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SERVICE MANUAL

S50/R50/SR50

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This service manual contains the technical data of each component inspection and
repair for the SANYANG Jet Sport X S50 / R50 / SR50 series scooters.

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 scooters, Jet Sport X S50 / R50 / SR50 series,
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.

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How to Use This Manual
This service manual describes basic information of different system parts and
system inspection & service for SANYANG Jet Sport X S50 / R50 / SR50 series
scooters. 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.
The 3rd to the 10th chapters covers engine and driving systems.
The 11th to the 14th chapters is contained the parts set of frame body.
The 15th chapter is electrical equipment.
The 16th chapter is wiring diagram.

Please see index of content for quick

having the special parts and system
information.

All information, illustration, directions and specifications included in this manual are
current as at the time of publication. SANYANG reserves the rights to make
changes at any time without prior notice and without incurring any obligation
whatever. Without written consent by SANYANG can not copy any part of this
manual.

There are 4 buttons, "Forward", "How to use this manual", "Mechanism

Illustrations", and "Contents" 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 main contents can reach to each chapter. There are two buttons,
Back to homepage and Main 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 main 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 "This chapter contents" button at
the top line of each page so that clicking the button can back to the contents of
this chapter.

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Contents

Page Content Index

1-1 ~ 1-18 General Information 1

2-1 ~ 2-14 Service Maintenance Information 2

3-1 ~ 3-6 Lubrication System 3

4-1 ~ 4-10 Fuel System 4

5-1 ~ 5-6 Engine Removal 5

6-1 ~ 6-4 Cylinder Head / Cylinder / Piston 6

7-1 ~ 7-14 A.C. Generator 7

8-1 ~ 8-6 "V" Type Belt Driving System / Kick-Starter 8

9-1 ~ 9-6 Final Driving Mechanism 9

10-1 ~ 10-10 Crankcase / Crankshaft 10

11-1 ~ 11-12 Body Cover 11

12-1 ~ 12-12 Brake System 12

13-1 ~ 13-10 Steering / Front Wheel / Shock absorber 13

14-1 ~ 14-4 Rear Wheel / Shock absorber 14

15-1 ~ 15-22 Electrical Equipment 15

16-1 ~ 16-4 Electrical Diagram 16

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Model illustration

Jet Sport X S50 / R50 / SR50 Series

ENG. Stop / Starter switch

Fuel tank cap

Rear turn signal

Taillight

Rear turn signal

Front turn signal

Helmet hook

High & Low beam / Passing /

Turn signal / Horn switch

Battery / Fuses / C.D.I. /

Eng. Oil tank cap
Frame number

Seat lock
Headlight
Luggage box

Air cleaner

Ignition switch
Front brake lever Rear brake lever

Engine number

Muffler

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1. General Information

Symbols and Marks ····················· 1-1 Torque values······························· 1-7 1

General Safety······························ 1-2 Cables and Harness Routing ······ 1-9
Service Precautions····················· 1-3 Troubleshooting··························· 1-13
Specifications······························· 1-6 Lubrication Points ······················· 1-20

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.

Means that serious injury or even death may result if procedures are not
Warning
followed.
Means that equipment damages may result if procedures are not
Caution
followed.
Limits to use SAE 20 JASO FC class oil. Warranty will not cover the
Engine oil damage that caused by not apply with the limited engine oil.
(Recommended oil: MAX-2 serial oils)

Grease King Mate G-3 is recommended.

King Mate gear oil serials are recommended. (Bramax HYPOID GEAR
Gear oil
OIL # 140)
Apply sealant; medium strength sealant should be used unless otherwise
Locking sealant
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.

O Correct Meaning correct installation.

X 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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 This chapter Contents

1. General Information
General Safety
Carbon monoxide Battery
If you must run your engine, ensure the place is
Caution
well ventilated. Never run your engine in a closed
area. Run your engine in an open area, if you • Battery emits explosive gases; flame is
have to run your engine in a closed area, be sure strictly prohibited. Keeps the place well
to use an extractor. ventilated when charging the battery.
Caution • Battery contains sulfuric acid (electrolyte)
which can cause serious burns so be careful
Exhaust contains toxic gas which may cause do not be spray on your eyes or skin. If you
one to lose consciousness and even result in get battery acid on your skin, flush it off
death. 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
Gasoline ophthalmologist.
Gasoline is a low ignition point and explosive • If you swallow it by mistake, drink a lot of
material. Work in a well-ventilated place, no flame water or milk, and take some laxative such
or spark should be allowed in the work place or as castor oil or vegetable oil and then go to
where gasoline is being stored. see a doctor.
• Keep electrolyte beyond reach of children.
Caution
Gasoline is highly flammable, and may explode
under some conditions, keep it away from
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.
Used engine oil
Caution
Caution Inhaling dust may cause disorders and cancer
Prolonged contact with used engine oil (or of the breathing system.
transmission oil) may cause skin cancer
although it might not be verified.
We recommend that you wash your hands with Brake fluid
soap and water right after contacting. Keep the
used oil beyond reach of children. Caution
Spilling brake fluid on painted, plastic, or rubber
parts may cause damage to the parts. Place a
Hot components clean towel on the above-mentioned parts for
protection when servicing the brake system.
Caution Keep the 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.

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 1. General Information
Service Precautions
• Always use with SANYANG genuine parts and • Rubber parts may become deteriorated when
recommended oils. Using non-designed parts old, and prone to be damaged by solvent and
for SANYANG scooter may damage the oil. Check these parts before installation to
scooter. make sure that they are in good condition,
• Special tools are designed for remove and replace if necessary.
install of components without damaging the • When loosening a component which has
parts being worked on. Using wrong tools may different sized fasteners, operate with a
result in parts damaged. diagonal pattern and work from inside out.
• When servicing this scooter, use only metric Loosen the small fasteners first. If the bigger
tools. Metric bolts, nuts, and screws are not ones are loosen first, small fasteners may
interchangeable with the English system, using receive too much stress.
wrong tools and fasteners may damage this • Store complex components such as
vehicle. transmission parts in the proper assemble
• Clean the outside of the parts or the cover order and tie them together with a wire for
before removing it from the scooter. Otherwise, ease of installation later.
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.

• 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.
• Never bend or twist a control cable to prevent
stiff control and premature worn out.

Caution
In addition to damaging paint finish, brake oil
can also damage the structural integration of
plastic or rubber parts.

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 1. General Information
• The length of bolts and screws for assemblies, • The ends of rubber hoses (for fuel, vacuum, or
cover plates or boxes is different from one coolant) should be pushed as far as they can
another, be sure they are correctly installed. In go to their connections so that there is enough
case of confusion, Insert the bolt into the hole room below the enlarged ends for tightening
to compare its length with other bolts, if its the clamps.
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.

• Rubber and plastic boots should be properly

reinstalled to the original correct positions as
designed.
• 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. Boots
• When 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 • The tool should be pressed against two (inner
smoothness and for burrs that may damage and outer) bearing races when removing a ball
the oil seal. bearing. Damage may result if the tool is
pressed against only one race (either inner
race or outer race). In this case, the bearing
Manufacturer's name should be replaced. To avoid damaging the
bearing, use equal force on both races.

• Remove residues of the old gasket or sealant

before reinstallation, grind with a grindstone if
the contact surface has any damage.

