Sym MAXSYM 400i Bedienungsanleitung

MAXSYM 400i

SERVICE MANUAL

20120303

FOREWORD

HOW TO USE THIS MANUAL

CONTENTS

MECHANISM ILLUSTRATION

Foreword

This service manual contains the technical data of each component inspection

and repair for the Sanyang MAXSYM 400i scooter. The manual is shown with

illustrations and focused on “Service rocedures”, “Operation Key oints”, and

“Inspection Adjustment” so that provides technician with service guidelines.

If the style and construction of the motorcycle, MAXSYM 400i, 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 Manua

This service manual describes basic information of different system parts and

system inspection & service for Sanyang MAXSYM 400i 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.

Th third to the twelfth chapter covers the engine and driving systems.

The thirteenth to the sixteenth is contained the parts set of assembly body.

The seventeenth chapter is electrical equipment.

The eighteenth chapter is wiring diagram.

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

information.

There are 4 buttons, “Foreword”, “Contents”, “How to Use This Manual” and

“Mechanism Illustration” in the DF version, and can be access to these items

by clicking on the buttons.

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, on 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 content so that clicking the button can back to the contents of this

chapter.

Homepage

Contents

Page Content Index

1-1 ~ 1-16 General Information

2-1 ~ 2-16 Maintenance Information

3-1 ~ 3-6 Lubrication System

4-1 ~ 4-58 uel Injection System

5-1 ~ 5-4 Engine Removal

6-1 ~ 6-16 Cylinder Head / Valve

7-1 ~ 7-8 Cylinder / Piston

8-1 ~ 8-14 V-Belt Drive System

9-1 ~ 9-8 inal Drive Mechanism

10-1 ~ 10-4 AC Generator / Starting Clutch

11-1 ~ 11-8 Crankshaft / Crankcase

12-1 ~ 12-12 Cooling System

13-1 ~ 13-16 Body Cover

14-1 ~ 14-12 Brake System

15-1 ~ 15-11 Steering / ront Wheel / ront Cushion

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

17-1 ~ 17-22 Electrical System

18-1 ~ 18-2 Wiring Diagram

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Contents

Mechanism Illustration

ront winker

Luggage box

Start / engine stop switch

Dimmer / winker / horn

seat open / pass switch

Muffler

Reserve tank

cap

Coolant filler cap

Main switch

uel tank /

fuel pump

Side stand

Back mirror

Headlight

ront brake lever

Rear brake lever

Home page

Contents

Main stand

Air cleaner

Taillight /

rear winker

Engine number

1. General Information

1-1

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

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

Before Servicing·································1-3

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

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

Troubleshooting································· 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 is needed. If

supplemental information is needed for these symbols and marks, explanations will be added in the text

instead of using the symbols or marks.

Warning Means that serious injury or loss of life may happen if procedures are not

correctly followed.

aution 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.

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

orrect Meaning correct installation.

Wrong Meaning wrong installation.

Indication Indication of components.

Directions Indicates position and operation directions

omponents 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

Before you start the engine, make sure the place

is well ventilated. Never start the engine in an

unventilated place. If you have to start the engine

in an unventilated place, an exhaust fume

extractor is needed.

Caution

Exhaust fume contains toxic gas which may

cause one to lose consciousness and even result

in loss of life.

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 the

children.

Used Engine Oil

Caution

Prolonged contact with the used engine oil (or

transmission oil) may cause skin cancer although

it might not be verified yet. We recommend that

you wash your hands with soap right after

contacting. Keep the used oil beyond reach of the

children.

Hot Components

Caution

omponents of the engine and exhaust system

can be extremely hot after engine running. They

remain very hot even after the engine has been

stopped for a period of time. Before performing

service work on these parts, wear the heat

insulation gloves or wait until the temperature

drops.

Battery

Caution

‧ Battery emits explosive gases; flame is strictly

prohibited. Keep the place well ventilated

when the battery is being charged.

‧ Battery contains sulfuric acid (electrolyte)

which can cause serious burns, be careful not

to spill it on your skin or eyes. If you get

battery fluid on your skin, flush it off with water

immediately. If you get battery fluid in your

eyes, flush it off immediately with water and

go to hospital to see an ophthalmologist

doctor.

‧ If you swallow the battery fluid by mistake,

drink a lot of water or milk, and take some

laxative such as Epsom salts or vegetable oil

and then go to see a doctor.

‧ Keep the battery and battery fluid beyond

reach of the children.

Brake Shoes

Do not use compressed air or brush to clean the

components of the brake system. Use a vacuum

cleaner or the equivalent to avoid dust drifting in

the air.

Caution

Inhaling brake shoes dust may cause disease or

even cancer of the respiratory system.

Brake Fluid

Caution

Brake fluid spilled on painted, plastic, or rubber

parts may cause damage to the parts. Place a

clean towel on the top of the parts for protection

when servicing the brake system. Keep the brake

fluid beyond reach of the children.

To this chapter contents

1. General Information

1-3

Before Servicing

 Always use SANYANG genuine parts and

recommended oil. Using improper parts may

cause damage to or destruction of the vehicle.

 Special tools are designed for removal and

installation of component parts without

damaging them. Using wrong tools may result

in parts damage.

 When servicing this vehicle, use only metric

tools. Metric bolts, nuts, and screws are not

interchangeable with the Britain system, using

wrong tools and fasteners may damage this

vehicle.

 lean the outside of the parts or the cover

before removing it from the vehicle. 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 flash point

solvent, and then blow dry with compressed air.

Pay special attention to O-rings or oil seals

because most of the cleaning agents have bad

effect on them.

 Never bend or twist control cables to avoid

unsmooth control and premature worn out.

 Rubber parts may become deteriorated when

old, and be damaged by solvent and oil easily.

heck 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).

 omponents 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.

 heck 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

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