Sym Jet 4 125 Bedienungsanleitung

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

1-1

SYMBOLS AND MARKS ................... 1-1

GENERAL SAFETY........................... 1-2

SERVICE PRECAUTIONS................ 1-3

SPECIFICATIONS............................. 1-9

TORQUE VALUES (ENGINE)..............1-10

TORQUE VALUES (FRAME)...............1-11

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 SH/CD class oil. Warranty will not cover the

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

Gear oil Limits to use SAE 85W-140 class oil. Warranty will not cover the damage

that caused by not apply with the limited gear oil.

Grease King Mate G-3 is recommended.

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 service 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).

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

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

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

Used engine oil

Caution

Hot components

Caution

Battery

Caution

Brake shoe

Do not use an compressed air or a dry brush to

clean components of the brake system, use a

vacuum cleaner or the equivalent to avoid

asbestos dust flying.

Caution

Brake fluid

Caution

Exhaust contains toxic gas which may cause

one to lose consciousness and even result in

death.

ŸBattery emits explosive gases; flame is

strictly prohibited. Keep the place well

ventilated when charging the battery.

ŸBattery 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, then go to hospital to see an

ophthalmologist.

ŸIf 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.

ŸKeep electrolyte beyond reach of children.

Gasoline is highly flammable, and may explode

under some conditions, keep it away from

children.

Prolonged contact with used engine oil (or

transmission oil) may cause skin cancer

although it might not be verdict.

Inhaling asbestos dust may cause disorders

and cancer of the breathing system.

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 brake fluid beyond reach of children.

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.

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

1-3

SERVICE PRECAUTIONS

ŸAlways use with SANYANG genuine parts

and recommended oils. Using non-designed

parts for SANYANG motorcycle may damage

the motorcycle.

ŸSpecial tools are designed for remove and

install of components without damaging the

parts being worked on. Using wrong tools

may result in parts damaged.

ŸWhen 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.

ŸClean 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.

ŸWash 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.

ŸNever bend or twist a control cable to prevent

stiff control and premature worn out.

ŸRubber 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.

ŸWhen 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.

ŸStore complex components such as

transmission parts in the proper assemble

order and tie them together with a wire for

ease of installation later.

ŸNote the reassemble position of the important

components before disassembling them to

ensure they will be reassembled in correct

dimensions (depth, distance or position).

ŸComponents not to be reused should be

replaced when disassembled including

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

snap rings, and split pins.

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

1-4

ŸThe 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.

ŸTighten assemblies with different dimension

fasteners as follows:

ŸTighten 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.

ŸWhen 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.

ŸRemove residues of the old gasket or sealant

before reinstallation, grind with a grindstone if

the contact surface has any damage.

ŸThe 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.

ŸRubber and plastic boots should be properly

reinstalled to the original correct positions as

designed.

ŸThe 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

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

1-5

ŸLubricate the rotation face with specified

lubricant on the lubrication points before

assembling.

ŸCheck if positions and operation for installed

parts is in correct and properly.

ŸMake sure service safety each other when

conducting by two persons.

ŸNote that do not let parts fall down

ŸBefore 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.

ŸAfter 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.

ŸMake sure that the battery post caps are

located in properly after the battery posts had

been serviced.

ŸIf fuse burned, it has to find out the cause

and solved it. And then replace with

specified capacity fuse.

capacity

verification

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

1-6

ŸWhen separating a connector, it locker has to

be unlocked firstly. Then, conduct the

service operation.

ŸDo not pull the wires as removing a

connector or wires. Hold the connector

body.

ŸMake sure if the connector pins are bent,

extruded or loosen.

ŸInsert 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.

ŸCheck if the connector is covered by the twin

connector boot completely and secured

properly.

ŸBefore terminal connection, check if the boot

is crack or the terminal is loose.

ŸInsert the terminal completely. Check if the

terminal is covered by the boot. Do not let

boot open facing up.

ŸSecure 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.

ŸWire band and wire harness have to be

clamped secured properly.

ŸDo not squeeze wires against the weld or its

clamp.

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

1-7

ŸDo not let the wire harness contact with

rotating, moving or vibrating components as

routing the harness.

ŸKeep wire harnesses far away from the hot

parts.

ŸRoute wire harness to avoid sharp edges or

corners and also avoid the projected ends of

bolts and screws.

ŸRoute harnesses so that they neither pull too

tight nor have excessive slack.

ŸProtect 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.

ŸSecure the rubber boot firmly as applying it

on wire harness.

ŸNever use wires or harnesses which

insulation has been broken. Wrap electrical

tape around the damaged parts or replace

them.