Both of these examples can result in bearing

damage.
• Lubricate the rotation face as assembling.
Check if positions and operation for installed
parts is in correct and properly.

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Specifications
Make SANYANG MODEL Jet Sport X 50 series

Overall Length 1840 mm Suspension Front Telescopic Fork

Dimension

Overall Width 690 mm System Rear Unit Swing

Overall Height 1120 mm Tire Front 120 / 70 – 12

Wheel Base 1275 mm Specifications Rear 130 / 70 – 12

Front 42 kg Front Disk (Ø190mm)

Weight
Curb

Rear 56 kg Brake System Disk (Ø160mm)

Rear
Total 98 kg DRUM (Ø110mm)
Weight

Passengers / One / 75 kg Max. Speed 48 km/hr Below

Weight
Total Weight

Front 64 kg Climb Ability 22° Below

Forman Perce
Rear 109 kg Primary Reduction BELT

Total 173 kg Secondary Reduction GEAR

Type Gasoline Clutch Centrifugal, dry type

Installation and Horizontal, below center,
Transmission C.V.T.
arrangement incline
Fuel Used Unleaded (92/95) Speedometer 0 ~ 80 km/hr

Cycle/Cooling 2-stroke/forced air cooled Horn 93 ~ 112 dB/A

Expansion & Pulse
Bore Ø 39 mm Muffler
Type
Cylinder

Exhaust Pipe Position and Right side, and

Stroke 41.4 mm
Direction Backward
Engine

Number/Arrang
Single Cylinder Lubrication System Separated-lubrication
ement
Concentration

1.0 g/km ↓
Displacement 49.4 cc
Exhaust

CO
Compression Ratio 7.2 : 1

Max. HP 2.6 kw / 6000 rpm HC+Nox 1.2 g/km ↓

Max. Torque 4.2 Nm / 5500 rpm E.E.C. X

Ignition C.D.I. P.C.V. X

Catalytic reaction control
Starting System Electrical & kick ○
system

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Torque values
Standard Torque Values for Reference
Type Torque value Type Torque value
5 mm Bolt, nut 0.45 ~ 0.6kgf-m 5 mm Screw 0.35 ~ 0.5kgf-m
6 mm Screw, flange bolt
6 mm Bolt, nut 0.8 ~ 1.2kgf-m 0.7 ~ 1.1kgf-m
(SH Type)
8 mm Bolt, nut 1.8 ~ 2.5kgf-m 8 mm Flange bolt, nut 1.0 ~ 1.4kgf-m
10 mm Bolt, nut 3.0 ~ 4.0kgf-m 8 mm Flange bolt, nut 2.4 ` 3.0kgf-m
12 mm Bolt, nut 5.0 ~ 6.0kgf-m 10 mm Flange bolt, nut 3.5 ~ 4.5kgf-m

The torque values listed in below table are for more important tighten torque values. Please see above
standard values for not listed in the table.

Engine
Thread Dia. Torque Value
Item Q’ty Remarks
(mm) (kgf-m)
Cylinder head bolt 4 7 1.6~2.0 When engine cooled

Spark plug 1 14 1.1~1.7

Inlet pipe nut 2 6 0.8~1.2

Flywheel nut 1 10 3.5~4.5

Movable drive face nut 1 12 5.5~6.5

Drive plate nut 1 28 5.0~6.0

Clutch outer nut 1 10 3.5~4.5

Mission oil check bolt 1 10 1.0~1.5

Mission oil drain bolt 1 8 1.0~1.5

Mission cover bolt 7 8 2.4~3.0

Crankcase bolts 6 6 1.0~1.5

Cooling fan bolts 4 6 0.6~1.0

Brake shoe anchor pin 1 8 1.5~2.0

Nuts for exhaust pipe 2 6 1.0~1.4

Mounting bolts for exhaust 2 8 3.0~3.6

Others - 6 0.8~1.2

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Frame
Thread Dia. Torque Value
Item Q’ty Remarks
(mm) (kgf-m)
Mounting nut for handle 1 10 4.0~5.0

Steering stem lock nut 1 25.4 1.0~2.0

Steering top cone race 1 25.4 0.2~0.3

Front cushion bolts 4 8 2.4~3.0

Front wheel axle nut 1 12 5.0~7.0

Air cleaner bolts 2 6 1.0~1.4

Brake master cylinder mounting bolts 4 6 1.0~1.4

Brake hose bolts 2 10 3.3~3.7

Brake caliper mounting bolts 2 10 3.1~3.5

Brake shoe guide bolts 2 6 1.5~2.0

Brake shoe guide bolts cap 2 6 0.8~1.2

Brake drain valve 1 6 0.8~1.0

Mounting bolt for brake disc 7 8 4.0~4.5

Rear brake arm bolts 1 5 0.8~1.2

Rear brake lever nuts 2 5 0.8~1.2

Bolt for engine hanger 4 12 5.5~6.5

Bolt for engine hanger bracket 1 10 4.5~5.5

Upper bolt for rear cushion 1 10 3.5~4.5

Lower bolt for rear cushion 1 8 2.4~3.0

Rear wheel nut 1 16 10.0~12.0

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Cables and Harness Routing
Note the following when routing cables
and wire harnesses:
• A loose wire, cable or harness may cause
safety hazard. After clamping, check each
wire to make sure it is secured.
• Do not squeeze wires against the weld or its
clamp.
• 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.
• 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.
• Route wire harnesses to avoid sharp edges or
corners.
• Avoid the projected ends of bolts and screws.
• Keep wire harnesses far away from the
exhaust pipes and other hot parts.
• Be sure grommets are seated in their groves
properly.
• After clamping, check each harness to be
certain that it is not interfered with any moving
or sliding parts.
• After routing, check that the wire harnesses
are not twisted or kink.
• Wire 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 O：Correct X：Wrong
steering positions.
• Thoroughly clean the surface where tape is to
be applied.
• Wrap electrical tape around the damaged parts
or replace them.

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Headlight
Winker switch
switch Speedometer High/low beam switch
Starter switch

Horn switch

Front brake
lamp switch Rear brake lamp
switch

Throttle cable

Speedometer
cable
Front brake cable
Rear brake cable
Headlight

Throttle cable Winker relay

Main switch

Regulator
Horn
Resistor

Front brake
Speedometer cable hose

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Front brake hose Speedometer cable Rear brake cable

Throttle cable

Winker relay

Fuel unit

Rear brake cable

Throttle cable
Front brake
hose

Rear brake cable

Throttle cable

Fuel unit cord

Front brake hose Fuel pump

Speedometer cable

Fuel filter

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Battery

Fuse
Purge control valve

Oil control cable C.D.I. UNIT

Fuel hose

Fuel pump
Carburetor

Fuel filter

Rear brake cable

Oil hose

Vacuum hose

Oil lever switch

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Troubleshooting
A. Engine hard to start or can not be started
Check and adjustment Fault condition Probable causes

Loosen carburetor drain bolt to

check if there is gasoline
inside the carburetor 1. No fuel in fuel tank
2. Check if the pipes, fuel tank to
carburetor and intake vacuum, are
clogged.
Fuel supplied tom No fuel is supplied to
3. Float valve clogged
carburetor sufficient carburetor
4. Lines in fuel tank evaporation system
clogged
5. Malfunction of fuel pump
Remove spark plug, install it 6. Loosen or damaged fuel pump vacuum
into spark plug cap, and hose
perform a spark test against 7. Fuel filter clogged
engine ground.

