do not remove the cap until handle bar stop. z Do not operate the brake lever after the cap had been removed. Otherwise, the brake fluid will spread out if operated the lever. z Do not mix non-compatible brake fluid together.

Brake Lining Wear: (Rear Drum Brake

Type)

Replace the brake lining if the wear limit mark

“△” on the brake arm aligning with the indicator of brake drum.

Brake Lining Wear: (Front Disc Brake

Type)

The arrow mark on brake lining is the wear limitation.

Replace the brake lining if the wear limit mark closed to the edge of brake disc.

Caution

In order to maintain brake power balance, the brake lining must be replaced with one set.

Lower limit

Arrow

Brake caliper

Brake fluid reservoir cap

Wear limit mark

Brake lining

Brake disc

2-8


2. SERVICE MAINTENANCE INFORMATION z z z

Remove the pin bolt cap.

Loosen the bolt.

Remove the front wheel shaft bolt.

Take out the front wheel. z

Remove brake caliper mounting bolt and then remove the brake caliper.

Pin bolt cap

Caution

Do not operate the brake lever after the clipper removed to avoid clipping the brake lining.

Pry out the brake lining with a flat driver if lining is clipped.

Remove brake lining bolt.

Take out the lining.

Tighten Torque:

Mounting bolt: 2.9-3.5 kgf-m

Pin bolt: 1.5-2.0 kgf-m

Pin bolt cap: 0.8-1.2 kgf-m

The brake LIGHT switch is to light up brake

LIGHT as brake applied. Replace the switch if the light does not light up in properly.

Caution

The brake light switch is un-adjustable.

Mounting bolt

Brake lining

Pin bolt

Pin bolt

2-9



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.

Suspension

Warning

Do not ride the scooter with poor suspension.

Looseness, wear or damage suspension system will make poor stability and drive-ability.

Front Shock Absorber

Press down the front shock absorber for several times to check it operation.

Check if the shock absorber assembly is damage. Replace it if damage found and can not be repaired.

Tighten all nuts and bolts.

Rear Shock Absorber

Park the scooter with its main stand.

Shake the rear wheel side to side to check engine suspension bushing for wear.

Replace the bushing if looseness found.

Check the shock absorber for damage.

Tighten all nuts and bolts.

Nuts, Bolts Tightness

Check if all bolts and nuts on the frame are tightened to specified torque in accord with the interval of Periodical Maintenance Schedule.

Check all split pins, snap rings, hose clamps, and wire holders for security.

2-10



Transmission Oil

Leak

Check if the transmission is leak.

Check

Caution

Park the scooter on flat ground with its main stand.

Draining bolt

Oil level check bolt

Remove the oil level check bolt, and check if the oil level is placed on the hole of check bolt.

Replacement

Remove the oil level check bolt.

Remove the oil draining bolt, and then drain oil out.

Install the oil draining bolt.

Tighten torque: 1.3 kg-m

Caution

Check if oil seal and washer is in good condition.

Replacement Quantity: 0.09 L (90 cc)

Recommended oil: King Bramax HYPOID

GEAR OIL #140

Spark Plug

Recommended plug: NGK BR8HSA z Remove the luggage box. z z z z z z

Remove the spark plug cap.

Clean any dirt on the spark plug seat.

Remove the spark plug.

Visually inspect the spark plug electrodes for wear.

The center electrode should have square edges and side electrode should have a constant thickness. Replace the spark plug if there is apparent wear or if the insulator is cracked and/or chipped. If the spark plug deposits can be removed by sandpaper, the spark plug can be reused.

Measure the spark plug gap with feeler gauge.

Spark plug gap: 0.6-0.7mm z z z

(0.024-0.028in)

Adjust the gap by careful bending the side electrode.

Install the spark plug by screwing it with hands after installed the spark plug washer so that can prevent the plug from out of thread. Then, tighten the spark plug with a spark plug wrench.

Install the spark plug cap.

0.6~0.7mm

Center electrode

Side electrode

Oil level check bolt hole

2-11



Control Cable Lubrication

Remove the throttle control and the brake cables periodically, and lubricate the moving parts of the cables thoroughly.

Driver Belt

z z z

Remove left crankcase cover.

Check if the belt is crack or worn out.

Replace the belt if necessary.

Measure the driving belt width

Allowable limit: 16.5mm

Ignition Timing

z

Caution

C.D.I ignition timing can not be adjusted. If the ignition timing is incorrect, check the

C.D.I. device and the alternator and replace damaged components. z Check ignition timing with standard instrument.

Remove the right-side cooling fan cover.

Check ignition timing with the timing light.

When engine speed setting to 1800 rpm, and if the mark aligns with “F” mark, then it means that the ignition timing is correct.

Throttle Valve Operation

Check if each steering positions are operated in smooth, and handle bar if its operation is smooth as the throttle valve wide opening or fully closed.

Check throttle cable and replace it if deteriorated, twisted or damaged.

Lubricate the cable if operation is not smooth

Measure throttle valve handle free play.

Free play：2~6 mm (1/8-1/4 in)

Loosen the mounting nut, and turn the free play adjustment nut of the throttle valve handle for adjustment.

Replace the cable if it can not be adjusted.

Tooth face

Ignition lamp

Belt width

“F” mark

2-12



Carburetor Idle Speed Adjustment

Pilot screw

Caution z Inspection & adjustment for idle speed have to be performed after all parts in engine had been adjusted in specification. z Idle speed check and adjustment have to be done after engine is being warn up. It around operates engine from stop to running for 10 minutes.


Park the scooter with main stand after warned up engine. According to the required idling and air screw to adjust to specified idle speed.

Idle speed: 2000±100 rpm (JET 50)

Idle speed: 2100±100 rpm (JET 100)

Carbon Removing For Exhaust

Pipe & Muffle


Remove the exhaust pipe & muffler.

Clean the carbon deposits on the muffler & cylinder exhaust edge.

Cylinder Compression Pressure

Test

Remove the left body cover, and warn up engine.

Stop the engine and remove the spark plug.

Insert the compression gauge and wide open the throttle, and then rotate the engine by means of the starting motor.

Compression pressure: 7.0±1 kg/cm

2

Probable causes for low compression pressure. z Damaged cylinder head gasket. z z

Worn piston ring

Worn cylinder

Probable causes for high compression pressure. z Carbon on the combustion chamber or cylinder head

Idle speed adjustment screw

Adjust the idling after warn up engine for 10 minutes.

1. Connect tachometer.

2. Adjust the idle speed screw to let engine speed in 2000±100 rpm.

3. Insert the sampling pipe of the CO/HC meter to the test hole on the front end of exhaust pipe. Adjust the idling emission value to standard range. (CO: 1.8-2.6%)

4. Slightly accelerate the throttle valve and release it. Repeat this operation for 1-2 times.

5. Read the engine idle speed and the emission value after engine speed in stable. Repeat the operation on step No. 2 – No. 4. until these value within standard range.

Compression pressure gauge

2-13



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.

JET Euro

Headlight mounting bolt

JET

Headlight mounting bolt

2-14

Home page

Lubrication System Diagram············ 3-1

Precautions In Operation·················· 3-2

Lubricant············································ 3-2

Trouble Shooting······························· 3-2

Lubrication System Diagram

Contents

3. LUBRICATION SYSTEM

Oil Pump Removal ···························· 3-3

Oil Pump Installation ························ 3-3

Oil Pump/Oil Tube Air Bleeding······· 3-4

Oil Tank ············································· 3-5

3

Oil lever switch

Oil tank

Oil output tube

Oil tube

Oil pump

3-1



Precautions In Operation

z z z z

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.

It should bleed the oil output tube (from oil pump to carburetor) as hose removed.

The adjustment of oil pump control cable. z z z

Lubricant

Appointed to apply SAE 20 JASO FC class oil. Otherwise, warranty shall not cover the damage.

Recommended Oil: MAX-2 oil.

Oil tank capacity: 1.2 lit.

Trouble Shooting

Too much smoke, carbon in spark plug.

1. Improperly oil pump adjustment (too much oil).

2. Poor quality oil.

3. Applying with poor quality oil.

Over heat

1. Improperly oil pump adjustment (insufficient oil).

2. Poor quality oil.

3. Applying with poor quality oil.

Piston seized

1. No oil in oil tank or clogged hose.

2. Improperly oil pump adjustment (insufficient oil).

3. Air in oil hose.

4. Malfunction of oil pump.

Oil did not flow out the oil tank

1. Clogged breath hole on the oil tank cover.

3-2


Oil output tube


Oil tube

Oil Pump Removal

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.

Remove the oil tube, and clip its end side to prevent oil from flowing out.

Remove the oil output tube form intake manifold.

Remove the oil pump mounting bolt, and then take out the oil pump.

Inspection

Inspect the following items on the removed oil pump. z z

Check if O-ring is damaged or softening.

Check if crankcase interface is damaged. z z z

Check if pump body is damaged.

Check if pump gear is damaged.

Check for oil leaking.

Caution

The oil pump can not be disassembled.

Oil Pump Installation

Install the oil pump onto the crankcase.

Caution z z

Apply with some grease onto oil pump

O-ring.

The connection between both oil pump and crankcase has to be installed in position security.

Tighten the oil pump mounting bolt security.

Install the oil tube.

Installation in the reverse order of removal.

Caution

Inspection and adjustment following items as installed.

The adjustment operation of control cable.

Air bleeding operation of oil pump.

Air bleeding operation of oil tube.

Check each section for leaking.

Control cable

Mounting nut Adjustment nut

Oil output tube

3-3



Oil Pump/Oil Tube Air Bleeding

Caution

The oil tube system has to be conducted air bleeding operation because air will clog or restraint oil flowing so that cause serious engine damage.

Caution

After disconnect the oil tube, air enters oil tube due to oil leak out without added oil.

There is why the oil tube and oil pump have to conduct air bleeding operation.

Oil Tube/Oil Pump z z z z z z

It has to add some oil into the oil tank.

Place a piece of dry cloth around the oil pump.

Disconnect the oil tube.

Fill out oil to oil pump connection section by means of the oil pot so that the oil pump body is full with oil.

Fill out oil to oil tube connection section so that the oil tube is full with oil. Then, install the tube onto oil pump.

Make sure whether air is in the oil tube or not after installation.

Caution

After bleeding the oil tube and oil pump, the oil tube has to be conducted air bleeding operation too.

Oil Tube Air Bleeding

Remove the oil output tube and plug its input connector. Bend the oil tube into “U “shape, and fill out new oil into the output tube.

Connect the oil output tube to the oil pump connection part.

Start engine, and run it in idling as the oil control lever in wide open position. Make sure oil flows out from the oil output tube.

Caution z z

Motorcycle’s exhaust gas includes with CO which causes human to coma or death so perform this operation in well-ventilation place.

Run the engine in extreme low speed to avoid to damaging the engine caused from clogged oil tube.

Oil output tube

Oil output tube

Oil tube

Oil tube

Control cable

Recommended oil

3-4



Mounting bolt

Oil Tank

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.