ŸNever clamp or squeeze the wire harness as

installing other components.

Do not touch it.

Do not extend

it too much.

Please do not clip or

squeeze the wire.

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

1-8

ŸDo not let the wire harness been twisted as

installation.

ŸWire 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.

ŸBefore operating a test instrument, operator

should read the operation manual of the

instrument. And then, conduct test in

accordance with the instruction.

ŸWith sand paper to clean rust on connector

pins/terminals if found. And then conduct

connection operation later.

Do you know how to set the

instrument to its measurement

position and the insert locations

of its two probes?

Clean rust.

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

1-9

SPECIFICATIONS

MAKER SANYANG MODEL AD12W1-6

Overall Length 1900 mm Front TELESCOPIC FORK

Overall Width 665 mm

Suspen

sion

System

Rear DOUBLE SWING ARM

Overall Height 1040 mm Front 120/60-13 56J

DIMENSION

Wheel Base 1330 mm

Tire

Specifi

cations

Rear 130/70-12 56J

Front 42 kg

Rear 67 kg Front DISK (ø226 mm)

Curb Weight

Total 109kg

Brake

System

Rear DRUM (ø130 mm)

Passengers/

Weight Two men/184 kg Max. Speed 120 km/hr Above

Front 76.5kg

Performa

nce

Climb Ability 22° Below

Rear 186.5 kg Primary Reduction

C.V.T.

WEIGHT

Total Weight

Total 263kg Secondary

Reduction GEAR

Type 4-STROKE ENGINE Clutch Centrifugal, dry type

Installation and

arrangement Vertical, below center,

incline 80°

Deceleration

equipment

Transmission V-belt

Fuel Used Unleaded (93/95) Speedometer 0 ~ 120 km/hr

Cycle/Cooling 4-stroke/forced air

cooled Horn 80~112 dB/A

Bore 52.4 mm Muffler Expansion & Pulse Type

Stroke 57.8 mm Exhaust Pipe Position

and Direction Right side, and

Backward

Cylinder

Number/Arra

ngement Single Cylinder Lubrication System Separated-lubrication

Displacement 124.6 cc CO%1.1~1.5

Compression

Ratio 10.5±0.2 : 1

Exhaust

Emission

(IDLE) HC%Less than2000

Idle speed 1800±100 rpm Fuel tank capacity 4.80L

Max. HP 6.5KW/ 7500 rpm Air Filtration Paper filter

Max. Torque 8.6N.m /7000 rpm Noise Emission < 80dB(A)

Ignition C.D.I.

ENGINE

Starting System

Electrical & Kick starter

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

1-10

TORQUE VALUES (ENGINE)

ITEM Q'TY

THREAD DIA

(mm) TORQUE

VALUE(Kg-m) REMARKS

A.C. generator flange bolt 260.8~1.2

L side cover plate pan screw

750.5~0.7

RR. brake shoe anchor fixing

nut 181.5~2.0

Rear brake arm flange bolt 160.7~1.1

Engine oil filter screen cover

130 1.0~2.0

Crankcase bolts 260.8~1.2

Oil pump flat screw 260.8~1.2

Cylinder/cylinder head

two

ends bolts

480.7~1.1

Tighten to crankcase

Cylinder head left side

bolts

260.7~1.1

Camshaft sprocket bolt 261.0~1.5

Valve adjustment fixing nuts

250.7~1.1 Apply oil to thread

Camshaft chain tensioner

pivot bolts 160.8~1.2

Camshaft chain adjuster

bolts 260.8~1.2

A/I fixing flange bolt 460.8~1.2

Oil pump separator bolt 260.8~1.2

One-way clutch lock nut 122 9.0~10.0 Apply oil to thread

Right crankcase cover bolts

10 60.7~1.1

Pulse generator bolts 250.4~0.6

A.C. generator flange bolt 250.8~1.2

Flywheel nut 112 5.0~6.0

Cooling fan flange bolt 460.8~1.2

Shroud A/B 260.7~1.1

Engine oil draining plug bolt

112 3.5~4.5

Start motor bolts 260.7~1.1

Transmission bolts 782.6~3.0

Gear oil draining plug 181.0~1.5

Gear oil filling bolt 181.0~1.5

Driven pulley nut 112 5.5~6.0

Driving face nut 112 5.0~6.0

Left crankcase cover bolts 860.8~1.2

Cylinder head holder nuts481.8~2.2

Cylinder head cover bolts 460.8~1.2

Spark plug 110 1.0~1.2

Carburetor heat protector

connecting nuts

260.7~1.1

Exhaust pipe bolts 283.0~3.6

Exhaust pipe connecting

nuts

261.0~1.4

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