QUAD SYM LANDER 250 Manual de Serviço

Quad Lander 250 SERVICE MANUAL FORWARD HOW TO USE THIS MANUAL CONTENTS SERIAL NUMBER

1. GENERAL INFORMATION 1-5 y Lubricate the rotation face with specified lubricant on the lubrication points before assembling. y Check if positio

8. V-BELT DRIVING SYSTEM 8-13 Install snap ring and mounting plate onto setting pin. Replacement of Driven Pulley Bearing Remove inner beari

8. V-BELT DRIVING SYSTEM 8-14 Installation of Clutch OUTER/Driven Pulley Assembly Install new oil seal and O-ring onto movable driven face. Apply wi

9. FINAL DRIVING MECHANISM 9-1 Mechanism Diagram - transmission cover······························································ 9-1 Precautions

9. TRANSMISSION 9-2 Precautions in operation Specification Application oil: scooter gear oil Recommended oil: KING MATE serial gear oils Oil quantit

9. FINAL DRIVING MECHANISM 9-3 Disassembly of Transmission Remove gear change lever (1 bolt). Loosen speedometer cable mounting nut, and

9. TRANSMISSION 9-4 Remove gear box cover bolts (9 bolts) and then remove the cover. Remove shift drum catch ball, spring and bolt.

9. FINAL DRIVING MECHANISM 9-5 Remove drive shaft bearing setting plate (1 bolt). Remove the drive shaft. Special tool: Shaft protecto

9. TRANSMISSION 9-6 Inspection of Mission Mechanism Check if the shift spindle is wear or damage. Check if the shift drum is wear or dam

9. FINAL DRIVING MECHANISM 9-7 Check if the reverse shaft is wear or damage. Check if the final shaft and gear are burn, wear or damage

9. TRANSMISSION 9-8 Bearing Replacement Caution y Never install used bearings. Once bearing removed, it has to be replaced with new one. Crankcase

1. GENERAL INFORMATION 1-6 y When separating a connector, it locker has to be unlocked firstly. Then, conduct the service operation. y Do not

9. FINAL DRIVING MECHANISM 9-9 Install drive shaft. Special tool: Drive shaft puller Drive shaft and oil seal install bush Clutch nut wrench

9. TRANSMISSION 9-10 Remove final shat out side bearing. Special tool: Inner bearing puller Remove oil seal from gear box cover and discard the seal

9. FINAL DRIVING MECHANISM 9-11 Re-assembly of Final Driving Mechanism Apply with grease onto the oil seal lip of final driving shaft. Ins

9. TRANSMISSION 9-12 Align the position mark on the shift spindle sprocket with that of shift drum, and then install shift spindle. Inst

10. ALTERNATOR/STARTING CLUTCH 10-1 Mechanism Diagram ··························· 10-1 Precautions in Operation···················· 10-2 Right Crank

10. ALTERNATOR/STARTING CLUTCH 10-2 Precautions in Operation General information y Refer to chapter 17: The troubleshooting and inspection of alter

10. ALTERNATOR/STARTING CLUTCH 10-3 Right Crankcase Cover Removal Remove left footrest. Drain out the engine oil and coolant, and then remove coolan

10. ALTERNATOR/STARTING CLUTCH 10-4 Check the oil seal for wear or damage. Replace it if necessary. Install a new one bearing (6201LU

10. ALTERNATOR/STARTING CLUTCH 10-5 Remove starter reduction gear and shaft. Pull out flywheel with A.C.G. flywheel puller. Special tool: A.C.G. Fly

10. ALTERNATOR/STARTING CLUTCH 10-6 Install starting clutch driven gear onto one way clutch. Hold flywheel and rotate starting clutch gear. The star

1. GENERAL INFORMATION 1-7 y Do not let the wire harness contact with rotating, moving or vibrating components as routing the harness. y Keep wi

10. ALTERNATOR/STARTING CLUTCH 10-7 One way clutch Installation Install the components in the reverse procedures of removal. Caution Tape a tighten