Remove the oil switch wire of the oil indicator.

Remove the mounting bolt on the oil tank upper side, and then remove the oil tank.

Installation in the reverse order of removal.

Air bleeding the oil tubes after installation.

Blot ×2

Screw ×2

Blot ×1

3-5


NOTES:


3-6

Home page

Contents

4. ENGINE REMOVAL

Maintenance Information ················ 4-1

Engine removal ································ 4-2

Engine installation···························· 4-4

Maintenance Information

There are parts that require removal of engine for maintenance. z Crankcase z Crankshaft

Related bolts tightening torque for removal of engine:

Engine hanger bolt

Engine bracket bolt

Rear shock absorber upper mounting bolts

Rear shock absorber lower mounting bolts

Exhaust pipe connection nut

Muffle mounting bolt

5.0kgf-m

6.0kgf-m

4.0kgf-m

2.7kgf-m

1.2kgf-m

3.3kgf-m

4

4-1



Engine removal

Remove body cover.

Remove the spark plug cap from the spark plug section.

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.

Remove the wire connectors of auto by starter and ACG.

Remove the upper part of the carburetor from its upper side.

Remove the vapor emission vacuum tube from carburetor intake manifold.

Vacuum tube

Fuel output tube

Fuel pump

Spark plug

Oil tube

Oil control cable

Wire connector

4-2


Remove rear brake cable from engine rear-lower side.

Remove air cleaner mounting bolts. (2 bolts)

Support the engine and then remove shock absorber lower mounting bolt.

Remove two exhaust pipe connection nuts.

Remove two bolts beside fan cover and exhaust pipe.


Mounting bolt

Brake cable

Shock absorber lower mounting bolt

Connection nut

Exhaust pipe

Bolt

4-3



Remove engine mounting nut and bolt.

Engine installation

Install in the reverse order of removal procedures.

Tighten the engine mounting and rear shock absorber upper/lower bolts.

Torque value:

Engine hanger bolt:

Rear shock absorber upper mounting bolts:

Rear shock absorber lower mounting bolts:

5.0kgf-m

4.0kgf-m

2.7kgf-m

Exhaust pipe connection nut: 1.2kgf-m

Muffle mounting bolt: 3.3kgf-m

Perform the following inspection and adjustment after installation. z z

Check if control cable is correct.

Check if throttle valve cable is correct. z z z

Check if oil pump control cable is correct.

Oil input and output of the oil pump.

Adjust rear brake.

Engine mounting bolt

4-4

Home page

Contents

5. CYLINDER HEAD/CYLINDER/PISTON

Maintenance Information·················· 5-2

Troubleshooting································ 5-2

Cylinder Head ·····································5-3

Cylinder/Piston ···································5-5

5

5-1




Precautions In Operation z z z z z

The inspection and maintenance of the cylinder head, cylinder and piston can be carried as engine mounted on the body.

It should clean the engine to prevent dirt from entering into cylinder and crankcase before removal.

Remove all washes from the interfaces of cylinder head, cylinder and crankcase.

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

Item

JET 50 series

Standard value

Limit (mm)

(mm)

JET 100 series

Standard value

Limit (mm)

(mm)

Cylinder

Deformation

head

Piston OD

Clearance between

- 0.100 - 0.100

39.030~39.045 38.935 51.030~39.045 50.935

Piston cylinder and piston

Piston pin hole

Piston pin OD

Clearance between piston and piston pin

0.040~0.050 0.100 0.040~0.050 0.100

12.002~12.008

11.994~12.000

12.030

11.970

14.002~14.008

13.994~14.000

14.030

13.970

0.002~0.014 0.030 0.002~0.014 0.030

Piston ring end gap

ID of connecting rod

0.100~0.250 0.400 0.100~0.250 0.400

17.05~17.015 17.025 17.05~17.015 17.025 small end

Cylinder

ID 39.000~39.015

ID: inner diameter

OD: outer diameter

Tighten torque value

Cylinder head

Spark plug

Troubleshooting

1.0 kgf-m Exhaust pipe connection nut

1.4 kgf-m Exhaust muffler mounting bolt

1.2 kgf-m

3.3 kgf-m

Compression Pressure Too Low/Difficult

To Start/Rough Idling

1. Cylinder head gasket leaking

2. Spark plug not tighten enough

3. Worn, seized or crack piston ring

4. Damaged, worn cylinder or piston

5. Poor reed

Compression Pressure Too

High/Overheat/Knock

1. Too much carbon deposit built up in combustion chamber

Piston Noise

1. cylinder and piston worn out

2. piston pin or piston pin hole worn out

3. connecting rod small end bearing worn out

Piston Ring Noise

1. Worn, seized or crack piston ring

2. Cylinder worn out or damaged

5-2


Cylinder Head

Cylinder Removal

Removal body covers.

Remove spark plug cap.

Remove fan cover.

Remove engine shield.

Remove two connection nuts of the exhaust pipe.

Remove exhaust muffle mounting bolt, and then remove the exhaust pipe.

Cylinder Head Removal

Remove the 4 cylinder head bolts and then remove the cylinder head.

Caution

Loosen the cylinder head bolts with diagonal direction to avoid to damaging it.


Tightening bolt

Tightening bolt

Muffle

Bolt x 2

Tightening bolts

Engine shield

Tightening bolt x 2

Cleaning Carbon In Combustion

Chamber

Clean carbon deposit in which built up in combustion chamber with shown chisel.

Caution

Do not scratch to the interfaces of combustion chamber and cylinder.

Chisel

5-3



Cylinder Head Inspection

Use a straight edge and a feeler gauge to measure the cylinder head for warp.

Service limit: 0.10 mm

Cylinder Head Installation

Replace the cylinder head gasket with new one, and place the cylinder head onto cylinder.

Tighten the 4 bolts with diagonal direction and by 2-3 sequences.

Tighten torque: 1.0 kgf-m

Install spark plug


Replace the exhaust pipe washer with new one and then install exhaust pipe.

Tighten exhaust pipe connection nut.


Tighten exhaust pipe mounting bolt.


Install the removed parts in the reverse order of removal procedures.

Inspect following item after installation.

Compression pressure test.

Check for engine noise.

Tightening bolts

Muffle

Bolt x 2

Tightening bolt x 2

5-4


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.

Remove piston pin clip (one piece) and then push piston pin out the piston.

Caution y Do not damage or scratch the piston. y Do not apply with lateral force to connecting rod. y Do not let piston pin snap ring falling into crankcase.

Piston Ring Removal

Caution

Pry out the opening end of each piston ring and then remove the ring from piston.

Check if cylinder and piston are worn or damaged, and then clean carbon deposit on exhaust opening area as the diagram shown.

Caution

Do not scratch both the cylinder and the piston.


Piston pin clip

Piston pin

Piston

5-5



Use a straight edge and a feeler gauge to measure the cylinder head for warp.


In “X” and “Y” direction, measure the cylinder for worn out as the three levels shown in the figure.

With the max. value to decide cylinder wear out condition.

Service limit

JET 50 : 39.050mm

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.


Measure the ID of piston pin hole.

Service limit

JET 50 : 12.030mm

JET 100 : 14.030 mm

Measure the OD of piston pin.

Service limit

JET 50 : 11.970 mm

JET 100 : 13.970 mm

The ID of piston pin hole

7mm

The OD of piston pin

5-6


Piston Ring Inspection

Measure the end gap of each piston ring.


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.

Measure the ID of connecting rod small end.

Service limit: 17.025mm

Piston/Cylinder Installation

Install the expanding ring into the groove of 2 nd ring.

Align the ring end with the lock pin in the ring groove.

Install the top ring and the 2 nd

ring onto the ring groove respective.

Caution

The top ring and the 2 nd

ring can not be changeable each other.

Push the rings into ring groove and then check rings’ mating condition.

If ring could not be push in the ring groove, it means that ring groove is dirty or wrong ring groove installation.

Caution y All rings should be installed with the marks facing up. y All ring should be replaced at same time, and it can not be replaced one ring only. y It should use same brand name piston ring in an engine and can not mix with other one.


1T: top ring

2T: 2 nd

ring

Clearance

Top ring

2 nd

ring

Piston ring mark

Expanding ring

5-7



Place a cleaning cloth onto the crankcase opening to prevent the piston pin snap ring from falling into the crankcase.

Apply with two-stroke engine oil onto needle bearing and piston pin, and then install the piston pin onto connecting rod. Install piston, and place “EX” mark of the piston toward to exhaust side.

Install new piston pin snap ring.

Clean all gaskets onto the interfaces of cylinder and crankcase.

Place a new gasket onto the crankcase.

Make sure that the piston ring aligns with the lock pin in piston ring groove.

Caution

Make sure that all rings in the piston ring groove can not be rotated around the lock pin to avoid to damaging the rings, piston and cylinder.

Lubricate cylinder and piston with two-stroke engine oil. Hold the piston and then install it into cylinder.

Caution

To avoid to damaging the piston and the cylinder sliding surface.

Install the cylinder head.

Piston

Piston pin snap ring

Lock pin

〝EX〞mark

Piston pin

5-8

Home page

Contents


Alternator Removal·························· 6-3

Alternator Installation······················· 6-4

6

3.8 kgf-m

6-1


6. ALTERNATOR


Precautions in Operation z z

The maintenance service of A.C. alternator can be carried out directly on the motorcycle.

Please refer to Chapter 15 for the relative alternator inspection.

Torque value:

Tool

General tool

Rotor puller

Universal holder

Coil resistance value for the A.C. alternator

JET 50/100 series

Earth 50~200Ω 0.2~0.8Ω 0.2~1.0Ω 400~800Ω

JET EURO 50/100 series

Y/L Y

Earth 50~200Ω

Y 0.4~0.8Ω

L/Y

AC.G

Y

Y

Y

3P

6-2


Alternator Removal


Remove two bolts and then take out cooling fan cover.

Remove four bolts, and then take out the cooling fan.

Hold flywheel with universal holder.

Support the flywheel and the remove the 10 mm nut on the flywheel.

Remove the flywheel with rotor puller.

Cooling fan cover

Bolt

Cooling fan

10mm flanged nut

Universal holder

Rotor puller

6-3


6. ALTERNATOR

Disconnect alternator wire connector and pulse generator connector.

Remove the pulse generator and alternator four

(4) bolts, and then take out the alternator assembly.

Caution

Wire harness connector

Care to be taken for not damaging the alternator coil.

Alternator Installation

Install the alternator assembly.

Connect the alternator connector.

Caution

Connect the alternator wire harness properly and then clip the harness with clipper.

Install the woodruff key onto the crankshaft groove.

Caution z z

Clean dirt and metal pieces inside the flywheel.

Make sure that there is no foreign material inside the flywheel.

Install the flywheel

Tighten the flywheel 10 mm nut.

Torque value: 3.8 kgf-m

Install the removed parts in reverse order of removal procedures.

Start engine and check its ignition timing.

