Sym GTS 250 Bedienungsanleitung

GTS 250

JOYMAX 250

SERVICE MANUAL

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HOW TO USE THIS MANUAL

CONTENTS

SERIAL NUMBER

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This service manual contains the technical data of each component inspection and

repair for the SANYANG LM25W series scooter. 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 scooter, LM25W series scooter, 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.

Homepage Contents

How To Use This Manual

This service manual describes basic information of different system parts and

system inspection & service for SANYANG LM25W series scooter. 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 and special tools

manual.

The third to the 11th chapters cover engine and driving systems.

The 12th chapter is cooling system.

The 13th to the 16th chapter is contained the parts set of assembly frame body.

The 17th chapter is electrical equipment.

The 18th chapter is wiring diagram.

Please see index of content for quick having the special parts and system

information.

There are 4 buttons, “Forward”, “Contents”, “How to use this manual” and

“Mechanism Illustrations” on the CD-R version, and can be access to these items

by click the mouse.

If user wants to look for the content of each chapter, selecting the words of each

chapter on the contents can reach to each chapter. There are two buttons,

“Homepage and contents, onto the top line of first page of the each chapter. Thus,

if the user needs to check other chapters, he can click the top buttons to back the

homepage or contents. The content of each chapter can be selected too.

Therefore, when needs to checking the content inside of the chapter, click the

content words of the chapter so that can back to the initial section of the content.

In addition, there is a “To this chapter contents” button at the second page of each

contents so that clicking the button can back to the contents of this chapter.

Homepage Contents

Contents

Page Content Index

1-1 ~ 1-16 General Information

2-1 ~ 2-18 Service Maintenance Information

3-1 ~ 3-8 Lubrication System

4-1 ~ 4-14 Fuel System

5-1 ~ 5-10 Engine Removal

6-1 ~ 6-16 Cylinder Head / Valve

7-1 ~ 7-8 Cylinder / Piston

8-1 ~ 8-14 “V” Type Belt Driving System / Kick-Starter

9-1 ~ 9-8 Final Driving Mechanism

10-1 ~ 10-10 Alternator

11-1 ~ 11-8 Crankshaft / Crankcase

12-1 ~ 12-14 Cooling System

13-1 ~ 13-14 Body Cover

14-1 ~ 14-12 Front Brake / Front Wheel

15-1 ~ 15-10 Steering / Front Cushion

16-1 ~ 16-6 Rear Brake / Rear Wheel / Rear Cushion

17-1 ~ 17-24 Electrical Equipment

18-1 ~ 18-10 Emission Control System

19-1 ~ 19-2 Electrical Diagram

Homepage

Serial Number

Home page Contents

1. General Information

1-1

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

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

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

Specifications·····································1-9

Torque Values···································· 1-10

Troubles Diagnosis···························· 1-12

Lubrication Points ····························· 1-16

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

Engine oil

Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the

damage that caused by not apply with the limited engine oil.

(Recommended oil: KING MATE G-3 oil)

Grease King Mate G-3 is recommended.

Gear oil

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

# 140)

Locking sealant

Apply sealant; medium strength sealant should be used unless otherwise

specified.

Oil seal Apply with lubricant.。

Renew Replace with a new part before installation.

Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid.

Special tools Special tools

Correct Meaning correct installation.

Wrong Meaning wrong installation.

Indication Indication of components.

Directions Indicates position and operation directions

Components assembly directions each other.

Indicates where the bolt installation direction, --- means that bolt cross

through the component (invisibility).

Homepage Contents

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 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

• Battery emits explosive gases; flame is strictly

prohibited. Keeps the place well ventilated

when charging the battery.

• 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.

• 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 brake shoe or pad ash 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.

To this chapter contents

1. General Information

1-3

Service Precautions

yAlways use with SANYANG genuine parts and

recommended oils. Using non-designed parts

for SANYANG ATV may damage the ATV.

ySpecial tools are designed for remove and

install of components without damaging the

parts being worked on. Using wrong tools may

result in parts damaged.

yWhen servicing this ATV, 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.

yClean the outside of the parts or the cover

before removing it from the ATV. Otherwise, dirt

and deposit accumulated on the part's surface

may fall into the engine, chassis, or brake

system to cause damage.

yWash 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.

yNever bend or twist a control cable to prevent

unsmooth control and premature worn out.

yRubber 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.

yWhen 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.

yStore complex components such as

transmission parts in the proper assemble order

and tie them together with a wire for ease of

installation later.

yNote the reassemble position of the important

components before disassembling them to

ensure they will be reassembled in correct

dimensions (depth, distance or position).

yComponents not to be reused should be

replaced when disassembled including gaskets

metal seal rings, O-rings, oil seals, snap rings,

and split pins.

To this chapter contents

1. General Information

1-4

yThe 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.

yTighten 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.

yWhen oil seal is installed, fill the groove with

grease, install the oil seal with the name of the

manufacturer facing outside, and check the

shaft on which the oil seal is to be installed for

smoothness and for burrs that may damage the

oil seal.

yRemove residues of the old gasket or sealant

before reinstallation, grind with a grindstone if

the contact surface has any damage.

yThe 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.

yRubber and plastic boots should be properly

reinstalled to the original correct positions as

designed.

yThe 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.

Both of these examples can result in

bearing damage.

Manufacturer's name

Groove

Clamp

Connector

Boots

To this chapter contents

1. General Information

1-5

yLubricate the rotation face with specified

lubricant on the lubrication points before

assembling.

yCheck if positions and operation for installed

parts is in correct and properly.

yMake sure service safety each other when

conducting by two persons.

yNote that do not let parts fall down.

yBefore battery removal operation, it has to

remove the battery negative (-) cable firstly.

Notre tools like open-end wrench do not contact

with body to prevent from circuit short and

create spark.

yAfter service completed, make sure all

connection points is secured.

Battery positive (+) cable should be connected

firstly.

yAnd the two posts of battery have to be greased

after connected the cables.

yMake sure that the battery post caps are

located in properly after the battery posts had

been serviced.

yIf fuse burned, it has to find out the cause and

solved it. And then replace with specified

capacity fuse.

Capacity

verification

To this chapter contents

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