10. ALTERNATOR/STARTING CLUTCH 10-8 Install reduction gear shaft and reduction gear. A.C.G. Set Installation Install the A.C.G. coil set

10. ALTERNATOR/STARTING CLUTCH 10-9 Install right crankcase cover (11 screws). Install the dowel pin, new gasket and water pump cover onto crankcase

10. ALTERNATOR/STARTING CLUTCH 10-10 Note: To this chapter contents

11. CRANKCASE / CRANK 11-1 Mechanism Diagram ··························11-1 General information ···························11-2 Trouble diagnosis ··

11. CRANKCASE / CRANK 11-2 General information Operational precautions y This Section concerns disassembly of the crankcase for repair purpose. y

11. CRANKCASE / CRANK 11-3 Disassembly of crankcase Remove the cam chain setting plate, and then remove cam chain. Loosen the pivot bolt and remove

11. CRANKCASE / CRANK 11-4 Remove balance shaft from right crankcase. Remove crankshaft from right crankcase. Remove gasket

11. CRANKCASE / CRANK 11-5 Crankshaft Inspection Use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit:

11. CRANKCASE / CRANK 11-6 Check balance shaft bearing Check bearings on right and left crankcase. Rotate each bearings inner ring with fingers. Che

1. GENERAL INFORMATION 1-8 y Do not let the wire harness been twisted as installation. y Wire harnesses routed along the handlebar should not be

11. CRANKCASE / CRANK 11-7 Install 2 dowel pins and new gasket. Install the left crankcase onto the right crankcase. Tigh

11. CRANKCASE / CRANK 11-8 Clean the crankshaft. Apply a layer of grease on the lip of oil seal, Puts on the left crank shaft. Install the oil seal

12. COOLING SYSTEM 12-1 Mechanism Diagram ··························12-1 General Information ···························12-2 Trouble Diagnosis······

12. COOLING SYSTEM 12-2 General Information General Warning: While the engine is running, never attempt to open the radiator filler cap, the pressu

12. COOLING SYSTEM 12-3 Trouble Diagnosis for Cooling System The temperature indicated is too h

12. COOLING SYSTEM 12-4 E-4. Remove thermostat from holder then heats it by water directly to check i

12. COOLING SYSTEM 12-5 System Test Test on the filler cap Hermetically seal the filler cap, apply water and pressure to the filler cap. Replace it

12. COOLING SYSTEM 12-6 Check reserve tank y Remove the front center cover, and then remove reserve tank filler cap. y Check the liquid level in t

12. COOLING SYSTEM 12-7 Loosen the radiator 4 bolts. Remove coolant upper side pipes. Remove coolant outlet pipe. Disconnect the coupler

12. COOLING SYSTEM 12-8 Water Pump Check water pump seal / cooling system divulges inspection y Disassembles the refrigerant drain bolt, overflows

1. GENERAL INFORMATION 1-9 Specifications MAKER SANYANG MODEL UA25A Overall Length 1890 mm Front Double arm Overall Width 1055 mmSuspension Sys

12. COOLING SYSTEM 12-9 Check any wear and damage of the mechanical seal and inside seal. Caution The mechanical seal and inside seal must be repla

12. COOLING SYSTEM 12-10 Install the new inner seal onto the right crankcase. Special tools: Water pump oil seal driver (inner) Install a

12. COOLING SYSTEM 12-11 Install the seal washer into the impeller. Caution Washer must be replaced together with the mechanical seal. Ins

12. COOLING SYSTEM 12-12 Thermostat Please refer to chapter 17 for inspection of temperature sensor. Removal Drain out the coolant. Remove the ther

13. BODY COVER 13-1 Mechanism Diagram ························· 13-1 Maintenance······································· 13-2 Handle front cover / Me

13. BODY COVER 13-2 Maintenance Body covers disassemble sequence: y Be careful not to damage various covers in assembly or

13. BODY COVER 13-3 Handle front cover / Meter cover Remove Loosen 4 bolts from handle cover right and left side. Remove couplers of meter.