6-4

10mm flanged nut


Home page

Contents

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER


Trouble Shooting ····························· 7-2

Left Crankcase Cover ······················ 7-3

Reassembly Of Kick Starter ············ 7-4

Installation Of The Left Crankcase

Cover················································· 7-4

Drive Belt··········································· 7-5

Movable Driven Pulley ····················· 7-6

Clutch/Driven Pulley························· 7-10

5.5 kgf-m

7

3.8 kgf-m

3.8 kgf-m

7-1




Precautions In Operation

The surfaces of drive belt and driven pulley must be free of grease.

Specification

Item Standard Limit(mm)

Drive belt width

ID of movable drive face

18.0 16.5

20.035~20.085 20.120

OD of movable drive face boss 23.964~23.985 23.918

OD of weight roller 15.92~16.08 15.40

ID of clutch outer 107.0~107.2 107.5

Thickness of clutch weight 4.0~4.1 2.0

Free length of driven pulley spring 87.9 82.5

OD of driven pulley 33.965~33.985 33.940

ID of movable driven face

ID: Inner Diameter

OD: Outer diameter

Torque Values:

Movable drive face: 3.8 kgf-m

Driven pulley: 5.5 kgf-m

Clutch outer: 3.8 kgf-m

33.000 34.060

Special Service Tools

Clutch spring compressor

Bearing driver

Clutch nut wrench 39x41 mm

Bearing driver accessory 39x41 mm

Universal holder

Driver

Trouble Shooting

Engine can be started but motorcycle can not be moved

1. Worn drive Belt

2. Worn ramp plate

3. Worn or damaged clutch weight

4. Broken driven pulley spring

Shudder or misfire when drive

1. Broken clutch weight

2. Worn clutch weight

Insufficient horsepower or poor high speed performance

1. Worn drive belt

2. Insufficient spring capacity of driven pulley

3. Worn weight roller

4. Driven pulley operation un-smoothly

7-2



Left Crankcase Cover

Left crankcase cover removal

Remove left body side cover.

Remove air cleaner.

Remove kick start arm.


Disassembly of Kick Starter

Remove snap clip and thrust washer from left crankcase cover.

Install kick start arm, rotate the lever slightly and then remove driven gear and washer.

Remove the kick starter arm, kick starter spindle, and return spring as well as socket.

Left crankcase cover

Kick start arm

Return spring

Starter spindle

Inspection of kick Starter

Check if starter spindle, driven gear for wear or damage.

Driven gear

Bolt

Kick start arm

Snap ring

Thrust washer

Return spring

Starter spindle

Bush

Thrust washer

Driven gear

Friction spring

7-3



Reassembly Of Kick Starter

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.

Install the friction spring of drive gear onto convex part of the cover.

Return spring

Width-tooth

Convex part

Kick starter spindle

Driven gear

Friction spring

Installation Of The Left Crankcase

Cover

Install the dowel pin and gasket.

Install the left crankcase cover.

Install kick start arm.

Dowel pin

7-4



Drive Belt

Removal


Hold clutch outer with universal holder, and remove nut and clutch outer.

Nut

Caution y Using special tools for tightening or loosening the nut. y Fixed rear wheel or rear brake will damage reduction gear system.

Push the drive belt into belt groove as diagram shown so that the belt can be loosened, and then remove the driven pulley.

Remove driven pulley/clutch. Do not remove drive belt.

Remove the drive belt from the groove of driven pulley.

Inspection

Check the drive belt for crack or wear. Replace it if necessary.

Measure the width of drive belt as diagram shown.

Service Limit: 16.5 mm

Replace the belt if exceeds the service limit.

Caution y Using the genuine parts for replacement y The surfaces of drive belt or pulley must be free of grease. y Clean up all grease or dirt before installation.

Installation

Clutch/drive belt

Belt tooth


Movable driven pulley

Caution y Pull out driven pulley to avoid it closing.

Install drive belt onto driven pulley.

7-5



Install the driven pulley that has installed the belt onto drive shaft.

Drive face

Install the clutch with universal holder, and then tighten nut to specified torque value.


Movable Drive Face

Removal


Hold generator flywheel with universal holder, and then remove drive face nut.

Remove drive face.

Drive belt

Clutch/driven pulley

Nut


Drive shaft

Clutch outer


Flywheel

Nut

Drive face

7-6



Removal

Remove movable drive face set and drive belt from crankshaft.

Drive face boss Movable drive face

Crankshaft

Remove ramp plate.

Ramp plate

Remove weight rollers from movable face.

Inspection

The weight roller is to press movable driven face by means of centrifuge force. Thus, if weight rollers are worn out or damage, the centrifuge force will be affected.

Check if rollers are wear out or damage.

Replace it if necessary.

Measure each roller’s outer diameter. Replace it if exceed the service limit.


Movable drive face

Weight roller

Weight roller

7-7



Check if movable drive face boss is worn or damage and replace it if necessary.

Measure the outer diameter of drive face boss, and replace it if it exceed service limit.


Measure the inner diameter of drive face, and replace it if it exceed service limit.


Reassembly / Installation

Install weight rollers.

Install ramp plate.

Apply with grease 4~5g to inside of movable drive face, and install drive face boss.

Caution y The drive face has to be free of grease.

Clean it with cleaning solvent.

Ramp plate

Drive face

Movable drive face

Drive face boss

Weight roller

7-8



Install movable drive face assembly onto

Drive face boss Movable drive face crankshaft.

Drive Face Installation

Crankshaft

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.


Caution y Make sure that two sides of drive face have to be free of grease. Clean it with cleaning solvent.

Hold flywheel with universal holder.

Tighten nut to specified torque.

Torque value: 3.5-4.0 kgf-m

Install left crankcase cover.

Flywheel

Nut

Drive face

7-9



Clutch/Driven Pulley

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 y Do not press the compressor too much.

Hold the clutch spring compressor onto bench vise, and then remove mounting nut with clutch nut wrench.

Release the clutch spring compressor and remove clutch and spring from driven pulley.

Remove socket from sliding pulley.

Remove guide pin, guide pin roller, and driven pulley, and then remove O-ring & oil seal seat from sliding pulley.

Inspection

Clutch outer

Measure the inner diameter of clutch outer friction face. Replace clutch outer if exceed service limit.


Sliding pulley

O-ring

Oil seal

Inner diameter

Clutch nut wrench

Clutch spring compressor

Guide pin or

Socket

Guide pin roller

Clutch outer

7-10



Clutch weight

Measure each clutch weight thickness.

Replace it if exceeds service limit.


Clutch weight

Driven pulley spring

Measure the length of driven pulley spring.

Replace it if exceeds service limit.


Driven pulley

Check following items: y If both surfaces are damage or wear. y If guide pin groove is damage or wear.

Replace damaged or worn components.

Measure the outer diameter of driven pulley and the inner diameter of sliding pulley. Replace it if exceeds service limit.

Service limit: Outer diameter 33.94 mm

Inner diameter 34.06 mm

Driven Pulley Bearing Inspection

Check if the inner bearing oil seal is damage.


Check if needle bearing is damage or too big clearance. Replace it if necessary.

Rotate the inside of inner bearing with fingers to check if the bearing rotation is in smooth and silent. Check if the bearing outer parts are closed and fixed. Replace it if necessary.

Free length

Driven pulley

Sliding pulley

Guide pin groove

Needle bearing

Caution y Some of models are equipped with two ball bearings. Outer ball bearing

7-11



Clutch Block Replacement

Spring

Remove clip and washer, and then remove clutch weight and spring from drive plate.

Caution y Some of models are equipped with one mounting plate instead of 3 snap clips.

Check if spring is damage or insufficient elasticity.

Check if shock absorption rubber is damage or deformation. Replace it if necessary.

Apply with grease onto lock pins.

Install new clutch weight onto lock pin and then push to specific location.

Apply with grease onto lock pins. But, the clutch weight should not be greased. If so, replace it.

Caution y Grease or lubricant will damage the clutch weight and affect the weight’s connection capacity.

Install the spring into groove with pliers.

Clutch weight

Shock absorption rubber

Shock absorption rubber

Clutch block

Spring

Drive plate

Snap clip

7-12



Install snap clip and mounting plate onto lock pin.

Snap clip

Replacement of Driven Pulley Bearing

Remove inner bearing.

Outer bearing

Clip

Caution y If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly. y If the pulley equipped with ball bearing, it has to remove snap clip and then the bearing.

Remove snap clip and then push bearing forward to other side of inner bearing.

Place new bearing onto proper position and its sealing end should be forwarded to outside.

Apply with specified grease.

Install new inner bearing.

Snap clip

Inner ball bearing

Inner needle bearing

Specified grease

Sealing end

Snap ring

Outer bearing

Inner bearing

Caution Sealing end y Its sealing end should be forwarded to outside as bearing installation. y Install needle bearing with hydraulic presser. Install ball bearing by means of hydraulic presser or driver.

Install snap clip into the groove of drive face.

Align oil seal lip with bearing, and then install the new oil seal (if necessary).

7-13



Installation of Clutch/Driven Pulley

Assembly

Oil seal

Install new oil seal and O-ring onto sliding pulley.

Apply with specified grease to lubricate the inside of sliding pulley.

O-ring

Install sliding pulley onto driven pulley.

Install guide pin and guide pin roller.

Install socket.

Install driven pulley, spring and clutch into clutch spring compressor, and press down the assembly by turning manual lever until mounting nut that can be installed.

Hold the compressor by bench vise and tighten the mounting nut to specified torque with clutch nut wrench.

Remove the clutch spring compressor.

Torque value: 5.0~6.0 kgf-m

Install clutch/driven pulley and drive belt onto drive shaft.

Sliding pulley

O-ring

Mounting nut

Oil seal

Guide pin

7-14

Specified grease

Guide pin or

Guide pin roller

Socket

Clutch nut wrench

Clutch spring compressor

Home page

Maintenance Information ················· 8-2

Troubleshooting ······························· 8-2

Disassembly of Final Driving

Mechanism········································ 8-3

Contents

8. FINAL DRIVING MECHANISM

Inspection of Final Driving Mechanism

···························································· 8-4

Bearing Replacement ······················· 8-4

Re-Assembly of Final Driving

Mechanism ········································ 8-4

8

8-1




Limited usage of gear oil：gear oil #140

Recommended oil：Bramax serial oil.

Oil quantity：120 c.c. (110 c.c. as replacement)

Special tools:

Inner type bearing puller (SYM-6204020)

Outer type bearing puller (SYM-6204010)

Final shaft oil seal installer (SYM-9125500)

Drive shaft oil seal installer (SYM-9120200)

Bearing driver 6204 (SYM-9110400)


Bearing driver 6203/6004UZ (SYM-9620000)

L. crank puller (SYM-1130000-L)

L. crank shaft install bush (SYM-1130010)

Troubleshooting

Trouble Diagnosis

Engine can be started but scooter can not be moved.

1. Damaged drive gear

2. Burnt out or seized drive gear

Noise

1. Seized, worn or damage gear

2. Worn or loose bearing

Gear oil leaks

1. Excessive gear oil.

2. Worn or damage oil seal

8-2


Disassembly of Final Driving

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.