1. Malfunction of spark plug

Check if sparks Week sparks or no 2. Spark plug foul
spark at all 3. Malfunction of CDI set
4. Malfunction of AC generator
5. Ignition coil is in open or short circuit
6. Ignition coil leads open or short circuit
Perform cylinder compression 7. Malfunction of main switch
pressure test.

1. Piston ring seized

Cylinder compression Low compression 2. Malfunction of cylinder valves
pressure normal pressure or no pressure 3. Worn cylinder and piston ring
4. Cylinder gasket leak
5. Sand hole in compression parts
6. Crankcase leakage for pre-compression
Re-start by following the
starting procedures

No ignition There are some signs of 1. Malfunction of throttle valve operation

ignition, but engine can 2. Air sucked into intake manifold
not be started 3. Incorrect ignition timing
Remove the spark plug again
and check it.

1. Fuel level in carburetor too high

Dry spark plug Wet spark plug 2. Malfunction of throttle valve operation
3. Throttle valve opening too wide

Remove carburetor after 30

minutes and connect a hose
onto fuel supplement circuit.
Then blow the hose with air.

Blowing in normal Blowing clogged 1. Malfunction of auto-starter

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B. Engine run sluggish (Speed does not pick up, lack of power)
Check and adjustment Fault condition Probable causes

Try gradual acceleration and

check engine speed

1. Air cleaner clogged

Engine speed can be Engine speed can not 2. Poor fuel supply
increased. be increased. 3. Lines in fuel tank evaporation system
clogged
4. Exhaust pipe clogged
Check ignition timing (Using
ignition lamp)

Ignition timing correct Incorrect ignition timing 1. Malfunction of CDI

2. Malfunction of AC generator

Check cylinder compression

pressure (using compression
pressure gauge)
1. Cylinder & piston ring worn out
2. Cylinder gasket leaked
Compression pressure No compression
3. Sand hole in compression parts
correct pressure
4. Valve deterioration
5. Crankcase leakage for pre-compression

Check if carburetor is clogged

Normal Clogged 1. Remove dirt

Remove spark plug

No foul or discoloration Fouled and discoloration 1. Remove dirt

2. Incorrect spark plug heat range

Check if engine over heat

1. Piston and cylinder worn out
2. Lean mixture
Normal Engine overheat 3. Poor fuel quality
4. Too much carbon deposited in
combustion chamber
Continually drive in 5. Ignition timing too advanced
acceleration or high speed
1. Too much carbon deposited in
combustion chamber
No knock Knock 2. Lean mixture
3. Poor fuel quality
4. Lean mixture

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C. Engine runs sluggish (especially in low speed and idling)

Check and adjustment Fault condition Probable causes

Check ignition timing (using

ignition lamp)

Normal Abnormal 1. Incorrect ignition timing (malfunction of

CDI or AC generator)

Adjust the air screw of

carburetor

Good Poor 1. Rich mixture (loosen the screw)

2. Lean mixture (tighten the screw)

Air sucked through carburetor

gasket

1. Poor heat insulation gasket

No air sucked Air sucked 2. Carburetor lock loose
3. Poor intake gasket
4. Poor carburetor O-ring
Remove spark plug, install
spark plug into spark plug cap
and perform spark test against
engine ground
1. Spark plug fouled
2. Malfunction of CDI
Good spark Poor 3. Malfunction of AC generator
4. Malfunction of ignition coil
5. Open or short circuit in spark plug leads
6. Malfunction of main switch
D. Engine runs sluggish (High speed)
Check and adjustment Fault condition Probable causes

Check ignition timing

Normal Abnormal 1. Malfunction of CDI

2. Malfunction of AC generator

Check for fuel supplying

system in automatic fuel cup

1. Insufficient fuel in fuel tank

Good Poor 2. Fuel filter clogged
3. Restricted fuel tank vent

Check if carburetor clogged

Normal Clogged 1. Cleaning

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E. CLUTCH, DRIVING AND DRIVING PULLEY

FAULT CONDITION PROBABLE CAUSES

1. Driving belt worn out or deformation

Engine can be started but 2. Driving disk damaged
motorcycle can not be driving 3. Driving pulley spring broken
4. Clutch ling broken
5. Driving slide-shaft gear groove broken
6. Transmission gear damage
7. Transmission gear worn out or burned

Engine running and misfire as

1. Clutch ling spring broken
motorcycle initial forward moving
2. Clutch outer cover stuck with clutch balance
or jumping sudden (rear wheel
weights
rotating as engine in running)
3. Connection parts in clutch and shaft worn out or
burned

1. Driving belt worn out or deformation

2. Balance weight roller worn out
Poor initial driving (Poor
3. Driving sliding gear shaft worn out
climbing performance)
4. Driving disk spring deformation
5. Driving sliding gear shaft worn out
6. Greased in driving belt and sliding gear.

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Lubrication Points

Throttle cable/
Front & rear brake lever pivot

Seat catch

Steering shaft bearing

Speedometer gear/ Side stand shaft Main stand shaft Rear wheel bearing
front wheel bearing

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Note:

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2. Service Maintenance Information

General Information ······························ 2-1 Transmission Oil··································· 2-10

Periodical Maintenance Schedule········ 2-2 Spark Plug ············································· 2-10
2
Air Cleaner ············································· 2-3 Control Cable Lubrication···················· 2-11
Fuel Lines ·············································· 2-3 Driver Belt·············································· 2-11
Fuel Filter ··············································· 2-4 Ignition Timing ······································ 2-11
Engine Oil Line ······································ 2-4 Throttle Valve Operation ······················ 2-11
Oil Pump Control Cable ························ 2-5 Carburetor Idle Speed Adjustment······ 2-12
Battery···················································· 2-5 Carbon Removing For Exhaust Pipe &
Muffle ····················································· 2-12
Tire·························································· 2-6
Cylinder Compression Pressure Test· 2-12
Rear Drum Brake Free Play ·················· 2-6
Headlight Adjustment··························· 2-13
Disc Brake System Hose ······················ 2-7
Special Tool Manual ····························· 2-14
Steering System ···································· 2-9
Suspension ············································ 2-9

General Information
Specification
Item Jet Sport X 50 series

Tire dimension Front: 120 / 70 – 12, Rear: 130 / 70 - 12

Tire pressure at cold Only rider Front: 1.75kg/cm2, Rear: 2.0 kg/cm2
Rear brake lever free play 10~20 mm
Type: HYPOID GEAR OIL
Transmission oil / Recommendation
Oil: SAE #140 Quantity: 0.12 L, Replacement: 0.11L

Spark plug / Recommendation Type: NGK BR8HAS / Plug gap: 0.6-0.7mm

Standard 18.0mm
Driving belt width Allowable limit: replace it if below 16.5mm

Ignition timing F mark 17°, BTDC/1500 rpm

Acceleration operation 2~6 mm
Idle speed 2000±100 rpm
Cylinder compression pressure 7±1 kgf/cm²

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2. Service Maintenance Information