13. BODY COVER 13-4 Remove meter stay and meters. Remove 3 screws and disassembly handle cover and meter. Installation Install in revers

13. BODY COVER 13-5 Fuel tank cover Remove Remove front center cover. Remove seat. Remove fuel tank cap. Remove 1 bolt, and then re

13. BODY COVER 13-6 Front fender Remove Remove seat. Remove fuel tank cap and fuel tank cover. Loosen the two bolts of front fender rear side.

1. GENERAL INFORMATION 1-10 Specifications MAKER SANYANG MODEL UA25A1 Overall Length 1890 mm Front Double arm Overall Width 1055 mmSuspension S

13. BODY COVER 13-7 Remove right and left side covers (each side 1 screw). Loosen the front fender two side bolts (each side 1 bolt).

13. BODY COVER 13-8 Remove front fender front side bolts (2 bolts). Remove the left crankcase cover duct. Remove front fen

13. BODY COVER 13-9 Remove headlights inner side 4 screws. Remove headlights front side 4 screws, and then remove headlights.

13. BODY COVER 13-10 Remove power outlet setting nut, and then remove power outlet. Installation Install in reverse order of removal procedures.

13. BODY COVER 13-11 Rear fender Remove rear carrier. Pull the “Seat Release Bar” up in order to remove the seat. This seat release bar is under t

13. BODY COVER 13-12 Remove rear fender front side bolts and screws (each side 1 screw and 1 bolt). Remove battery, CDI unit, start rel

13. BODY COVER 13-13 Disassembly Remove rear fender and rear bumper upper side 2 screws. Remove rear fender and rear bumper inner screws

13. BODY COVER 13-14 Footrest Remove Loosen the 6 bolts, which connect the footrest and frame, these 6 bolts just be twin under the footrests.

14. FRONT BRAKE & FRONT WHEEL 14-1 Mechanism Diagram···························14-1 Maintenance Description···················14-2 Trouble Diagn

14. FRONT BRAKE & FRONT WHEEL 14-2 Maintenance Description Operational precautions Caution Inhaling asbestos may cause disorders of respiratio

1. GENERAL INFORMATION 1-11 Torque Values The torque values listed in above table are for more important tighten torque values. Please see standard

14. FRONT BRAKE & FRONT WHEEL 14-3 Trouble Diagnosis Soft brake lever 1. Air inside the hydraulic system 2. Hydraulic system leaking 3. Worn mas

14. FRONT BRAKE & FRONT WHEEL 14-4 Front Wheel Removal Raise the front wheels off the ground by placing a jack or other support under the frame

14. FRONT BRAKE & FRONT WHEEL 14-5 Inspection Check bearings on wheel hub. Rotate each bearing’s inner ring with fingers. Check if bearings can

14. FRONT BRAKE & FRONT WHEEL 14-6 Remove 4 socket bolts, and then remove the brake disk from wheel hub. Assembly Install brake dis

14. FRONT BRAKE & FRONT WHEEL 14-7 Disk Brake System Inspection Inspection By visual examination whether divulges or the damage, with spanner in

14. FRONT BRAKE & FRONT WHEEL 14-8 Adding Brake Fluid Before the brake fluid reservoir is removed, turn the handle so that the brake fluid rese

14. FRONT BRAKE & FRONT WHEEL 14-9 Brake fluid replacement / Air-bleed Connect drain hose to air-bleed valve. Open the drain valve on the calipe

14. FRONT BRAKE & FRONT WHEEL 14-10 Front Brake Caliper Removal Place a container under the brake caliper, and loosen the brake hose bolt and f

14. FRONT BRAKE & FRONT WHEEL 14-11 Brake Disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk a

14. FRONT BRAKE & FRONT WHEEL 14-12 Remove the rubber boot. Remove the cir clip. Remove the piston and the spring. Clean the master cylinder wi

1. GENERAL INFORMATION 1-12 Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks Handlebar upper holder bolt 4 6 2.40 Stee

14. FRONT BRAKE & FRONT WHEEL 14-13 Master Cylinder Install Install the rubber pad into the groove correctly. Place the master cylinder onto han