Remove final gear, final shaft and counter gear, counter shaft.

Remove the drive shaft from left crankcase.

Caution y The bearing must be replaced when removing the drive shaft.

Remove drive shaft oil seal and bearing from left crankcase.


Final gear & shaft

Oil filling hole

Drive shaft

Bearing

Oil seal

Oil draining hole

Counter gear & shaft

8-3



Inspection Of Final Driving

Mechanism

Check if the drive shaft, counter shaft and final gear shaft are worn or damage.

Check if the gear box cover bearing, oil seal and the inner diameter of counter shaft are worn or damage.

Check if the left crankcase cover bearing, oil seal and the inner diameter of countershaft are worn or damage.

Bearing Replacement

Countershaft

Drive shaft

Final driven gear & shaft

Caution y Never install used bearings. Once bearing removed, it has to be replaced with new one.

Remove gear box bearing from left crankcase and gear box cover using following tools:

Special tool:

Inner type bearing puller

Re-Assembly Of Final Driving

Mechanism

Re-assemble the gearbox cover and left crankcase with special tools:

Special tool:

Gear Box Cover

Final shaft bearing:



Final shaft oil seal installer (SYM-9125500)

Left Crankcase

Drive shaft bearing:



L. crank puller (SYM-1130000-L)

L. crank shaft install bush (SYM-1130010)

Drive shaft oil seal installer (SYM-9120200)

With the special service tools to install drive shaft by through the bearing.

Install a new drive shaft oil seal.

Install a new final shaft oil seal.

Adapter

Driver

Punch guide

Drive shaft

8-4


Install countershaft, final driven gear and thrust washer.

Install new gasket and lock pin.

Install gearbox cover.

Install clutch/driven pulley assembly.

Install driven pulley, drive belt, and left crankcase side cover.

Install body cover.

Install rear wheel.

Fill out specified oil quantity into gearbox.


Final driven gear & shaft

Counter gear & shaft

8-5



Notes:

8-6

Home page

Contents

CRANKCASE/CRANKSHAFT

Maintenance Information····················9-2

Troubleshooting··································9-2

Crankcase Disassembly ·····················9-3

1.0 kgf-m

Crankshaft Removal ···························· 9-3

Crankshaft Inspection ························· 9-4

Crankcase Installation························· 9-5

Apply liquid gasket

9

9-1


9. CRANKCASE/CRANKSHAFT


z z z z

This chapter concerns disassembly of the crankcase for repair purpose.

Before disassembling crankcase, except removing engine firstly, following components must be removed too.

•

•

•

•

•

•

Carburetor (chapter 10)

Oil pump (chapter 3)

Reed valve (chapter 10)

Driving belt (chapter 7)

Alternator (chapter 6)

Cylinder head/cylinder/piston (chapter 5)

Except above components are needed be removed, when disassembling L crankcase, following components must be removed too.

• Final driving mechanism (chapter 8)

When assembling both crankcase and crankshaft, it has press the inner ring edge of the crankshaft bearing to push the crankshaft into the crankcase hole by using the specified service tools. The old bearing onto the crankshaft has to be removed. Then install a new bearing onto the crankshaft on the crankcase side. Oil seal has to be replaced with new one after assembled the crankcase.

─

─

─

─

0.60

0.04

0.10

0.10

Lateral clearance of the big end of the connecting rod

Radial clearance of the big end of the connecting rod

Crankshaft run-out point A

Crankshaft run-out point B

Special Tools

Crankcase disassemble tool (SYM-1120100-G5)

Outer bearing puller (SYM-6204010)

R. Crank shaft puller (SYM-1130000-R)

R. Crank shaft install bush (SYM-1130020)

L. Crank shaft puller (SYM-1130000-L)

L. Crank shaft install bush (SYM-1130010)

20*32*6 Oil seal driver (SYM-9120200)


Troubleshooting

Engine noise

1. Worn bearing of connecting rod bog end

2. Bend connecting rod

3. Worn crankshaft bearing

9-2



Crankcase Disassembly

Remove the crankcase bolts.

Install the crankcase puller onto the right crankcase with two (2) bolts, 6mm, as the diagram shown.

Disassemble the right crankcase.

Crankshaft Removal

As the diagram show with 3 special bolts to install the specified service tool onto the left crankcase.

Remove the crankcase.

Caution

Do not use iron hammer to knock out the crankshaft.

Remove crankshaft bearing with bearing puller.

Remove the right and left side oil seals.

Caution

Replace the oil seal with new one as removing the crankshaft.

Right crankcase

Shaft protection collar

Bolts

Crankcase puller

Crankcase puller

Left crankcase

Outer bearing puller

9-3



Crankshaft Inspection

Measure the clearance of connecting rod big end.


Measure the radial clearance of connecting rod big end at X-Y directions as diagram show.


Place the crankshaft on a V-block, measure run-out points A and B of the crankshaft with dial gauge.

Service limit: A: 0.10 mm

B: 0.10 mm

Check the crankshaft bearing by means of turning it with hand. If any noise and bigger clearance are detected, replace the bearing with new one.

A

70mm

Clearance

37mm

B

Clearance

Lateral Radial

9-4



Crankcase Installation

Clean the crankshaft with solvent and blow it with compressed air. Then, check for damage or other foreign materials attached.

Install new bearing into right crankcase.

Caution y All rotation and sliding surfaces have to be applied with clean engine oil. y Remove all gaskets onto the crankcase interfaces and flat it with special tool.

Install new bearing into left crankcase.

Install crankshaft onto the left crankcase.

Install left crankshaft puller and install bush onto crankshaft.

Screw the left crankshaft puller onto crankshaft.

Turn the puller in C.W. direction and then completely screw the puller to bottom.

Lubricate crankshaft bearing and bearing seat with 2-stroke engine oil.

Apply liquid gasket and dowel pin onto the interface of left crankcase.

Bearing driver 6204

Bearing driver 6204

Collar

L. Crank shaft puller

L. Crank shaft install bush

Apply liquid gasket

Dowel pin

9-5



Assemble the right crankcase with assembly tools.

Install right crankcase onto the crankshaft.

Install right crankshaft puller and install bush onto crankshaft.

Screw the right crankshaft puller onto crankshaft.

Turn the puller in C.W. direction and then completely screw the puller to bottom.

Lubricate crankshaft bearing and bearing seat with 2-stroke engine oil.

Install the bolts and tighten them.


With right crank shaft install bush, install new oil seal into the right crankcase. Its installation depth is 4mm as the diagram shown.

With the specified tool to install a new oil seal onto the left crankcase to the depth of 1 mm as the diagram shown.

Caution

Make sure that the crankshaft can be rotated freely after tightening the bolts.

Install the following components:

~ Final driving mechanism (chapter 8)

~ Alternator (chapter 6)

~ Piston/cylinder/cylinder head (chapter 7)

~ Oil pump (chapter 3)

~ Reed valve and carburetor (chapter 10)

~ Engine (chapter 4)

9-6

Oil seal

R. Crank shaft puller

R. Crank shaft install bush

Bolts

R. Crank shaft install bush

Oil seal driver

Home page



Throttle Valve ···································· 10-3

Carburetor Remove ·························· 10-4

Auto By-Starter ································· 10-4

Float/Float Valve/Jet ························· 10-6

Contents

10. FUEL SYSTEM

Flaot Level Inspection ······················10-7

Carburetor Installation ·····················10-7

Reed Valve ········································10-7

Fuel Pump ·········································10-8

Air Cleaner ········································10-9

Throttle valve cable

Air hose

Oil tube

Vacuum hose

10

Carburetor

Fuel cap

Fuel pump

Fuel unit

Fuel tank

Fuel filter

Vacuum tube

10-1


10. FUEL SYSTEM


Precautions in Operations

Warning

Gasoline is a highly flammable material and may explosive under circumstance. Thus, always work in a well-ventilated place and strictly prohibit flame when working with gasoline. y Care must be taken when dealing with gasoline, and always work in a well-ventilated place and strictly prohibit flame. y When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly y It has to conduct air bleeding operation as removed the oil tube. y Idle speed adjustment.

Specification

Item

Venturi diameter

Fuel level

Air screw opener

Idle speed

Throttle handle free play

JET 50

15 mm

JET 100

16 mm

2000±100 rpm

8.8±1.0mm

1 3/8

2100±100 rpm

2~6 mm

Troubleshooting

Engine can not be started

1. No fuel in fuel tank

2. Fuel can not reach to carburetor

3. Too much fuel in cylinder

4. Clogged air cleaner

Stall after started

1. Incorrect idle speed adjustment

2. No spark on the spark plug

3. Low compression pressure

4. Rich mixture

5. Lean mixture

6. Clogged air cleaner

7. Inlet pipe leaking

8. Polluted fuel

Lean Mixture

1. Clogged carburetor jet

2. Clogged hose from carburetor to canister

3. Bend, squeezed or clogged fuel lines

4. Clogged fuel filter

5. Malfunction of float valve

6. Low fuel level in float chamber

7. Clogged vent pipe

8. Malfunction of fuel pump

Rich Mixture

1. Malfunction of float valve

2. Low fuel level in float chamber

3. Clogged carburetor air injector

10-2


Throttle Valve

Removal


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.

Carburetor upper part

Oil hose

10. FUEL SYSTEM

Inspection

Throttle valve spring

Sealed cap

Throttle valve cable


Needle clamp

Fuel needle clip

Fuel needle

Washer

Installation

Throttle valve

Place the fuel needle onto the throttle valve and clip it with needle clamp.

Install the sealed cap, carburetor upper part, and throttle valve spring.

Connect the throttle valve cable to the throttle valve.

Install the throttle valve into the carburetor body.

Caution

Align the groove inside the throttle valve with the throttle stopper screw of the carburetor body.

Tighten the carburetor upper part.

Install carburetor protector.

Adjust the free play of throttle valve cable.

10-3


10. FUEL SYSTEM

Carburetor Remove


Disconnect the auto by-starter connector.

Loosen draining screw and then drain out fuel inside the carburetor.

Loosen carburetor upper part and remove carburetor upper part.

Remove fuel and oil hoses from carburetor.

Remove carburetor mounting bolt and carburetor.

Auto By-Starter

Inspection

Connect resistor meter to the terminals of auto by-starter, and then measure its resistance.

If the resistance value exceeds specification too much, it means that the PTC in the auto by-starter is malfunction. Then, replace the auto by-starter.

Resistance value: Max. 10Ω(at cold engine)

Caution

If the resistance value exceeds the standard a little bit, the auto by-starter may still in normal.

However, it is necessary to check other relative components for damage.

Bolt

Fuel hose

Draining screw

Auto by-starter

Auto by-starter


Connection hose clamp

10-4


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.

Pump compressed air into the fuel rich circuit.

Air should not flow into the circuit.

If air flow through the circuit, then, replace the starter.