Periodical Maintenance Schedule
Maintenance Every Every Every Every
300KM
kilometer 1000KM 3000KM 6000KM 12000KM
Reference
Maintenance
Check item New 1 month 3 month 6 month 1 year
interval
☆ 1. Air cleaner I C R
☆ 2. Fuel filter C
☆ 3. Engine oil filter cleaning C C
☆
4. Oil pump linkage operation
check
I I
5. Tire pressure I I
6. Battery inspection I I
7. Brake & free play check I I
8. Steering handle check I I
9. Cushion operation check I I
10. Every screw tightening check I I
11. Gear oil check for leaking I I
☆ 12. Spark plug check or change I R
☆ 13. Gear oil change R Replacement for every 5000km
14. Frame lubrication L
15. Exhaust pipe I I
☆ 16. Carburetor I I
17. Driving belt check I
☆ 18. Ignition timing I I
☆ 19. Emission check in Idling I I
☆ 20. Idle speed check I I
21. Fuel lines I I
☆ 22. Throttle operation I I
☆ 23. Engine bolt tightening I I
☆ 24. Engine screw torque I
25. Carbon cleaning for cylinder
☆ head, cylinder, and piston I
head, and exhaust system.
Have your scooter checked, adjusted periodically by your SYM Authorized Dealer to maintain the scooter at the
optimum condition.
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement
C ~ Cleaning (replaced if necessary) L ~ Lubrication
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever
comes first.
Remarks:
1. Clean or replace the air cleaner element more often for pro-long engine life-span when the scooter is
operated on dusty roads or in the Heavily- polluted environment.
2. Maintenance should be performed more often if the scooter is frequently operated in high speed and
after the scooter has accumulated a higher mileage.

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2. Service Maintenance Information

Air Cleaner 5 screws

Remove the mounting screw from the air
cleaner cover

Remove the air cleaner cover

Air cleaner element

Remove the air cleaner element

Clean the element with non-flammable or
high-flash point solvent and then squeeze it for
dry.
Caution
Never use gasoline or acid organized solvent to
clean the element.

Soap the element into cleaning engine oil and

then squeeze it out. Install the element onto the
element seat and then install the air cleaner
cover. Soap
Clean

Limit to use SAE 20 JASO FC class engine oil;
otherwise, SYM is no responsible for the
warranty.

Recommended engine oil: MAX-2 serial oils.

Squeeze oil out Squeeze out remaining oil

Carburetor

Fuel Lines
Fuel pump
Remove the luggage box.
Check fuel lines and replace damaged lines if
found.
Install the luggage box.

Fuel line

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2. Service Maintenance Information

Fuel Filter
Remove the luggage box.
Remove the fuel line from the fuel filter.
Replace the fuel filter with new one.
Install the fuel filter. The arrow indicates the fuel
flowing direction.
Check the fuel line for leaking.
Fuel filter

Engine Oil Line

Remove the body cover.
Check the engine oil line and replace damaged
parts. Engine oil pipe
Oil pump
Remove the filling pipe from the oil pump, and
drain oil into a cleaning container.
Loosen the clamp under the engine oil tank, and
then remove the oil pipe.
Bleed the air inside the oil pump and oil pipe if air
found.
Install the body cover.

Oil filling pipe

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2. Service Maintenance Information

Oil Pump Control Cable
Caution
To adjust the oil pump control cable after
adjusted the throttle grip play.

Remove the luggage box.

Wide open the throttle valve, and check if the
calibration point aligns on the oil pump lever with
the mark of pump body.

Mounting nut
Loosen the adjustment nut of the oil pump control
cable.
Turn the adjustment nut and align with the point,
then tighten the mounting nut.

Adjustment nut

Battery
Open the seat.
Loosen two screws of battery cover and then
remove the cover.
Check if the battery terminals are loosened.
Remove the battery if its terminals are corroded
obviously.

Battery Removal
1. Remove the Negative (-) battery cable at first.
2. Then, remove the Positive (+) battery cable.
3. Remove the battery.
Clean the rust with steel brush.
Install the battery in reverse order of removal, and
apply with grease onto two terminals.

Caution
The electrolyte is contained sulfuric acid so be
careful not to let it touch to eyes, skin, or
clothes. If touched by accident, flush them
with clean water immediately. However, if the
electrolyte sprays to eyes, medical care should
be done quickly.

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2. Service Maintenance Information

Tire
Caution
Tire pressure should be checked when cold.

Check tire for cracks, damage, nail, or other

object stuck in tread.
Recommended tire and tire pressure
Front: Rear:
Tire size
120 / 90 - 10 130 / 90 - 10
Tire pressure
1.75 2.0
(cold) kg/cm2
Check if the tire tread and wall rubber for crack or
damage, and replace if necessary.
Check if foreign materials such as nail, metal
pieces, and stones stuck on tire.
The thread depth can be checked by visual
inspection or by a depth gauge.

If the tread bend too much, replace the tire.

If tire wear exceeds limitation, replace the tire,
and check it for un-even wear.
Caution
Wear indicator “△ ” is distributed on average Wear indicator △ Mark

along the wall rubber for check.

Rear Drum Brake Free Play

Measure the free play of the rear brake lever at 10~20mm
the end of the lever. (3/8~3/4in)
Free play: 10-20 mm (3/8-3/4 in)

Adjust the free play by turning the front brake Adjustment nut
adjustment nut if necessary.
Brake Confirmation
Caution
After brake adjustment, it has to check the
brake operation to make sure the front and rear
wheel can be braked. Decreasing free
play
Increasing
free play

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2. Service Maintenance Information

Disc Brake System Hose
Make sure that the brake hose is corrosion or
damage, and also check the system for leaking.
Brake Fluid:
Check brake fluid level in the brake fluid reservoir.
If the level is lower than the LOWER limit, add
brake fluid DOT-3 to UPPER limit. Also check
brake system for leaking if low brake level found.
Caution

In order to maintain brake fluid in the
reservoir in horizontal position, do not Lower level
remove the cap until handle bar stop.

Do not operate the brake lever after the cap Arrow
had been removed. Otherwise, the brake
fluid will spread out if operated the lever.

Do not mix non-compatible brake fluid
together.

Brake Lining Wear: (Rear Drum Brake

Type)
Replace the brake lining if the wear limit mark “△ ”
on the brake arm aligning with the indicator of
brake drum. Wear limit mark
Brake lining replacements refer to chapter 12.

Brake pad Wear: (Disc Brake Type)

The arrow mark on brake pad is the wear Brake pad
limitation.
Replace the brake pad if the wear limit mark
closed to the edge of brake disc.
Caution
In order to maintain brake power balance, the
brake lining must be replaced with one set.
Brake pad replacements refer to chapter 12. Brake caliper
Brake disc

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2. Service Maintenance Information

Loosen the guide pin bolts. Front brake
Remove the front wheel shaft bolt.
Take out the front wheel.

Lining guide bolts

Remove brake caliper mounting bolt and then

remove the brake caliper.
Caution
Caliper bolt
Do not operate the brake lever after the clipper
removed to avoid clipping the brake lining.

Pry out the brake lining with a flat driver if lining is Brake lining
clipped.

Remove brake lining bolt.

Take out the lining.
Tighten Torque:
Mounting bolt: 2.9-3.5kgf-m
Pin bolt: 1.5-2.0kgf-m
Pin bolt cap: 0.8-1.2kgf-m

Pin bolt

The brake light switch is to light up brake light as

brake applied. Replace the switch if the light
does not light up in properly.
Caution
The brake light switch is un-adjustable.

