Sym GTS 250 Bedienungsanleitung

GTS 250

JOYMAX 250

SERVICE MANUAL

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HOW TO USE THIS MANUAL

CONTENTS

SERIAL NUMBER

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

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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

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).

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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

Always use with SANYANG genuine parts and

recommended oils. Using non-designed parts

for SANYANG ATV may damage the ATV.

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 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.

Clean 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.

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.

Never bend or twist a control cable to prevent

unsmooth control and premature worn out.

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.

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.

Store complex components such as

transmission parts in the proper assemble order

and tie them together with a wire for ease of

installation later.

Note the reassemble position of the important

components before disassembling them to

ensure they will be reassembled in correct

dimensions (depth, distance or position).

Components 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

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.

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.

When 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.

Remove residues of the old gasket or sealant

before reinstallation, grind with a grindstone if

the contact surface has any damage.

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.

Rubber and plastic boots should be properly

reinstalled to the original correct positions as

designed.

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.

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

Lubricate the rotation face with specified

lubricant on the lubrication points before

assembling.

Check if positions and operation for installed

parts is in correct and properly.

Make sure service safety each other when

conducting by two persons.

Note that do not let parts fall down.

Before 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.

After service completed, make sure all

connection points is secured.

Battery positive (+) cable should be connected

firstly.

And the two posts of battery have to be greased

after connected the cables.

Make sure that the battery post caps are

located in properly after the battery posts had

been serviced.

If 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

1. General Information

1-6

When separating a connector, it locker has to

be unlocked firstly. Then, conduct the service

operation.

Do not pull the wires as removing a connector

or wires. Hold the connector body.

Make sure if the connector pins are bent,

extruded or loosen.

Insert the connector completely.

If there are two lockers on two connector sides,

make sure the lockers are locked in properly.

Check if any wire loose.

Check if the connector is covered by the twin

connector boot completely and secured

properly.

Before terminal connection, check if the boot is

crack or the terminal is loose.

Insert the terminal completely.

Check if the terminal is covered by the boot.

Do not let boot open facing up.

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.

Wire band and wire harness have to be

clamped secured properly.

Do not squeeze wires against the weld or its

clamp.

To this chapter contents

1. General Information

1-7

Do not let the wire harness contact with rotating,

moving or vibrating components as routing the

harness.

Keep wire harnesses far away from the hot

parts.

Route wire harnesses to avoid sharp edges or

corners and also avoid the projected ends of

bolts and screws.

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. Thoroughly clean the surface where

tape is to be applied.

Secure the rubber boot firmly as applying it on

wire harness.

Never use wires or harnesses which insulation

has been broken. Wrap electrical tape around

the damaged parts or replace them.

Never clamp or squeeze the wire harness as

installing other components.

Never Touch

Never too tight

Never clamp or

squeeze the wire

harness

To this chapter contents

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