Check resistor to make sure that the auto by-starter is in normal. Engine is running.

If the resistor is in open-circuit, then current will not flow into the PTC. Thus, the auto by-starter is not operated.

However, if the resistor is in short-circuit, current higher than specification will flow into the PTC.

Then, it will cause the fuel rich circuit close rapidly, and difficult to start the scooter.

Resistance value: 10.2Ω

Automatci By-Starter


Remove the cover of the auto by-starter.

Remove screw and mounting plate.

Remove the auto by-starter from carburetor.


Alternator

Auto by-starter

10. FUEL SYSTEM

Battery

Resistor

Screw

Mounting plate

10-5


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 installation.

Caution

Do not tighten the screw forcedly to avoid to damaging the valve seat.

Remove main jet, needle jet seat and idle jet and clean them and each component with compressed air.

Installation

Install the idle jet, the needle jet seat and main jet. Then install the throttle valve stopper and air screws to their original position according to the marks as removal. Adjust the screws if replace with new ones.

Float cap

Air inlet for idle speed

Air inlet for fuel rich circuit

Air screw

Float

Float valve

Float pin

Throttle valve stopper screw

Idle jet

Needle jet

Needle jet seat

O-ring

Float cap

Main jet

Screw

Draining screw

10-6


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 Installation

Caution

Do not let foreign materials into the carburetor.

Install the carburetor and insulator onto intake pipe with bolts.

Install fuel and vent pipes onto carburetor.

Install the carburetor upper part.

Tighten the connection hose.

Tighten the draining screw.

Connect the automatic by-starter connector.

Install air cleaner cap.

Conduct following operations y Adjustment of throttle valve cable. y Adjustment of oil pump. y Adjustment of idle speed.

Reed Valve

Removal


Remove the carburetor.

Remove carburetor insulator.

Remove inlet pipe.

Remove the reed valve.

Bolt

Fuel hose

Draining screw

10. FUEL SYSTEM

Inlet pipe


Connection hose clamp

Reed valve

10-7


10. FUEL SYSTEM

Inspection

Check the reed valve for damage and its reed strength.

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.

Otherwise, it will cause its strength insufficient and rough engine running. If the reed valve or its seat is damaged, replace with a set.

Installation


Check for leaking after installed.

Fuel Pump

Inspection


Warm up the engine and adjust idle speed.

Remove fuel hose from carburetor and then wait for 5 minutes.

Measure the output of fuel pump. Its output time is 10 seconds.

Output quantity: Min. 20 c.c.

If the output quantity is lower than 20 c.c., check fuel hose, vacuum hose and fuel filter.


Remove floor plate.

Remove fuel inlet, outlet and vacuum hoses.

Remove 2 bolts and fuel pump.

Install the fuel pump in the reverse order of removal procedures.

Reed valve

Reed valve seat

Fuel hose

Carburetor

Bolt

Fuel inlet hose

Reed stopper

Fuel hose connector

Fuel outlet hose

Vacuum hose

10-8


Air Cleaner


Loosen connection hose clamp.

Remove 2 bolts and then remove the air cleaner.


Bolts

10. FUEL SYSTEM

Hose clamp

10-9

10. FUEL SYSTEM

Notes:


10-10

Home page

Front Disc Brake System ···············11-1

Rear Drum Brake System ··············11-2

Maintenance Information ···············11-3

Troubleshooting ·····························11-4

Hydraulic Disc Brake······················11-5

Front Disc Brake System

Contents

11. BRAKE SYSTEM

Disc Brake -Air Bleed······················· 11-6

Disc Brake - Caliper ························· 11-6

Brake Disc········································· 11-7

Disc Brake - Master Cylinder··········· 11-7

Drum Brake······································· 11-10

2.5 kgf-m

0.55 kgf-m

3.5 kgf-m

11

1.8 kgf-m

1.0 kgf-m

4.5 kgf-m

6.0 kgf-m

11-1

11-2


Rear Drum Brake System

11.0 kgf-m

2.5 kgf-m


0.55 kgf-m



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.

y The brake caliper can be removed without removing the hydraulic system. y After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic system. y While refilling brake fluid, care should be taken not to let the foreign material entering into the brake system. y Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage. y Check the operation of the brake system before you go.

Specifications

Item Standard (mm) Limit (mm)

The thickness of front brake disc

Front brake disc run-out

Master cylinder inner diameter

Master cylinder piston outer diameter

ID of rear brake drum

Thickness of front brake lining

Thickness of rear brake lining

Torque values

Brake hose bolt

Bolt for brake caliper

Bolts for the lining guide pin

Bolts for the lining guide pin cap

Air-bleed valve

Bolts for the brake disc

Nuts for the wheel rim

Nuts for the front wheel

Nuts for the rear wheel

Bolt for rear brake arm

3.5

< 0.10

12.700 – 12.743

12.657 – 12.684

110.0

4.0

4.0

3.5 kgf-m

3.3 kgf-m

1.8 kgf-m

1.0 kgf-m

0.55 kgf-m

4.5 kgf-m

2.5 kgf-m

6.0 kgf-m

11.0 kgf-m

0.55 kgf-m

2.0

0.3

12.55

12.654

110.5

2.0

2.0

11-3



Troubleshooting

Disc Brake

Soft brake lever

1. Air inside the hydraulic system

2. Hydraulic system leaking

3. Worn master piston

4. Worn brake pad

5. Poor brake caliper

6. Worn brake lining/disc

7. Low brake fluid

8. Blocked brake pipe

9. Warp/bent brake disc

10. Bent brake lever

Hard operation of brake lever

1. Blocked brake system

2. Poor brake caliper

3. Blocked brake pipe cylinder piston

5. Bent brake lever

Uneven brake

1. Dirty brake lining/disc

2. Poor wheel alignment

3. Clogged brake hose

4. Deformed or warped brake disc

5. Restricted brake hose and fittings

Drum Brake

Poor brake performance

1. Improper brake adjustment

2. Worn brake lining

3. Worn brake drum

4. Worn brake cam

5. Improper brake lining installation

6. Seized brake cable

7. Dirty brake lining

8. Dirty brake drum

9. Brake pad worn in brake cam area.

10. Poor contact between brake arm and camshaft indent

Tight operation or low return speed of brake lever

1. Worn/broken/crack return spring

2. Worn drum


4. Brake seized caused from dirty brake drum

5. Seized brake cable

6. Worn brake cam

7. Improper brake lining installation

Tight brake

1. Dirty brake lining/disc

2. Poor wheel alignment

3. Deformed or warped brake disc

Brake noise

1. Dirty lining

2. Deformed brake disc

3. Poor brake caliper installation

4. Imbalance brake disc or wheel

Brake noise

1. Worn brake lining

2. Worn drum


4. Dirty brake drum

11-4


Hydraulic Disc Brake

Close the drain valve of the hydraulic disc brake.

Replace the brake fluid.

Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, then remove the brake fluid reservoir.

Cover the painted surfaces, plastic or rubber components with a rag when servicing brake system.

Caution

Spilled brake fluid on painted surfaces, plastic or rubber components may result in their damages.

Remove the master cylinder cap and diaphragm.

Use brake fluid to clean the dirty brake disc.

Caution

The dirty brake lining or disc will reduce the brake performance.

Refill up same grade brake fluid into the reservoir.

Caution

To mixed non-compatible brake fluid will reduce brake performance. Foreign materials will block the system causing brake performance to be reduced or totally lost.

Connect drain hose to drain valve.

Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out. Close the drain valve and add specified brake fluid into the brake master cylinder.

Recommended brake fluid: WELLRUN DOT 3 brake fluid

Caution

To reuse the spent brake fluid will effect brake performance.

Lower level

Air bubble


Drain valve

Cap

Cap plate

Diaphragm

Upper level

Drain hose

Connect one end of transparent hose to the drain valve, and put the other end into a container.

Open the drain valve around 1/4 turns, and at the same time hold the brake lever until the there is no air bubble in the drain hose and also feeling resistance on the brake lever.

Close the drain valve when finishing the brake system refilling fluid procedure, and operate the brake lever to check whether air bubble is in brake system or not. If brake is still soft, please bleed the system as described below.

11-5



Disc Brake -Air Bleed

1. Tightly hold the brake lever and open the drain valve around 1/4 turns, and then close the valve.

Caution y Do not release the brake lever before the drain valve is closed. y Always check the brake fluid level when carrying out the air bleeding procedure to avoid air enter into the system.

2. Slowly release the brake lever, and wait for a few seconds until it reaches its top position.

3. Repeat the steps 1 and 2 until there is no air bubble at the end of the hose.

4. Tightly close the drain valve.

5. Make sure the brake fluid is in the UPPER level of the master cylinder, and refill the fluid if necessary.

6. Cover the cap.

Air bubble

Caliper bolt

Collar bolt

Disc Brake - Caliper

Removal

Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hoses.

Caution

Do not spill brake fluid on painted surfaces.

Remove the bolt cap and loosen the lining guide bolts.

Remove two caliper bolts and the caliper.

Drain valve

Drain hose

Brake hose bolt

Installation

Install the brake caliper and tighten the attaching bolts securely.

Torque: 3.3 kgf-m

Caution y Use M8 x 35 mm flange bolt only. y Long bolt will impair the operation of brake disc.

Tighten the lining guide bolt.


Install bolt cap.


Use two seal washers and hose bolts to lock the hose and brake caliper in place.


Refill up the brake fluid to the reservoir and make necessary air bleeding.

11-6


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

Remove the brake disc from wheel.

Check the disc for deformation and bend.


Disc Brake - Master Cylinder

Master Cylinder Removal

Caution

Do not let foreign materials enter into the cylinder.

Caution

The whole set of master cylinder, piston, spring, diaphragm and cir clip should be replaced as a set.

Remove the front and rear handlebar guards.

Remove the leads of brake lamp switch.

Drain out the brake fluid.

Remove the brake lever from the brake master cylinder.

Remove the brake hose.

Remove the master cylinder seat and the master cylinder.

Remove the rubber pad.

Remove the cir clip.

Remove the piston and the spring.

Clean the master cylinder with recommended brake fluid.

Brake disc

Rubber pad

Piston

Spring


Brake hose

Clip

Micrometer

Master cylinder

Master cylinder

11-7



Master Cylinder Inspection

Check the master cylinder for damage or scratch.


Measure the cylinder inner diameter at several points along both X and Y directions.

Replace the cylinder if the measured values exceed allowable limit.


Measure the outer diameter of the piston.

Replace the piston if its measured value exceeds allowable limit.


Master Cylinder Assembly

Caution y It is necessary to replace the whole set comprising piston, spring, piston cup, and cir clip. y Make sure there is no dust on all components before assembling.

Apply clean brake fluid to the piston cup, and then install the cup onto the piston.

Install the larger end of the spring onto the master cylinder.

The master cup’s cavity should be face inside of master cylinder when installing the master cup.

Install the cir clip.

Caution y Never install cup lip in the opposite direction. y Make sure the cir clip is seated securely in the groove.

Install the rubber pad into groove properly.

