Sym RV 250i Bedienungsanleitung

GTS 250i/ RV 250i

GTS 300i/ JOYMAX 300i

SERVICE MANUAL

FOREWORD

HOW TO USE THIS MANUAL

CONTENTS

SERIAL NUMBER

Foreword

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

repair for the SANYANG LM25W5 / LM30W series scooter. The manual is shown

with illustrations and focused on “Service Procedures”, “Operation Key Points”,

and “Inspection Adjustment”, providing technicians with service guidelines.

If the style or the mechanical structures of the scooter, LM25W5 / LM30W series

scooter are different from those of the photos or pictures shown in this manual, the

actual vehicle shall prevail. Specifications are subject to changes without notice.

Service Department

SANYANG INDUSTRY CO., LTD.

Homepage Contents

How To Use This Manual

This service manual describes the basic information of different system parts and

system inspection & service for SANYANG LM25W5 / LM30W series scooter. In

addition, please refer to the manual contents in detail for the model you serviced in

inspection and adjustment.

The first chapter covers the general information and the trouble diagnosis.

The second chapter covers the periodic maintenance information and the special

tool models.

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

The 12th chapter is the cooling system.

The 13th to the 16th chapter contain the relative parts of the body frame assembly.

The 17th chapter is the electrical system.

The 18th chapter is the emission control system.

The 19th chapter is the wiring diagram.

Please 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 Illustrations” on the PDF 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 ~ 1-18 General Information

2-1 ~ 2-18 Maintenance Information

3-1 ~ 3-8 Lubrication System

4-1 ~ 4-60 Fuel Injection System

5-1 ~ 5-12 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 Final Drive Mechanism

10-1 ~ 10-10 AC Generator / Start Clutch

11-1 ~ 11-8 Crankshaft / Crankcase

12-1 ~ 12-14 Cooling System

13-1 ~ 13-14 Body Cover

14-1 ~ 14-12 Brake System

15-1 ~ 15-10 Steering / Front Wheel / Front Cushion

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

17-1 ~ 17-22 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

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

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

Torque Values···································· 1-12

Trouble Diagnosis······························ 1-14

Lubrication Points ····························· 1-18

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.

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

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

Components 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

yAlways use SANYANG genuine parts and

recommended oil. Using improper parts may

cause damage to or destruction of the vehicle.

ySpecial tools are designed for removal and

installation of component parts without

damaging them. Using wrong tools may result in

parts damage.

yWhen 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.

yClean 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.

yWash 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.

yNever bend or twist control cables to avoid

unsmooth control and premature worn out.

yRubber parts may become deteriorated when

old, and be damaged by solvent and oil easily.

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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