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2. Service Maintenance Information

Steering System
Caution
The control cables cannot interfere with the
rotation of steering handle.
Lift the front wheel out of ground, and check if the
steering handle turning is smoothly.
If handle turning is uneven and bending, stuck, or
the handle can be operated in vertical direction,
then adjust the handle top bearing by adjusting
the steering nut.

Suspension
Warning
Do not ride the scooter with poor suspension.
Looseness, wear or damage suspension
system will make poor stability and drive-ability.

Front Shock Absorber

Press down the front shock absorber for several
times to check it operation.
Check if the shock absorber assembly is damage.
Replace it if damage found and can not be
repaired.
Tighten all nuts and bolts.

Rear Shock Absorber

Park the scooter with its main stand.
Shake the rear wheel side to side to check engine
suspension bushing for wear.
Replace the bushing if looseness found. Check
the shock absorber for damage.
Tighten all nuts and bolts.

Nuts, Bolts Tightness

Check if all bolts and nuts on the frame are
tightened to specified torque in accord with the
interval of Periodical Maintenance Schedule.
Check all split pins, snap rings, hose clamps, and
wire holders for security.

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2. Service Maintenance Information

Transmission Oil Oil level check bolt

Leak
Check if the transmission is leak.
Draining bolt
Check
Caution
Park the scooter on flat ground with its main
stand.

Remove the oil level check bolt, and check if the

oil level is placed on the hole of check bolt.

Replacement Oil level check bolthole

Remove the oil level check bolt.
Remove the oil draining bolt, and then drain oil
out.
Install the oil draining bolt.
Tighten torque: 1.3kgf-m
Caution
Check if oil seal and washer is in good
condition.
Replacement Quantity: 0.09 L (90 cc)
Recommended oil: King Bramax HYPOID
GEAR OIL #140

Spark Plug
Recommended plug: NGK BR8HSA 0.6~0.7mm

Remove the luggage box.

Remove the spark plug cap.

Clean any dirt on the spark plug seat.

Remove the spark plug.

Visually inspect the spark plug electrodes for
wear.

The center electrode should have square Center electrode
edges and side electrode should have a Side electrode
constant thickness. Replace the spark plug if
there is apparent wear or if the insulator is
cracked and/or chipped. If the spark plug
deposits can be removed by sandpaper, the
spark plug can be reused.

Measure the spark plug gap with feeler gauge.
Spark plug gap: 0.6-0.7mm (0.024-0.028in)

Adjust the gap by careful bending the side
electrode.

Install the spark plug by screwing it with hands
after installed the spark plug washer so that
can prevent the plug from out of thread. Then,
tighten the spark plug with a spark plug wrench.

Install the spark plug cap.

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2. Service Maintenance Information

Control Cable Lubrication
Remove the throttle control and the brake cables
periodically, and lubricate the moving parts of the Tooth face
cables thoroughly. Belt width

Driver Belt

Remove left crankcase cover.

Check if the belt is crack or worn out. Replace
the belt if necessary.

Measure the driving belt width
Allowable limit: 16.5mm

Ignition Timing Ignition lamp “F” mark

Caution

C.D.I ignition timing cannot be adjusted. If
the ignition timing is incorrect, check the
C.D.I. device and the alternator and replace
damaged components.

Check ignition timing with standard
instrument.
Remove the right-side cooling fan cover.
Check ignition timing with the timing light.
When engine speed setting to 1800 rpm, and if
the mark aligns with “F” mark, then it means that
the ignition timing is correct.

Throttle Valve Operation

Check if each steering positions are operated in
smooth, and handle bar if its operation is smooth
as the throttle valve wide opening or fully closed.
Check throttle cable and replace it if deteriorated,
twisted or damaged.
Lubricate the cable if operation is not smooth
Measure throttle valve handle free play.
Free play：：2~6 mm (1/8~1/4 in)
Loosen the mounting nut, and turn the free play
adjustment nut of the throttle valve handle for
adjustment.
Replace the cable if it can not be adjusted.

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2. Service Maintenance Information

Carburetor Idle Speed Adjustment Pilot screw

Caution

Inspection & adjustment for idle speed have
to be performed after all parts in engine had
been adjusted in specification.

Idle speed check and adjustment have to be
done after engine is being warned up. It
around operates engine from stop to running
for 10 minutes.

Remove the body cover. Idle speed adjustment screw

Park the scooter with main stand after warned up
engine. According to the required idling and air
screw to adjust to specified idle speed. Adjust the idling after warn up engine for 10
minutes.
Idle speed: 2000± ±100 rpm 4. Connect tachometer.
5. Adjust the idle speed screw to let engine
speed in 2000±100 rpm.
6. Insert the sampling pipe of the CO/HC meter to
the test hole on the front end of exhaust pipe.
Adjust the idling emission value to standard
range. (CO: 1.8-2.6%)
7. Slightly accelerate the throttle valve and
release it. Repeat this operation for 1-2
times.
8. Read the engine idle speed and the emission
value after engine speed in stable. Repeat the
operation on step No. 2 – No. 4. until these
value within standard range.
Carbon Removing For Exhaust Pipe
& Muffle
Remove the body cover.
Remove the exhaust pipe & muffler. Compression pressure gauge
Clean the carbon deposits on the muffler &
cylinder exhaust edge.

Cylinder Compression Pressure Test

Remove the left body cover, and warn up engine.
Stop the engine and remove the spark plug.
Insert the compression gauge and wide open the
throttle, and then rotate the engine by means of
the starting motor.
Compression pressure: 7.0±1 kg/cm2
Probable causes for low compression pressure.

Damaged cylinder head gasket.

Worn piston ring

Worn cylinder

Probable causes for high compression pressure.

Carbon on the combustion chamber or cylinder
head

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2. Service Maintenance Information

Headlight Adjustment
Turn the headlight- adjustment bolt for adjustment
its light beam.
Caution
Higher Lower
Improper headlight beam adjustment will make
in coming driver dazzled or insufficient lighting
for safety distance.

Headlight adjustment bolt

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2. Service Maintenance Information

Special Tool Manual

R/L. Crankcase disassemble

Name Name R/L. Crank puller Name R. Crank shaft puller
tool
No. SYM-1120100-G5 No. SYM-1130000-L No. SYM-1130000-R

Nam
L. Crankshaft install bush Name R. Crankshaft install bush Name Extension bush
e
SYM-1130031(long)
No. SYM-1130010 No. SYM-1130020 No.
SYM-1130032(short)

(ø28mm) (ø20mm)
Nam
Crankcase bush puller Name Crankcase bush puller Name ACG. Flywheel puller
e
No. SYM-1120310 No. SYM-1120320 No. SYM-3110A01

(25*37*6) (20*32*6) (27*42*7)

Nam
Oil seal driver Name Oil seal driver Name Oil seal driver
e

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No. SYM-9121600 No. SYM-9120200 No. SYM-9125500

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2. Service Maintenance Information

(6301) (6203/6004UZ) (6204)

Name Bearing driver 6301 Name Bearing driver Ø17mm Name Bearing driver 6204
No. SYM-9610000 No. SYM-9620000 No. SYM-9110400

Name Inner bearing puller Name Inner bearing puller Name Outer bearing puller
No. SYM-6204020 No. SYM-6204022 No. SYM-6204001

Name Clutch nut wrench Name Clutch spring compressor Name Universal holder
No. SYM-9020200 No. SYM-2301000 No. SYM-2210100

Name Multi-meter
No. SYM-HE07007-01

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3. Lubrication System

Lubrication System Diagram················ 3-1 Oil Pump Removal ································· 3-3

Precautions In Operation······················ 3-2 Oil Pump Installation ····························· 3-3
Lubricant ················································ 3-2 Oil Pump/Oil Tube Air Bleeding············ 3-4
Trouble Shooting ·································· 3-2 Oil Tank ·················································· 3-5
3

Lubrication System Diagram

Oil lever switch

Oil tank

Oil tube

Oil output tube

Oil pump

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3. Lubrication System
Precautions in Operation
Be careful not let dirt enters into engine or oil hoses when removing or installing the oil pump.
If air is found in the oil tube (from oil tank to oil pump) or oil tube is removed, the oil pump should be
conducted air-bleeding operation.
It should bleed the oil output tube (from oil pump to carburetor) as hose removed.
The adjustments of oil pump control cable.