Master cylinder

Piston

Rubber bush

Cir clip

Piston

Sub-cup

Sub-cup

Spring

Cylinder gauge

Micrometer

Master cylinder

11-8


Install the rubber pad into the groove correctly.

Place the master cylinder onto handlebar, and install the bolts.

Install the brake lever, and connect leads to brake lamp switch.

Connect brake hoses with 2 new washers.

Tighten the brake hose bolt to the specified torque value.

Make sure the hose is installed correctly.

Install all wires, hoses, and components carefully so avoid to twisting them together.

Caution

Improper routing may damage leads, hoses or pipes.

Caution

Kink of brake leads, hose or pipe may reduce brake performance.

Add specified brake fluid and bleed the system.

Master cylinder

Washers

Hose bolt


Brake lamp switch

Brake hose

11-9



Rear Drum Brake

To use vacuum cleaner or other alternatives to avoid danger caused from dusts.

Caution y Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use compressed air or dry brush to clean brake parts. y Brake performance will be reduced by grease on brake lining.

Remove wheel and brake drum.

Inspection

Check brake drum for damage or wear out, and replace it if necessary.

Measure the inner diameter of brake drum and record the max. value.

Allowable limit: rear (110.5mm)

Caution y Clean the rust onto the brake drum with

#120 sand-paper. y Measure the inner diameter of brake drum with micrometer.

Measure the thickness of brake lining at three points (both ends and center).

If the thickness is less than specified value or if it is contaminated by oil or grease, replace as a set.

Service limit: Rear: 2.0 mm

Removal

Rear brake drum

Brake lining

Caution

Brake linings must be replaced as a shoes.

Remove the brake linings from brake panel. Brake shoes

Brake shoe spring

11-10


Installation

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.

Caution

Brake efficiency will be reduced if brake linings is contaminated by oil or grease.

Install the brake cam and arm after aligning it with the punched point.

Tighten the bolts and nuts to specified torque:

Torque value: 0.4-0.7 kgf-m

Use a brake cleaner to clean brake hub and replace the two brake shoes if brake linings are contaminated.

Caution

Brake efficiency will be reduced if brake linings is contaminated by oil or grease.

Install spring onto the brake shoes.

Install the brake shoes to the brake panel one after one, and make sure the shoe springs are in correct position.

Install the wheel.

Brake shoes

Bolt


Brake arm

Bolt

Rear brake arm

Brake arm big indent

Wear indicator plate



Brake shoes

11-11


Notes:


11-12

Home page

Body Overview ······························· 12-1

Maintenance Information ··············· 12-2

Side Covers····································· 12-3

Luggage Box··································· 12-3

Body Cover ····································· 12-4

Front Cover ····································· 12-6

Body Overview

Contents

Seat

12. BODY COVER

Front Under Spoiler ························ 12-7

Front Inner Box······························· 12-8

Floor Panel ······································ 12-9

Front Fender ··································· 12-9

Steering Handle Cover ··················· 12-10

Under Cover ···································· 12-11

Floor mat

Battery cover

Luggage box

Battery case

Rear fender

Handle front cover

Front cover

Handle rear cover

Right body cover

Rear mudguard

12

Right side cover

Plug maint. cover

Fuel lid

Center cover

Floor panel

Rear center cover

Left body cover

Left side cover

Front inner cover

Front fender

Front under spoiler

Under cover

12-1


12. BODY COVER


Body covers disassemble sequence:

Handlebar Front Cover

Handlebar Rear Cover

Front Cover

Front Spoiler

Luggage Box/Seat

Center Cover

Front Fender Front InnerCover Left/Right Side Cover

Rear Mudguard

Body Cover

Rear Fender

Floor Panel

Under Cover y Be careful not to damage various covers in disassembly or re-assembly operation. y Never injure hooks molded on the body covers in disassembly or re-assembly operation. y Align the buckles on the guards with slot on the covers. y Make sure that each hook is properly installed during the assembly. y Never compact forcefully or hammer the guard and the covers during assembly.

12-2


Side Covers

1. Removal: y Remove 3 screw (front/middle) from two side covers. y Slide the side cover backward so that their hooks are out of slots. y Take out the side cover end part and then remove the cover.

2. Installation: y Install in reverse order of removal procedures.

Caution

The tail of each cover is held with buckles and slot, never pull them with force, or it would crack the buckles.

Luggage Box

1. Removal: y Lift up seat cushion. y Remove battery compartment screw and cover. y Remove luggage box mounting screws

(1 screw). y Remove luggage box nut (2 nuts) y Remove luggage box bolt (1 bolt) y Remove oil tank cap and oil guide rubber. y Hold the luggage box in both front and rear sides by two hands, and then lift up the box to remove it.


Screw

12. BODY COVER

Screws

Nut

Bolt

12-3


12. BODY COVER

Body Cover

1. Removal: y Remove 4 bolts from rear carrier, and then remove rear carrier. y Remove 1 screw and 2 nuts and 1bolt from luggage box, and then remove luggage box. z Remove 3 screws from the tail cover,.and then remove the tail cover.

Remove 2 screws astern of the body cover

Bolts

12-4

Screws


Remove 2 screw form of the body cover



12. BODY COVER

Bolts

12-5


12. BODY COVER

Front Cover

1. Removal: y Remove 2 bolts from the front side reflector, and then remove front side reflector. y Remove 2 screws from the front inner box and front cover. y Remove 1 screw from the front cover. y Remove electric cord coupler from the head light. y Remove the front cover.

2. Installation y Install in reverse order of removal procedures.

Screws

12-6

Screws

Screws


Front Under Spoiler

1. Removal: y Remove right and left side cover. (6 screws) y Remove 4 screws from the front inner box. y Remove 2 screws from the front upper part of the front spoiler and the front inner box. y Remove the front spoiler.


12. BODY COVER

Screws

Screws

Screw

12-7


12. BODY COVER

Front Inner Box

1. Removal: y Remove the front cover. y Remove the front under spoiler. y Remove hook and 1 screw. y Remove key set cover. y Remove 2 bolts from the floor panel. y Remove the front inner box.


Hook & 1 screw

Key set cover

Bolts

12-8


Floor Panel

1. Removal: y Remove 6 screws and the side cover. y Remove 6 screws and the body cover. y Remove the floor panel. (4 bolts)


Front Fender

Removal: y Ramoval 1 bolt and fr brake hose clamp. y Ramoval 2 screws form front fender right and left side. y Ramoval front fender.

Screws

12. BODY COVER

Bolts

Bolt

Screws

12-9


12. BODY COVER

Steering Handle Cover

1. Removal: y Remove 6 screws from the handle rear cover. y Remove handle front cover. y Remove front winker electric cord coupler y Remove 1 screw from rear side by handle rear cover. y Remove 2 inner screws. y Disconnect each switch connectors. y Remove speedometer cable. y Remove handle rear cover.


Caution

Push the front connection part of rear handle cover at first when removing front cover so that the buckles are out of the cover. Never push it forcefully to cause buckles broken or cover damaged.

12-10

Screw

Electric cord coupler

Speedometer cable 2 Screws

Screws


Under Cover

1. Removal: y Remove 2 bolts from the under cover. y Remove under cover.


2 bolts

12. BODY COVER

2 nuts

12-11

12. BODY COVER

Note:


12-12

Home page

Contents

13. STEERING/FRONT WHEEL/SUSPENSION



Steering Handle ································ 13-3

Front Wheel ······································· 13-4

Front Shock Absorber ······················ 13-8

Front Fork·········································· 13-9

1.5 kgf-m

0.25 kgf-m

4.5 kgf-m

3.3 kgf-m

13

2.7 kgf-m

6.0 kgf-m

13-1




Specification

Item

Shaft bending

Standard value (mm)

─

Limit (mm)

0.2 (0.01 in)

Radial ─

─

2.0 (0.08 in)

Rim wobbling

Axial 2.0 (0.08 in)

Torque Value

Steering handle nut

Front wheel axle

4.5 kgf-m Front brake caliper bolt

6.0 kgf-m Steering stem mounting nut

3.3 kgf-m

1.5 kgf-m

Front shock absorber mounting nut 2.7 kgf-m Top cone race

Special Tools

Inner bearing puller

Bearing driver

Troubleshooting

Hard To Steer

1. The steering shaft bolt is too tight.

2. The steering shaft bearing are damaged

3. The ball and the top cone of the steering shaft are damaged.

4. Insufficient tire pressure.

The Steering Handle Is Tilted

1. Uneven arrangement of the front shock absorbers.

2. The front fork is bent.

3. The front wheel axle is bent.

0.25 kgf-m

The Front Wheel Wobbling

1. The rim is bent.

2. The wheel axle nut is not tightened improperly

3. Bend wheel rim

4. Side-worn or poor tire.

5. The bearing play of the wheel axle is too large.

Soft Shock Absorber

1. Weak front shock absorber spring

Noise In Front Shock Absorber

1. Shock absorber outer tube noise

2. The joint of the shock absorber gets loose.

13-2



Master cylinder

Steering Handle

Removal

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 removed.

Remove handle mounting bolt and nut, and then remove the handle.

Installation

Install handle and align with bolt hole.

Install bolt and nut and then tighten it.


Apply with grease onto throttle cable and the sliding surface of handle.

Align the lock pin of the handle outer tube with the hole on the handle, and then install the handle.

Tighten the bolt.

Rear brake lever seat

Nut

Bolt

Caution

Align the lock pin with the hole on the handle and also install brake lever seat. Then, tighten the lever with clamp and bolt.

13-3



Place master cylinder onto handle and align its 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.

Conduct following adjustment: y Oil pump control cable.

Master cylinder

Brake lever free play

Front Wheel

Removal

Remove speedometer cable from speedometer gear box.

Remove front wheel axle nut, and then pull out the axle and remove the wheel.


Axle nut

Bolt

13-4



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.


Place the wheel on to a rotation seat, and turn the wheel to check its bearing free play. If the bearing is noisy or its free play is too much, replace it.

Place the wheel on to a rotation seat to check its rim wobbling. Turn the wheel with hand and measure its rim wobbling value with a dial gauge.

Service limit:

Radial: 2.0 mm (0.08 in)

Axial: 2.0 mm (0.08 in)

Remove 5 bolts and brake disc.

Free play

Bolts

Wheel axle

Free play

13-5



Remove dust seal, bearing and side collar.

Special tools

Inner bearing puller (SYM-6204020)

Installation

Fill out the block of bearing by grease.

Drive the left bearing and install the dist. collar.

Install the right bearing.

Caution y Carefully install the bearing in correct and evenly. y Bearing outer face should be faced up as bearing installation.

Install the brake disc and then tighten the bolts

(disc brake).


Dust seal

Bolts

Dist. collar

Dust seal

Bearing

13-6



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.

Apply with grease onto the dust seal.

Install the dust seal and side collar.

Place the front wheel between the front shock absorbers.

Caution

Align the brake disc groove with the stopper flange.

Insert the wheel axle into the wheel and the install the wheel axle nut.