14. FRONT BRAKE & FRONT WHEEL 14-14 Notes: To this chapter contents

15. STEERING / FRONT SUSPENSION 15-1 Mechanism Diagram ··························15-1 Operational Precautions····················15-2 Trouble Diagno

15. STEERING / FRONT SUSPENSION 15-2 Operational Precautions Torque Values Handlebar upper holder bolt 2.4kgf-m Handlebar under holder nut 4.0kgf-m

15. STEERING / FRONT SUSPENSION 15-3 Steering Handle Removal Remove the handle cover, meter set, handle protect cover and front fender. (Refer to ch

15. STEERING / FRONT SUSPENSION 15-4 Loosen 2 screws, and then remove handle left switch and choke hosing. Remove switch wire band. Rem

15. STEERING / FRONT SUSPENSION 15-5 Steering Shaft Remove Remove cotter pins, and loosen right and left steering tie-rod nuts. Remove tie-rod.

15. STEERING / FRONT SUSPENSION 15-6 Steering Tie-Rod Remove Remove cotter pin and tie-rod nut from steering shaft side. Remove cotter pi

15. STEERING / FRONT SUSPENSION 15-7 Knuckle Remove Remove front wheel, front brake caliper, front wheel hub and brake disk. Remove cotte

15. STEERING / FRONT SUSPENSION 15-8 Front Cushion Remove Remove front cushion under bolt nut, and remove the bolt. Remove front cushion u

1. GENERAL INFORMATION 1-13 Troubles Diagnosis A. Engine hard to start or can not be started Cylinder compression

15. STEERING / FRONT SUSPENSION 15-9 Suspension Arm Remove Remove front wheel, wheel hub, and brake caliper, brake disk, tie-rod, knuckle and front

15. STEERING / FRONT SUSPENSION 15-10 Toe-In When repair or disassemble steering system parts, must to adjustment the toe-in. Keep the vehicle on le

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-1 Mechanism Diagram···························16-1 Maintenance Description···················1

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-2 Maintenance Description Operational precautions Caution Inhaling asbestos may cause disord

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-3 Trouble Diagnosis Soft brake lever 1. Air inside the hydraulic system 2. Hydraulic system le

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-4 Rear Wheel Removal Raise the rear wheels off the ground by placing a jack or other support

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-5 Rear Wheel Axle Remove right and left rear wheel, wheel connecter. Remove 2 bolts, and then

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-6 Remove 4 nuts, and remove driven sprocket. Bend out the rear axle nut fixed plate.

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-7 Remove rear wheel axle and driven sprocket holder. Inspection Check bearings on

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-8 Installation Install rear wheel axle and driven sprocket holder. Install rear b

1. GENERAL INFORMATION 1-14 B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fau

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-9 Install driven sprocket, drive chain, drive chain cover and brake caliper. Caution y Note

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-10 Disk Brake System Inspection Inspection By visual examination whether divulges or the dama

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-11 Adding Brake Fluid Before the brake fluid reservoir is removed, turn the handle so that the

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-12 Brake fluid replacement / Air-bleed Connect drain hose to air-bleed valve. Open the drain

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-13 Rear Brake Caliper Removal Place a container under the brake caliper, and loosen the brake

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-14 Brake Disk Inspection Visually check the brake disk for wear or break. Measure the thick

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-15 Right footrest side – rear brake master cylinder B Place a container under the brake master

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-16 Measure the outer diameter of the piston. Replace the piston if its measured value excee

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-17 Right footrest side – rear brake master cylinder B Install the master cylinder bolts and th

16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-18 Rear Cushion Removal Support the frame. Loosen rear cushion under bolt nut, and remove rea

FORWARD This service manual contains the technical data of each component inspection and repair for the SANYANG Quad Lander 250 ATV. The manual

1. GENERAL INFORMATION 1-15 C. Engine runs sluggish (especially in low speed and idling) D. Engine runs sluggish (High speed)

17. ELECTRICAL SYSTEM 17-1 Mechanism Diagram ··························17-1 Maintenance Data·······························17-2 Technical Specificat