Lubricant
Appointed to apply SAE 20 JASO FC class oil. Otherwise, warranty shall not cover the damage.
Recommended oil: MAX-2 oil.
Oil tank capacity: 1.2 lit.

Trouble Shooting
Too much smoke, carbon in spark plug
1. Improperly oil pumps adjustment (too much oil).
2. Poor quality oil.
3. Applying with poor quality oil.

Over heat
1. Improperly oil pumps adjustment (insufficient oil).
2. Poor quality oil.
3. Applying with poor quality oil.

Piston seized
1. No oil in oil tank or clogged hose.
2. Improperly oil pumps adjustment (insufficient oil).
3. Air in oil hose.
4. Malfunction of oil pump.

Oil did not flow out the oil tank

1. Clogged breath hole on the oil tank cover.

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3. Lubrication System
Oil Pump Removal Adjustment nut Mounting nut 1 bolt

Caution
Before removing the oil pump, clean the oil
pump and crankcase.
Remove the luggage box and seat.
Loosen the mounting nut of the oil pump control
Control cable
cable, and remove the control cable.
Remove the oil tube, and clip its end side to
prevent oil from flowing out.

Remove the oil output tube form intake manifold. Oil tube Oil output tube
Remove the oil pump mounting bolt, and then
take out the oil pump.
O-ring
Inspection
Inspect the following items on the removed oil
pump.
Check if O-ring is damaged or softening.
Check if crankcase interface is damaged.
Check if pump body is damaged.
Check if pump gear is damaged. Pump gear
Check for oil leaking.
Caution
The oil pump cannot be disassembled.

Oil Pump Installation

Install the oil pump onto the crankcase.
Caution
Apply with some grease onto oil pump O-ring.
The connection between both oil pump and
crankcase has to be installed in position
security.

Tighten the oil pump mounting bolt security.

Install the oil tube.
Install in the reverse order of removal.
Caution
Inspection and adjustment following items as
installed.
The adjustment operation of control cable.
Air bleeding operation of oil pump.
Air bleeding operation of oil tube.
Check each section for leaking.

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3. Lubrication System
Oil Pump/Oil Tube Air Bleeding Control cable Oil output tube

Caution
The oil tube system has to be conducted air
bleeding operation because air will clog or
restraint oil flowing so that causes serious
engine damage.

Caution
After disconnect the oil tube, air enters oil tube
due to oil leak out without added oil. There is Oil tube
why the oil tube and oil pump have to conduct
air bleeding operation.

Oil Tube/Oil Pump

It has to add some oil into the oil tank.
Place a piece of dry cloth around the oil pump.
Disconnect the oil tube.
Fill out oil to oil pump connection section by
means of the oil pot so that the oil pump body is
full with oil.
Fill out oil to oil tube connection section so that
the oil tube is full with oil. Then, install the tube
onto oil pump. Oil tube
Make sure whether air is in the oil tube or not
after installation.
Caution
After bleeding the oil tube and oil pump, the oil Oil output tube
tube has to be conducted air bleeding
operation too.

Oil Tube Air Bleeding

Remove the oil output tube and plug its input
connector. Bend the oil tube into “U “shape, and Recommended oil
fill out new oil into the output tube.
Connect the oil output tube to the oil pump
connection part.
Start engine, and run it in idling as the oil control
lever in wide open position. Make sure oil flows
out from the oil output tube.
Caution
Motorcycle’s exhaust gas includes with CO,
which causes human to coma or death so
perform this operation in well-ventilation place.
Run the engine in extreme low speed to avoid
to damaging the engine caused from clogged
oil tube.

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3. Lubrication System
Oil Tank 1 bolt
Removal
Remove the luggage box and seat.
Remove the right / left side covers, right / left rear
side covers, center cover, rear carrier, body
covers, rear fender and rear inner fender. (Refer
to chapter 11)
Remove the battery and battery case (1 bolt).

Remove the oil input tube from oil pump, and then
drain oil to a clean container.

Remove the oil level switch wire coupler of the oil

indicator.

Oil level switch coupler

1 blot
Remove the mounting bolt on the oil tank upper
side, and then remove the oil tank.

Installation
Install in the reverse order of removal.
The oil tubes air bleeding after installation.

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3. Lubrication System
Notes:

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4. Fuel System

Maintenance Information ······················4-2 Flaot Level Inspection ·························· 4-7

Troubleshooting ····································4-2 Carburetor Installation·························· 4-7
Throttle Valve ·········································4-3 Reed Valve············································· 4-7
Carburetor Remove ·······························4-4 Fuel Pump·············································· 4-8
Auto By-Starter ······································4-4 Air Cleaner············································· 4-9 4
Float/Float Valve/Jet······························4-6

Throttle valve cable

Vacuum tube Fuel output tube

Carburetor
Fuel inlet tube Fuel pump

Fuel filter

Fuel cap

Fuel unit

Fuel tank

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4. Fuel System
Maintenance Information
Precautions in Operations
Warning
Gasoline is a highly flammable material and may explosive under circumstance. Thus, always work in
a well-ventilated place and strictly prohibit flame when working with gasoline.

Care must be taken when dealing with gasoline, and always work in a well-ventilated place and
strictly prohibit flame.

When disassembling fuel system parts, pay attention to O-ring position, replace with new one as
re-assembly

It has to conduct air bleeding operation as removed the oil tube.

Idle speed adjustment.

Specification
Item Jet Sport X 50
Ventura diameter 15 mm
Fuel level 8.8±1.0mm
Air screw opener 1 3/8
Idle speed 2000±100 rpm
Throttle handle free play 2~6 mm

Troubleshooting
Engine cannot be started Lean Mixture
1. No fuel in fuel tank 1. Clogged carburetor jet
2. Fuel can not reach to carburetor 2. Clogged hose from carburetor to canister
3. Too much fuel in cylinder 3. Bend, squeezed or clogged fuel lines
4. Clogged air cleaner 4. Clogged fuel filter
5. Malfunction of float valve
6. Low fuel level in float chamber
7. Clogged vent pipe
Stall after started 8. Malfunction of fuel pump
5. Incorrect idle speed adjustment
6. No spark on the spark plug
7. Low compression pressure
8. Rich mixture Rich Mixture
9. Lean mixture 13. Malfunction of float valve
10. Clogged air cleaner 14. Low fuel level in float chamber
11. Inlet pipe leaking 15. Clogged carburetor air injector
12. Polluted fuel

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4. Fuel System
Throttle Valve Carburetor upper part
Removal
Remove the body cover.
Remove the carburetor upper part, throttle valve
spring and sealed cap.
Remove the throttle valve cable from the throttle
valve.
Remove needle clamp and fuel needle.