Tighten the nut to specified torque.


Connect the speedometer cable to the speedometer gear.

Front fork groove

Stopper

Shaft nut Speedometer cable

13-7



Front Shock Absorber

Removal y Front under spoiler

Disc Brake

Remove the caliper mounting bolt and the caliper.

Take out the hose from hose clamp.

Remove the front shock absorber upper bolt and the shock absorber.

Installation

Align the cover flange with upper level of the shock absorber clamp, and then tighten bolts.


Install the removed components in reverse order of removal procedures.

Bolts

Shock absorber

Bolts

Hose clamp

Brake caliper

13-8


Front Fork

Removal y Handle y Front wheel y Front shock absorber

Remove the steering stem mounting nut.

Remove top cone race and front fork.


Steering stem mounting nut

Caution

Place the steel ball onto a parts container to prevent from missing.

Slightly tap the top and bottom ball bearing seats with a plastic hammer to remove the seats.

Remove bottom cone race body with a punch.

Caution

Do not damage the steering stem.

Installation

Install a new bottom cone race onto the steering stem.

Push the cone race until to mounted position.

Caution

Do not tilt the ball bearing seats as installation.

Apply with grease onto the ball bearing seats, and install steel balls onto the seats.

(Top: 26 balls, bottom: 29 balls)

Lubricate the top cone race seat with grease.

Screw the cone race in to top ball bearing seat till touching, and then screw out the cane race

1/4~3/8 turns.


Caution

Check the steering stem that should be rotated freely and no clearance in vertical direction.


Top cone race

Steering lock nut

Top cone-race

Top ball bearing seat

Bottom ball bearing seat

Top cone race

Steel balls

Bottom cone race

Return 1/2 turns

Locking to

1/4~3/8 turns

13-9



Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body.


Install in reverse order of removal procedures.


Top cone race

13-10

Home page



Contents

14. REAR WHEEL/SUSPENSION

Rear Wheel ······································· 14-3

Rear Shock Absorber ······················ 14-4

2.7 kgf-m

4.0 kgf-m

11.0 kgf-m

3.3 kgf-m

14

14-1




Specification

Item

Rear wheel rim run out

Standard value (mm)

-

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

Exhaust muffler bolt: 3.3 kgf-m

Troubleshooting

Rear wheel wobbling

1. bend wheel rim

3. loosen wheel shaft

Shock absorber too soft

1. insufficient shock absorber spring force

Poor brake performance

1. Poor brake adjustment

2. contaminated brake lining

3. worn brake lining cam

4. worn brake cam lever

5. worn brake drum

6. improper installation of brake arm gear set.

Limit (mm)

2.0 (0.08 in)

14-2



Rear Wheel

Remove

Remove exhaust pipe nut. (2 connection nuts)

Remove exhaust muffler bolt (3 bolts), then remove the muffler.

Remove rear wheel shaft nut and then remove the rear wheel.

Inspection

As the diagram shown, measure wheel rim wobbling with a dial gauge.

Service limit:

Radial: 2.0 mm (0.08 in)

Axial: 2.0 mm (0.08 in)

Bolts

Muffler

Connection nuts

Shaft nut

14-3



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.


Installation

Install the rear wheel and tighten the nut.


Install exhaust pipe & muffler.

Tighten torque (bolt): 3.3 kgf-m

Tighten torque (nut): 1.2 kgf-m


Rear Shock Absorber

Removal

Remove body cover.

Remove rear shock absorber upper & lower bolts.

Remove rear shock absorber.

Installation

Install the rear shock absorber.

Tighten the upper & lower mounting bolts to specified torque.

Torque value:

Upper mounting bolt: 4.0 kgf-m

Lower mounting bolt: 2.7 kgf-m

Press down the tail of the scooter for several times to check shock absorber operation.

Installation all components in reverse order of removal procedures.

14-4

Upper mounting bolt

Lower mounting bolt

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Maintenance Information ··············· 15-2

Troubleshooting ····························· 15-3

Battery············································· 15-4

Charging System···························· 15-5

Ignition System······························· 15-10

Starting System ······························ 15-13

Oil Level Switch······························ 15-15

Fuel Unit ·········································· 15-16

Switch/Horn ···································· 15-17

Bulb Replacement ·························· 15-19

Head Light Relay

(Jet Euro only)

Winker Relay

Head Light Control Unit

(Jet Euro only)

Clock

Horn / Winker /

Dimmer Switch

Fuel Unit

Resistor Comp

Headlight Fuse

(Jet Euro only)

Reg. Rec. Comp

Horn

Main Switch

Start / Headlight Switch

Spark Plug

IG. Coil

AC. Generator

15

Battery

Oil Level Switch

Fuse Box

Start Relay

CDI Unit

15-1


15. ELECTRICAL EQUIPMENT


Precautions in Operation y When remove the battery, the disconnection sequence of cable terminals shall be strictly observed.

(First disconnect the negative cable terminal, next, the positive cable terminal.) y The model of the spark plug and the tightening torque. y The ignition timing. y Adjustment of headlight. y Removal and installation of AC generator. y The maintenance-free battery requires no inspection of electrolyte level and refilling of distilled water. y To recharge the battery, remove the battery from the motorcycle without removing ventilation caps. y Unless in emergency, never rapid charge the battery. y The voltage must be checked with the voltmeter while charging the battery. y As C.D.I assembly does not require an ignition timing check. In case ignition timing is incorrect, check C.D.I and AC generator. Verify with an ignition timing light after replacement if necessary. y The starter motor can be removed after the engine is removed.

Specification

Charging System

Item Specification

Battery

Leak current

Charging current

Capacity 12V3Ah

Charging rate 0.4A / 5 hours (standard), 4A / 0.5 hour (fast charging)

Control voltage in charging

< 1 mA

1.2 A / 5000 rpm

14.0 - 15.0 V / 5000 rpm

Control voltage in headlight

Ignition System

Spark plug

12.6 - 13.6 V / 5000 rpm (JET 50/100)

Item Specification

Model

JET 50 series

NGK BR8HSA

(Recommended)

JET 100 series

NGK BR6HSA

(Recommended)

Gap 0.6 - 0.7 mm

Ignition coil and resistance

Ignition timing “F” mark

Primary coil

Secondary coil

0.19 – 0.23 Ω

2.8 – 3.4 K Ω

17 ° BTDC / 1800 rpm

15-2


Troubleshooting

No voltage y Battery y The cable disconnected y The fuse is blown y Improper operation of the main switch

Low voltage y The battery is not fully charged y contact y Poor charging system y Poor voltage regulator

No spark produced by spark plug y The spark plug is out of work y The cable is poorly connected, open or short-circuited

- Between AC.G. and C.D.I. y Poor connection between C.D.I. and ignition coil

- Poor connection between C.D.I. and the main switch y Poor main switch y Poor y AC.G. is out of work

Starter motor does not work y The fuse is blown y The battery is not fully charge y Poor main switch y Poor starter switch y The front and rear brake switches do not operate correctly y Starter relay is out of work y The ignition coil is poorly connected, open or short-circuited y The starter motor is out of work

Intermittent power supply y The connector of the charging system becomes loose y Poor connection of the battery cable y Poor connection or short-circuit of the discharging system y Poor connection or short-circuit of the power generation system

Charging system does not operate properly y Burnt y Poor contact, open or short circuit y Poor y Poor

Engine does not crank smoothly y Primary coil circuit

- Poor ignition coil

- Poor connection of cable and connectors

- Poor main switch y Secondary coil circuit

- Poor ignition coil

- Poor spark plug

- Poor ignition coil cable

- Current leakage in the spark plug cap y Incorrect ignition timing

- Poor AC.G.

- Improper installation of the pulse sensor

- Poor C.D.I.

Weak starter motor y Poor charging system y The battery is not fully charged y Poor connection in the windings y The motor gear is jammed by foreign material

Starter motor is working, but engine does not crank y Poor starter motor pinion y The starter motor run in reverse direction y Poor

15-3



Battery

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.

Voltage Check

Open seat and battery cover.

Remove wires from battery.

Check battery voltage.

Voltage:

Fully charged: 13.0 – 13.2V

Undercharged: 12 V

Charging

Remove the battery.

Connect the positive terminal (+) of the charger to the battery positive terminal (+).

Connect the negative terminal (-) of the charger to the battery negative terminal (-).

Standard charging current/time: 0.4A/5 hrs.

Fast charging current/hrs: 4A/0.5 hr.

Caution

Strictly keep flames and sparks away while recharging to avoid to explosion causing by hydrogen.

Stop charging battery when electrolyte temperature is over 45℃(117℉).

Caution

Fast charging the battery is for in emergency only. Battery should be charged in standard.

Negative terminal Positive terminal

15-4

Charging System

JET 50 / JET 100

White

Yellow


Green

Red

Green/

Black

Pink

AC. Generator

JET EURO 50 / JET EURO 100

Main Switch

Fuse 15A

Battery

Green

Black

Red

Regulator rectifier

Auto by- starter

Yellow

Yellow

Yellow

Green/

Black

Yellow

AC. Generator

15-5



Current Leakage Inspection

Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery.

Connect an ammeter between the negative cable terminal and the battery negative terminal.

Caution y In the current leakage test, set the current range at larger scale, then gradually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse. y Do not turn the main switch to ON position during test.

If the leaked current exceeds the specified value, it may indicate a short circuit.

Allowable current leakage: Less than 1 mA

Disconnect each cable one by one and take measurement of the current of each cable to locate the short circuit.

Ground circuit

Ammeter

Digital voltmeter

Battery (-) terminal

Ammeter

Fuse connector

Charging Voltage Inspection

Caution y Before conducting the inspection, be sure that the battery is fully charged. If undercharged, the current changes dramatically. y Use a fully charged battery having a voltage larger than 13.0 V y While starting the engine, the starter motor draws large amount of current from the battery.

After the engine is warmed up, replace original battery with a fully charged battery. Connect a digital voltmeter to the battery terminals.

Connect an ammeter between both ends of the main fuse.

Caution

When the probe is reversibly connected, use an ammeter having an indication that shows both positive and negative direction current.

The measurement would be at zero, if the ammeter is one direction only.

Caution y Do not use short-circuit cable. y It is possible to measure the current by connecting an ammeter between the battery positive terminal and the + cable position terminal, however, while the starter motor is activated, the surge current of the motor draws from the battery may damage the ammeter. Use the kick starter to start the engine. y The main switch shall be turned to OFF position during the process of inspection.

Never tamper with the ammeter and the cable while there is current flowing through.

It may damage the ammeter.

Connect a tachometer.

Turn on the headlight to high beam and start the engine.

Accelerate the engine to the specified revolution per minute and measure the charging voltage.

Specified Charging Current: 1.2 A / 5000 rpm

Control Charging Voltage: 14.0~15.0 V / 5000 rpm

15-6


Caution

To replace the old battery, use a new battery with the same current and voltage.

The following problems are related to the charging system, follow the instructions provided in the checking list to correct it if any one of the problems takes place.