17. ELECTRICAL SYSTEM 17-2 Maintenance Data Operational precaution y When remove the battery, the disconnection sequence of cable terminals shall

17. ELECTRICAL SYSTEM 17-3 Trouble Diagnosis No voltage y Battery discharged y The cable disconnected y The fuse is blown y Improper operation of

17. ELECTRICAL SYSTEM 17-4 Battery Removal Remove the seat, and then you can see the battery. Disconnect the negative cable terminal first, then th

17. ELECTRICAL SYSTEM 17-5 Charging System Charging circuit Current Leakage Inspection Turn the main switch to OFF position, and remove the negat

17. ELECTRICAL SYSTEM 17-6 Inspection on Charging Voltage Caution y Before conducting the inspection, be sure that the battery is fully charge

17. ELECTRICAL SYSTEM 17-7 Inspection on regulator rectifier Remove the seat, rear carrier and rear fender. Disconnect two 3 pin couplers of the reg

17. ELECTRICAL SYSTEM 17-8 Ignition System Ignition circuit diagram C.D.I unit Disconnect connectors of the C.D.I unit. Check the following con

17. ELECTRICAL SYSTEM 17-9 Inspection on Ignition Coil Disengage the connector of the ignition coil and the spark plug cap. Measure the resistance b

17. ELECTRICAL SYSTEM 17-10 Starting System Starting circuit diagram Inspection on starter relay Open the main switch. Press the brake. Push dow

1. GENERAL INFORMATION 1-16 E. Clutch, driving and driving pulley F. Poor handling y Clutch weights spring broken

17. ELECTRICAL SYSTEM 17-11 Removal of Starter motor Remove the seat. Disconnect the cable negative terminal (-), then the cable positive terminal (

17. ELECTRICAL SYSTEM 17-12 Meters Removal Loosen 4 bolts of the meter stay. Remove the front center cover, and then remove meter couple

17. ELECTRICAL SYSTEM 17-13 Light / Bulb Replacing Bulb for Headlight Remove 4 screws for the headlight cover, and remove the cover. Loosen

17. ELECTRICAL SYSTEM 17-14 Replacing the Front winker light Bulb Pull out the front winker light bulb seat. Replace with new front win

17. ELECTRICAL SYSTEM 17-15 Replacing Bulb of Taillight and Rear Winker Light Turn the taillight and rear winker light bulb connectors by CCW.

17. ELECTRICAL SYSTEM 17-16 Switch / Horn Main Switch Inspection Remove the front center cover. Disconnect the main switch coupler. Check the conti

17. ELECTRICAL SYSTEM 17-17 Headlight Switch Pin Position BAT3 LO HI PL ● Wire color White / Black White Blue Brown Winker sw

17. ELECTRICAL SYSTEM 17-18 Front Brake Switch While grasp the brake lever firmly, the terminals of brown/blue and green/yellow of the brake should

17. ELECTRICAL SYSTEM 17-19 Fuel Unit Remove the seat. Remove the fuel tank cap. Remove the fuel tank cover and front fender (refer chapter 13). Dis

17. ELECTRICAL SYSTEM 17-20 Cooling Fan Thermo Switch The thermo switch mounted on the radiator controls the operation of the cooling fan motor.

1. GENERAL INFORMATION 1-17 G. Loss power Check and adjustment Fault condition Probable cause

17. ELECTRICAL SYSTEM 17-21 Thermo unit Remove the thermo unit. Hang the thermo unit in an oil heater, heat the oil and measure the resistance at ea

17. ELECTRICAL SYSTEM 17-22 Notes: To this chapter contents

18. ELECTRICAL DIAGRAM 18-1 18Home pageContents QUAD LANDER 250 ELECTRICAL DIAGRAM

18. ELECTRICAL DIAGRAM 18-2 Notes: Home pageContents

1. GENERAL INFORMATION 1-18 Lubrication Points Drive chain Acceleration cable/ Front & rear brake lever pivot Speedometer gear