Inspection

Sealed cap Throttle valve spring

Needle clamp
Throttle valve cable
Fuel needle clip

Fuel needle

Carburetor upper part

Washer

Throttle valve

Installation
Place the fuel needle onto the throttle valve and clip it with needle clamp.
Install the sealed cap, carburetor upper part, and throttle valve spring.
Connect the throttle valve cable to the throttle valve.
Install the throttle valve into the carburetor body.
Caution
Align the groove inside the throttle valve with the throttle stopper screw of the carburetor body.

Tighten the carburetor upper part.

Adjust the free play of throttle valve cable.

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4. Fuel System
Carburetor Remove
Remove the rear side cover.

Auto by-starter coupler

Disconnect the auto by-starter coupler.

Fuel hose Carburetor

Loosen draining screw and then drain out fuel upper part
inside the carburetor.
Loosen carburetor upper part and remove 2 bolts
carburetor upper part.
Remove fuel and oil hoses from carburetor.
Remove carburetor mounting bolt and carburetor.

Draining screw
Connection hose clamp
Auto By-Starter
Inspection
Connect resistor meter to the terminals of auto Auto by-starter
by-starter, and then measure its resistance.
If the resistance value exceeds specification too
much, it means that the PTC in the auto by-starter
is malfunction. Then, replace the auto by-starter.
Resistance value: Max. 10Ω (at cold engine)
Caution
If the resistance value exceeds the standard a
little bit, the auto by-starter may still in normal.
However, it is necessary to check other relative
components for damage.

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4. Fuel System
Remove carburetor, and allow it to cool off for 30
minutes.
Connect fuel rich circuit with a hose and pump
compressed air to the hose.
Air should flow into fuel rich circuit.
Replace the auto by-starter if the circuit clogged.

Connect battery to starter’s connectors and wait

for several minutes.
Pump compressed air into the fuel rich circuit.
Air should not flow into the circuit.
If air flow through the circuit; then replace the
auto-by starter.
Battery

Check resistor to make sure that the auto Alternator

by-starter is in normal. Engine is running.
If the resistor is in open-circuit, then current will
not flow into the PTC. Thus, the auto by-starter
is not operated.
However, if the resistor is in short-circuit; current
higher than specification will flow into the PTC.
Then, it will cause the fuel rich circuit close rapidly,
and difficult to start the scooter. Resistor
Resistance value: 10.2Ω

Auto by-starter
Auto By-Starter Removal/Installation 2 screws
Remove the cover of the auto by-starter.
Remove screw and mounting plate.
Remove the auto by-starter from carburetor.
Install in the reverse order of removal procedures.

Mounting
plate

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4. Fuel System
Float/Float Valve/Jet
Removal
Remove the float from carburetor body.
Remove the float pin and then remove float and
float valve.
Check the valve seat for worn out or damage.
Check float for bend and if fuel inside the float.
Before removing both the throttle valve stopper
and air screws, record their original turns for close
to their original set up position as installation.
Float cap
Caution
Do not tighten the screw forcedly to avoid to
damaging the valve seat.

Remove main jet, needle jet seat and idle jet and
clean them and each component with
compressed air.

Installation Air inlet for

Install the idle jet, the needle jet seat and main jet. fuel rich
circuit
Then install the throttle valve stopper and air
screws to their original position according to the
marks as removal. Adjust the screws if replace
with new ones.
Air inlet for idle speed

Air screw
Float valve

Float
Float pin

Throttle valve
stopper screw

O-ring

Needle jet
Float cap

Idle jet
Needle jet seat

Main jet

Screw

Draining screw

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4. Fuel System
Float Level Inspection
Measures float fuel level to have the upper end of
float just contact with the float.
Float fuel level: 8.8 mm
Carefully bend the float arm for adjustment.
Check the float operation and the install it.

Fuel hose Carburetor

Carburetor Installation upper part
Caution
2 bolts
Do not let foreign materials into the carburetor.

Install the carburetor and insulator onto intake

pipe with bolts.
Install fuel and vent pipes onto carburetor.
Install the carburetor upper part.
Tighten the connection hose.
Tighten the draining screw. Draining screw
Connection hose clamp
Connect the automatic by-starter connector.
Install air cleaner cap.
Conduct following operations

Adjustment of throttle valve cable.

Adjustment of oil pump.

Adjustment of idle speed.

Inlet pipe

Reed Valve Reed valve

Removal
Remove the luggage box.
Remove the carburetor.
Remove carburetor insulator.
Remove inlet pipe.
Remove the reed valve.

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4. Fuel System
Inspection Reed valve Reed valve stopper
Check the reed valve for damage and its reed
strength.
Check the reed valve seat for crack, damage and
the clearance between the seat and the valve.
Replace reed valve if necessary.
Caution
Do not bend the reed valve stopper. Otherwise,
it will cause its strength insufficient and rough
engine running. If the reed valve or its seat is
Reed valve seat
damaged, replace with a set.

Installation
Install in the reverse order of removal procedures.
Check for leaking after installed.

Carburetor
Fuel Pump
Inspection Fuel hose
Remove the rear side cover.
Warm up the engine and adjust idle speed.
Remove fuel hose from carburetor and then wait
for 5 minutes.
Measure the output of fuel pump. Its output time
is 10 seconds.
Output quantity: Min. 20 c.c.
If the output quantity is lower than 20c.c., check
fuel hose, vacuum hose and fuel filter.

2 bolts
Removal/Installation
Remove floor plate.
Remove fuel inlet, outlet and vacuum hoses.
Remove 2 bolts and fuel pump.
Fuel outlet
Install the fuel pump in the reverse order of Fuel inlet hose
removal procedures. hose

Vacuum
hose

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4. Fuel System
Air Cleaner 1 screw
Removal/Installation
Remove air cleaner and rear inner fender
mounting screw.

Hose clamp
Loosen connection hose clamp.
Remove 2 bolts and then remove the air cleaner.

Install in the reverse order of removal procedures.

2 bolts

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4. Fuel System
Notes:

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5. Engine Removal

Maintenance Information······················ 5-2 Engine installation ······························· 5-6

Engine removal······································ 5-3

5.5~6.5kgf-m
2.4~3.0kgf-m

2.4~3.0kgf-m
5.5~6.5kgf-m

5.5~6.5kgf-m
4.5~5.5kgf-m

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5. Engine Removal
Maintenance Information
There are parts that require removal of engine for maintenance.
● Crankcase
● Crankshaft

Related bolts tightening torque for removal of engine:

Engine hanger bolt 5.5~6.5kgf-m
Engine hanger bracket bolt 4.5~5.5kgf-m
Rear cushion upper mounting bolts 3.5~4.5kgf-m
Rear cushion lower mounting bolts 2.4~3.0kgf-m
Exhaust pipe connection nut 1.0~1.4kgf-m
Muffle mounting bolt 3.0~3.5kgf-m

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5. Engine Removal
Engine removal Fuel output tube Spark plug
Remove body cover.
Remove the spark plug cap from the spark plug.
Remove the fuel output and the vacuum tubes
from fuel pump.

Vacuum tube

Control cable
Remove the oil control cable from oil pump.
Remove the oil tube from oil pump and then clip
the tube.