(1) The charging voltage can not exceed the voltage between two battery terminals and the charging current is in the discharging direction.

(2) The charging voltage and current are too much higher than the standard values.

Headlight Voltage Inspection


Connect a tachometer.

Do not disconnect the headlight harness connector after engine started.

Turn the headlight ON and to high beam position.

Measure the voltage between the blue wire (+) and green wire (-) while the headlight harness is still in connection. Measure alternating current voltage with a voltmeter.

Gradually increase engine speed and read the voltage in each specified rpm.

Control voltage: 12.0~14.0 V / 5000 rpm

Resistance Measurement of Resistor at 20℃.

Resistor (10.2Ω5W) Green/Black and Body

ground: 9.0Ω~10.0Ω

Resistor (5.9Ω5W) Pink and Body ground:

5.6Ω~6.2Ω


Turn the headlight ON and to high beam position.

Measure the voltage between the blue wire (+) and green/white wire (-) while the headlight harness is still in connection. Measure direct current voltage with a voltmeter.

Resistance Measurement of Resistor at 20℃.

Resistor (8Ω5W) Green/Black and Yellow:

7.0Ω~9.0Ω

The following problems are not related to the charging system; correct it if any by following steps indicate in the checking list.

(1) The standard charging voltage and current can only reach when the revolution of the engine exceeds the specified rpm.

- Bulbs used exceed their rate and consume too much power.

- The replacement battery is aged and does not have enough capacity.

(2) The charging voltage is normal, but the current is not.

- The replacement battery is aged and does not have enough capacity.

- Battery used do not have enough electricity or is over charged.

- The fuse of the ammeter is blown.

- The ammeter is improperly connected.

(3) The charging current is normal, but the voltage is not.

-

The fuse of the voltmeter is blown.

Front cover

Resistor

Headlight connector

15-7



Voltage Regulator Inspection –

JET 50/100

Check the each pins of connector on the voltage regulator.

Voltage regulator

Voltage regulator connector

Check voltage between battery terminal (red) and ground

(green).

Check continuity between ground and frame.

Check charging coil (white to ground) if its resistance is within 0.2~1.0Ω

Check charging /illumination coil (yellow to ground) if its resistance is within 0.2~0.8Ω

If wire circuit check is in normal and there is no loose in the pins of voltage regulator connector, then measure the resistance among pins on the connectors of voltage regulator.

Voltage Regulator

Multi-meter(+)

White

A

Multi-meter (-)

White A

Yellow B

Red B

Yellow

L

Red

B

Green

E

∞ 4~7

∞

4~7 ∞

∞ 2.4~4.8

∞

Green E ∞ 2.4~4.8 ∞

If the resistance values are abnormal among the pins, replace the voltage regulator.

Caution y If the probe is touched by finger, then the resistance values will be incorrect. y It contains semi-conductor in circuit so the measured resistance value will be in different if different testers are used. Thus, these values cannot be judged with standards.

Red (B)

Blown fuse or poor main switch contact

Open-circuit wire

Open-circuit in alternator charging coil or in illumination switch.

White (A)

Yellow (L)

Green (E)

AC Generator Inspection

Remove body cover.

Disconnect the generator harness connector.

Measure the resistance on both charging coil

(the white to ground) and illumination coil (the yellow to ground).

Resistance Measurement: (20℃)

Charging coil (white - green): 0.2~1.0Ω

Illumination coil (yellow - green): 0.1~0.8Ω

AC. Generator harness connector

15-8


Inspection on SCR – JET EURO 50/100

Remove the front cover.

Disconnect 4P connectors to remove the SCR.

Item

Main switch connection

Battery connection

Charging coil

Check Points Standard Value

R – B Battery voltage

(ON)

R – G Battery voltage

Y – Y 0.4~0.8Ω

If the readings measured are not normal, check parts in the circuit.

If the parts are normal, then trouble is in the wiring.

If there is nothing wrong with parts and wiring, replace the SCR.

Inspection on the Charging Coil

Caution

The test can be carried out without removing the charging coil from the engine.

Measure the resistance between each yellow wire of the SCR.

Standard resistance: 0.4~0.8Ω

Regulator rectifier

AC generator harness connector

15-9



Ignition System


Blue/Yellow

Black/Red

Green

Black/Yellow

Black/White


Blue/Yellow

Green

Black/Yellow

Black/Blue

Black

Red

15-10


Ignition Coil Inspection y Remove body cover.

Measure the primary coil resistance

Resistance :0.19~0.23KΩ (A)→(B)

Measure the secondary coil resistance

Resistance : 8.2~9.3KΩ (A)→(C)

(A)

(C)

(D)

(B)

Remove the high voltage coil cap, and measure its negative (-) terminal for the secondary coil resistance.

Resistance : 3.1~3.2KΩ (A)→(D)

(C)

(A)

(B)

(D)

Ignition coil

15-11



Electrical System Circuit Inspection

Pulse Generator/Exciting Coil

Remove body cover.

Disconnect alternator connector.

Resistance Measurement: (20℃)

Pulse generator coil (blue/yellow - ground):

50~200Ω

Exciting (yellow - ground): 400~800Ω

CDI Electrical System Circuit Inspection

Remove body cover.

Disconnect the CDI set connector, and check its circuit to diagnosis related ignition components.

CDI Electrical System Circuit Inspection

AC generator harness connector

C.D.I.

Main Switch (compatible with JET 50/100)

Main Switch (compatible with JET EURO 50/100)

Exciter Coil (compatible with JET 50/100)

Pulse Generator

Black/white-green

Black/ Blue -green

Blue/Yellow-green

Continuity as main switch OFF

Continuity (battery voltage) as master switch ON

50 ~200Ω

Primary Black/yellow-green 0.21Ω±10%

Ignition Coil Green-high voltage cable -w/o Cap 3~5KΩ

Secondary

Green-high voltage cable - w/ Cap 7~12KΩ y If above checks are in normal but spark plug is still no spark. Then it probable causes from CDI set or high voltage coil. y If abnormal circuits are found in above checks, at first check all items, and then check each item one by one.

15-12


Starting System

Starter Relay Inspection

Remove luggage box.

Connect both the green/yellow (-) and the yellow/red (+) pins to battery posts directly.

If the red and red/white pins are also in continuity, it means it is in normal.

Starter relay

Starter relay

Battery

Starter Motor Pinion Removal/Installation


Remove starter motor pinion.

Install the starter motor pinion in reverse order of removal.

Starter Motor Pinion Inspection y Pinion, reduction gear for wear out or damage

→ replace it with new one. y Gear journal for wear out or damage → replace it with new one.

Check the pinion for sliding in axial direction smoothly. y The pinion sliding in axial direction not in smooth → replace it with new one.

Starter motor pinion

15-13



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 gasket.

Remove 2 bolts for disassembly the starter motor.

Starter motor

Connector

Armature

Motor housing

Spring

O-ring

Carbon bracket

Armature Inspection

Check the armature for discoloration or other damage. It may be short-circuit if dark surface on the shifter found.

Caution

Do not clean the shifter surface with sandpaper.

Check continuity 1) both the shifter surface and shaft, 2) among the shifter surfaces. It can be in continuity among the shifter surfaces, but both the shifter surface and the shaft can not be in continuity.

Starter Motor Re-Assembly/Installation

Re-assemble and install the starter motor in reverse order of removal procedures.

15-14

Front bracket


Oil Level Switch

Troubleshooting y 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 main switch to ON position.

Indicator light up Indicator not light up

Short-circuit between indicator and oil gauge

Malfunction of oil gauge y If there is no oil in oil tank or low oil level, but the oil level indicator still not goes on.

1. Remove body cover.

2. Disconnect oil gauge wire and connect a jump wire among connector, and then turn the main switch to ON position.

Indicator light up Indicator not light up

Poor wire connection Malfunction of oil gauge

3. Disconnect oil gauge connector, and check voltage between wire and ground.

No voltage y Open-circuit between oil gauge and indicator. y Blown bulb

Voltage y Malfunction of oil gauge y Poor connection of oil gauge


Remove oil tank.

Remove oil level switch from the oil tank.

Install the oil level switch in reverse order of removal procedures.

Main switch Fuse

Indicator

Indicator

Oil level switch

Main switch

Fuse



15-15



Fuel Unit


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.

Install in reverse order of removal procedures.

Remark: Aligning the slot of fuel unit with the ring of oil tank as installation, and then turn the snap ring in CW direction until matching to the arrow.

Inspection

1. Connect the fuel unit connector.

Turn the main switch ON.

Move the float in up and down, and make sure that the fuel indicator can be reached to F (Full) and E (Empty) positions.

Conduct the step 2 if the needle on the fuel indicator is not moved.

2. Measure the connector resistance while the float in up and down positions.

Float position Resistance value

Float

Up (full) 3~10Ω

Down (empty) 90~100Ω

Check the fuel indicator if the resistance is in normal.

Replace the fuel gauge if the resistance is abnormal.

Fuel unit

Fuel unit plastic

15-16


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 color

Black

Black /

White

Green Red

Mark BAT2 IG E BAT1

LOCK

● ●

OFF

ON

●

●

●

●

Turn signal light switch

Wire color Gray Light blue Orange

Mark WR R L

R

N

L

●

●

Horn Switch

●

●

Wire color Light green Black

Mark HO BAT2

FREE

PUSH

●

High/Low Beam switch

●

Wire color Brown White Blue

Mark HL LO HI

LO

(N)

HI

●

●

●

●

● ●

● ●

High / low beam switch

Turn signal switch

Horn switch

High / low beam switch

Turn signal switch

Horn switch

15-17



Light Switch

Wire color Brown Yellow Pink

Mark HL CI RE

OFF

●

ON

● ●

●

Start Switch

Wire color Yellow / Red Green

Mark ST E

FREE

PUSH

● ●

Front / Rear Brake Light Switch

If the switch is in continuity as braking, it is in normal. The switch is non-adjustable.

Horn

If the horn give out sound as connecting to 12V battery, it means that it is in normal.

Light switch

Start switch

Horn

Light switch

Start switch

15-18


Bulb Replacement

Headlight/position light

JET EURO 50/100

Remove front cover.

Remove bulb seat and replace the bulb.

Install the all removed parts.

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.


Tail light / Brake light

Remove 3 screws and then remove tail cover

Remove 1 screw and then remove tail light lens.

Replace tail light or winker light bulb

Headlight

Screw

Position light

Headlight

Position light

Screws

15-19



Rear winker light

Remove rear winker lens.

Replace winker light bulb.

Front winker light

Remove 6 screws and then remove handle front cover

Replace winker light bulb

1 Screw

15-20

6 Screws


Clock unit – JET EURO 50/100

Remove 6 screws and then remove handle front cover

Remove 2 screws and then remove clock unit.

Meter

Remove handlebar front cover.

Take out the bulb seat from the bottom of instrument panel.


Clock Handle rear cover

15-21



Notes:

15-22

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16. ELECTRICAL DIAGRAM

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