2. MAINTENANCE INFORMATION 2-1 Precautions in Operation···················· 2-1 Periodical Maintenance Schedule······ 2-2 Fuel Lines················

2. MAINTENANCE INFORMATION 2-2 Periodical Maintenance Schedule Maintenance Code Item Every 300KM1 Month every 1,000KM3 month every 3,000KM6 month ev

2. MAINTENANCE INFORMATION 2-3 Fuel Lines Remove the seat. Loosen 2 screws and 2 bolts Remove the tank cover Check all lines, and replace it whe

2. MAINTENANCE INFORMATION 2-4 Valve Clearance Caution Checks and adjustment must be performed when the engine temperature is below 35℃. Remove fro

2. MAINTENANCE INFORMATION 2-5 Carburetor Idle Speed Adjustment Caution y Inspection & adjustment for idle speed have to be performed after al

2. MAINTENANCE INFORMATION 2-6 Ignition System Caution y C.D.I ignition system is set by manufacturer so it can not be adjusted. y Ignition timin

HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for SANYANG Q

2. MAINTENANCE INFORMATION 2-7 Drive Belt Loosen the 2 clamp strips of left crankcase cover, and then remove the left crankcase cover vapor hose. Re

2. MAINTENANCE INFORMATION 2-8 Brake System (Disk Brake) Brake System Hose Make sure the brake hoses for corrosion or leaking oil. Brake Flu

2. MAINTENANCE INFORMATION 2-9 Brake Lining Wear The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear limit

2. MAINTENANCE INFORMATION 2-10 Headlight Beam Distance Turn on main switch Headlight beam adjustment. Turn the headlight adjustment screw to adjust

2. MAINTENANCE INFORMATION 2-11 Steering Handle Caution Check all wires and cables if they are interfered with the rotation of steering handle bar.

2. MAINTENANCE INFORMATION 2-12 Special Tools List NAME Rocker arm pin puller NAME Tappet adjusting wrench NAME Tappet adjusting wrench NO SYM-1445

2. MAINTENANCE INFORMATION 2-13 NAME Counter shaft needle bearing driver HK2016 NAME Bearing driver 6305 NAME Left crank case cover bearing dri

2. MAINTENANCE INFORMATION 2-14 NAME Inner bearing puller NAME Inner bearing puller NAME Outer bearing puller NO SYM-6204002 NO SYM-6204022

3. LUBRICATION SYSTEM 3-1 Mechanism Diagram······························ 3-1 Precautions in Operation ······················ 3-2 Troubleshooting ··

3. LUBRICATION SYSTEM 3-2 Precautions in Operation General Information: z This chapter contains maintenance operation for the engine oil pump and g

CONTENTS Page Content Index 1-1 ~ 1-18 GENERAL INFORMATION 1 2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION 2 3-1 ~ 3-8 LUBRICATION SYSTEM 3 4-1 ~

3. LUBRICATION SYSTEM 3-3 Engine Oil Turn off engine, and park the ATV in flat surface with main stand. Check oil level with oil dipstick. So not sc

3. LUBRICATION SYSTEM 3-4 Oil Pump Oil Pump Removal Remove generator and starting gear. (Refer to chapter 10) 。 Remove cir clip and take ou

3. LUBRICATION SYSTEM 3-5 Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance betw

3. LUBRICATION SYSTEM 3-6 Tighten the oil pump screw. Oil Pump Installation Install the oil pump, and then tighten screws. Torque value：0

3. LUBRICATION SYSTEM 3-7 Gear Oil Gear Oil Change Remove oil join bolt. Remove drain bolt and drain gear oil out. Install the drain bolt after drai

3. LUBRICATION SYSTEM 3-8 Notes: To this chapter contents

4. FUEL SYSTEM 4-1 Mechanism Diagram ... 4-1 Precautions in Operation... 4-2 Trouble Diagnosis...

4. FUEL SYSTEM 4-2 Precautions in Operation General Information Warning Gasoline is a low ignition point and explosive materials, so always work in

4. FUEL SYSTEM 4-3 Trouble Diagnosis Poor engine start y No fuel in fuel tank y Clogged fuel tube y Too much fuel in cylinder y No spark

4. FUEL SYSTEM 4-4 Carburetor Remove / Install Removal Drain out fuel in the float chamber. Loosen the choke cable fixed iron sheet screw

SERIAL NUMBER Frame number Engine number Home pageContents

4. FUEL SYSTEM 4-5 Air Cut-Off Valve Disassembly Remove 2 screws. Remove air cut-off valve cover, spring and valve. Inspecti

4. FUEL SYSTEM 4-6 Throttle Valve Disassembly Remove carburetor upper parts, and then remove throttle valve and throttle cable. Disconnec

4. FUEL SYSTEM 4-7 Float Chamber Disassembly Remove 3 mounting screws and remove float chamber cover. Remove the fuel level plate, float pi

4. FUEL SYSTEM 4-8 Remove main jet, needle jet holder, needle jet, slow jet and air adjustment screw. Caution Take care not to damage jets and adj

4. FUEL SYSTEM 4-9 Adjustment of Idle Speed Caution y Air screw was set at factory, so no adjustment is needed. Note the number of turns it takes

4. FUEL SYSTEM 4-10 Fuel Tank Fuel unit removal Open the seat. Remove the front cover and fuel tank. Remove the side covers and lower side covers. R

4. FUEL SYSTEM 4-11 Air Cleaner Removal Loosen the clamp strip of air cleaner and carburetor, and then remove the vapor hose. Loosen the c

4. FUEL SYSTEM 4-12 Notes: To this chapter contents

5. ENGINE REMOVAL 5-1 Precautions in Operation ... 5-1 Removal of Engine ... 5-2 Engine Installation..

5. ENGINE REMOVAL 5-2 Removal of Engine Remove the seat. Remove battery negative post (-). Remove battery positive (+) post. Remove front fender and

1. GENERAL INFORMATION 1-1 Symbols and Marks... 1-1 General Safety ... 1-2 Service Preca

5. ENGINE REMOVAL 5-3 Remove muffler protect (2 bolts). Loosen muffler front side bolt. Remove 2 bolts, and then remove the exha

5. ENGINE REMOVAL 5-4 Loosen 1 screw and disconnect the choke cable. Remove fuel pipe and vacuum pipe. Release the clamp strip of air cl

5. ENGINE REMOVAL 5-5 Remove coolant drain bolt, and drain out coolant. Remove coolant inlet hoses from water pump. Remove the thermo-senso

5. ENGINE REMOVAL 5-6 Loosen speedometer cable mounting nut, and then remove the cable. Remove 3 bolts and remove drive chain protector. Turn the so

6. CYLINDER HEAD/VALVE 6-1 Mechanism Diagram··························· 6-1 Precautions in Operation ··················· 6-2 Troubleshooting········

6. CYLINDER HEAD/VALVE 6-2 Precautions in Operation General Information y This chapter is contained maintenance and service for cylinder head, valv

6. CYLINDER HEAD/VALVE 6-3 Troubleshooting Engine performance will be affected by troubles on engine top parts. The trouble usually can be determine

6. CYLINDER HEAD/VALVE 6-4 Cylinder Head Removal Remove engine. (Refer to chapter 5) Remove the inlet pipe (2 nuts). Remove 1 bolt of the

6. CYLINDER HEAD/VALVE 6-5 Remove left crankcase cover, and turn the Turn the drive face, and align the timing mark on the sprocket with that of c

6. CYLINDER HEAD/VALVE 6-6 Remove the 2 cylinder head mounting bolts from cylinder head right side, and then remove 4 nuts and washers from cylinder

1. GENERAL INFORMATION 1-2 General Safety Carbon monoxide If you must run your engine, ensure the place is well ventilated. Never run your engine in

6. CYLINDER HEAD/VALVE 6-7 Remove valve stem seals. Clean carbon deposits in combustion chamber. Clean residues and foreign materials o

6. CYLINDER HEAD/VALVE 6-8 Rocker Arm Measure the cam rocker arm I.D., and wear or damage, oil hole clogged? Service Limit: Replace when it is les

6. CYLINDER HEAD/VALVE 6-9 Valve guide Caution Before measuring the valve guide, clean carbon deposits with reamer. Tool: 5.0 mm valve guide reamer

6. CYLINDER HEAD/VALVE 6-10 Valve Stem Replacement Heat up cylinder head to 100~150 ℃ with heated plate or toaster. Caution y Do not let torch he

6. CYLINDER HEAD/VALVE 6-11 Valve Seat Inspection and Service Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly

6. CYLINDER HEAD/VALVE 6-12 Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Use 45° cutter

6. CYLINDER HEAD/VALVE 6-13 After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all

6. CYLINDER HEAD/VALVE 6-14 Cylinder Head Installation Clean up all residues and foreign materials onto the matching surfaces of both cylinder and c

6. CYLINDER HEAD/VALVE 6-15 Install cam chain on to sprocket and align the timing mark on the sprocket with that of cylinder head. Align sprocket bo

6. CYLINDER HEAD/VALVE 6-16 Install Air Injection system (AI) pipe. (4 bolts) Install inlet pipe onto cylinder Install and tighten spark plug Torque

1. GENERAL INFORMATION 1-3 Service Precautions y Always use with SANYANG genuine parts and recommended oils. Using non-designed parts for SANYANG A

7. CYLINDER/PISTON 7-1 Mechanism Diagram···························· 7-1 Precautions in Operation ···················· 7-2 Trouble Diagnosis········

7. CYLINDER/PISTON 7-2 Precautions in Operation General Information y Both cylinder and piston service cannot be carried out when engine mounted o

7. CYLINDER/PISTON 7-3 Cylinder and Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder.

7. CYLINDER/PISTON 7-4 Check cylinder if warp. Service limit: 0.05 mm Measure clearance between piston rings and grooves. Service Limit:

7. CYLINDER/PISTON 7-5 Measure the outer diameter of piston pin. Service Limit: 16.96 mm Measure the inner diameter of connecting rod small

7. CYLINDER/PISTON 7-6 Piston Ring Installation Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully

7. CYLINDER/PISTON 7-7 Clean up all residues and foreign materials on the matching surface of crankcase. Pay attention to not let these residues

7. CYLINDER/PISTON 7-8 Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder.

8. V-BELT DRIVING SYSTEM 8-1 Mechanism Diagram ··························· 8-1 Maintenance Description···················· 8-2 Trouble Diagnosis····

8. V-BELT DRIVING SYSTEM 8-2 Maintenance Description Precautions in Operation General Information y Drive face, clutch outer, and driven pulley can

1. GENERAL INFORMATION 1-4 y The length of bolts and screws for assemblies, cover plates or boxes is different from one another, be sure they are c

8. V-BELT DRIVING SYSTEM 8-3 Left Crankcase Cover Left crankcase cover removal Release the 2 clamp strips of left crankcase cover ducts, and then re

8. V-BELT DRIVING SYSTEM 8-4 Left crankcase cover inspection Remove 2 bolts to remove left crankcase cover bearing setting plate. Check bear

8. V-BELT DRIVING SYSTEM 8-5 Drive Belt Removal Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. S

8. V-BELT DRIVING SYSTEM 8-6 Installation Caution z Pull out driven face to avoid it closing. z Cannot oppress friction plate comp in order to av

8. V-BELT DRIVING SYSTEM 8-7 Drive Face Removal Remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut.

8. V-BELT DRIVING SYSTEM 8-8 Inspection The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are

8. V-BELT DRIVING SYSTEM 8-9 With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution The movabl

8. V-BELT DRIVING SYSTEM 8-10 Clutch Outer/Driven Pulley Disassembly Remove drive belt, clutch outer and driven pulley. Install clutch spring compre

8. V-BELT DRIVING SYSTEM 8-11 Clutch lining Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 3.0 mm

8. V-BELT DRIVING SYSTEM 8-12 Clutch weight Replacement Remove snap ring and washer, and then remove clutch weight and spring from driving plate. C