Oil tube

Remove the wire couplers of auto by starter and

ACG.

Wire couplers

Carburetor
Remove the upper parts of the carburetor from its upper parts
upper side.
Remove the carburetor heater electric wire.

Heater wire

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5. Engine Removal
Drum type rear brake
Remove rear brake cable from engine rear-lower
side.
Remove brake cable from cable clamp.

Rear brake cable

Disc type rear brake

Remove rear brake caliper (2 bolts) from engine
rear-upper side.
Remove brake hose from hose clamp.

Caliper
bolt

1 screw
Remove air cleaner and rear inner fender
mounting screw.

Hose clamp

Loosen connection hose clamp.

Remove 2 bolts and then remove the air cleaner.

2 bolts

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5. Engine Removal
Remove two exhaust pipe connection nuts. Connection nut
Remove two bolts beside fan cover and exhaust
pipe.

3 bolts

Support the engine and then remove cushion Rear cushion lower
lower mounting bolt. mounting bolt

Remove engine mounting nut and bolt. (Each

side 1 bolt and 1 nut)
Remove the engine.

Engine mounting nut

Engine mounting bolt

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5. Engine Removal
Engine Hanger Bracket
Removal
Remove the frame side right and left side bolts of
engine hanger bracket. (1 bolt on each side)

Disassembly
Remove the engine hanger bracket nut and bolt. 2 bolts
Disassembly engine hanger bracket A and engine
hanger bracket B.
Check if the engine hanger rubber bushes, Rubber bush
Engine hanger bracket A
hanger bushes and collar for damage. If so,
replace with new ones.

Assembly Rubber bush

Install hanger bushes and collar into engine
hanger bracket B. Bush
Install engine hanger bracket A and engine
hanger bracket B and tighten the bolts and nuts Collar
Bush
of engine hanger bracket.
Torque Value: 4.5~5.5kgf-m
Engine hanger bracket B

Engine installation
Install in the reverse order of removal procedures.
Tighten the engine mounting bolts and rear
cushion upper/lower bolts.

Torque value:
Engine hanger bolt 5.5~6.5kgf-m
Rear cushion upper mounting bolts 3.5~4.5kgf-m
Rear cushion lower mounting bolts 2.4~3.0kgf-m
Exhaust pipe connection nut 1.0~1.4kgf-m
Muffle mounting bolt 3.0~3.5kgf-m Engine mounting nut

Perform the following inspection and adjustment

after installation.
● Check if control cable is correct.
● Check if throttle valve cable is correct.
● Check if oil pump control cable is correct.
● Oil input and output of the oil pump.
● Adjust rear brake.

Engine mounting bolt

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6. Cylinder Head/Cylinder/Piston

Maintenance Information ······················6-2 Cylinder Head········································· 6-3

Troubleshooting ····································6-2 Cylinder/Piston······································· 6-5

1.6~2.0kgf-m

1.1~1.7kgf-m

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6. Cylinder Head/Cylinder/Piston
Maintenance Information
Precautions in Operation

The inspection and maintenance of the cylinder head, cylinder and piston can be carried as engine
mounted on the body.

It should clean the engine to prevent dirt from entering into cylinder and crankcase before removal.

Remove all washes from the interfaces of cylinder head, cylinder and crankcase.

Be careful do not damage cylinder head, cylinder and piston when removing.

Inspect the removed & cleaned parts thoroughly, and apply with oil onto the rotation surfaces before
installation.

Specification
Jet Sport X 50 series
Item
Standard value (mm) Limit (mm)
Cylinder head Deformation - 0.100
Piston OD 39.030~39.045 38.935
Clearance between cylinder and piston 0.040~0.050 0.100
Piston pin hole 12.002~12.008 12.030
Piston Piston pin OD 11.994~12.000 11.970
Clearance between piston and piston pin 0.002~0.014 0.030
Piston ring end gap 0.100~0.250 0.400
ID of connecting rod small end 17.05~17.015 17.025
ID 39.000~39.015 39.050
Cylinder
Deformation - 0.100
ID: inner diameter OD: outer diameter

Tighten torque value

Cylinder head 1.6~2.0kgf-m
Spark plug 1.1~1.7kgf-m
Exhaust pipe connection nut 1.0~1.4kgf-m
Exhaust muffler mounting bolt 3.0~3.6kgf-m

Troubleshooting
Compression Pressure Too Low/Difficult Piston Noise
To Start/Rough Idling 1. Cylinder and piston worn out
1. Cylinder head gasket leaking 2. Piston pin or piston pin hole worn out
2. Spark plug not tighten enough 3. Connecting rod small end bearing worn out
3. Worn, seized or crack piston ring
4. Damaged, worn cylinder or piston Piston Ring Noise
5. Poor reed 1. Worn, seized or crack piston ring
2. Cylinder worn out or damaged
Compression Pressure Too
High/Overheat/Knock
1. Too much carbon deposit built up in
combustion chamber

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6. Cylinder Head/Cylinder/Piston
Cylinder Head Vacuum tube Fuel output tube
Cylinder Head Removal
Removal luggage box, body covers and center
cover.
Remove fuel pump tubes.

Fuel inlet tube

2 nuts
Remove spark plug cap.
Remove fuel pump bracket (2 nuts).

Plug cap

Remove vacuum tube and oil pump control cable

from engine shield.

1 bolt
Remove fan cover (3 bolts).
Remove engine shield mounting bolt (1 bolt).

3 bolts Engine shield

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6. Cylinder Head/Cylinder/Piston
Remove engine shield.

4 bolts
Cylinder Head Removal
Remove spark plug.
Remove the 4 cylinder head bolts and then
remove the cylinder head.
Caution
Loosen the cylinder head bolts with diagonal
direction to avoid to damaging it.

Cleaning Carbon in Combustion Chamber

Clean carbon deposit in which built up in
combustion chamber with shown chisel.
Caution
Do not scratch to the interfaces of combustion
chamber and cylinder.

Chisel

Cylinder Head Inspection

Use a straight edge and a feeler gauge to
measure the cylinder head for warp.
Service limit: 0.10 mm

Cylinder Head Installation

Replace the cylinder head gasket with new one,
and place the cylinder head onto cylinder.
Tighten the 4 bolts with diagonal direction and by
2-3 sequences.
Tighten torque: 1.6~2.0kgf-m
Install spark plug
Tighten torque: 1.1~1.7kgf-m

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6. Cylinder Head/Cylinder/Piston
Cylinder/Piston Connection nut
Remove spark plug cap.
Remove fan cover.
Remove engine shield.
Remove two connection nuts of the exhaust pipe.
Remove exhaust muffle mounting bolt, and then
remove the exhaust muffler.

3 bolts

Cylinder Removal
Remove cylinder head.
Be careful to pull the cylinder up and prevent
piston from damage.
Caution
Do not have pry out operation between cylinder
and crankcase. Or let radiation fan be
knocked seriously.

Piston Removal
Piston
Place a clean rag onto crankshaft to cover the
piston.
Remove piston pin clip (one piece) and then push
piston pin out the piston.
Caution

Do not damage or scratch the piston.

Do not apply with lateral force to connecting
rod. Piston pin clip Piston pin

Do not let piston pin snap ring falling into
crankcase.

Piston Ring Removal

Caution
Pry out the opening end of each piston ring and
then remove the ring from piston.

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6. Cylinder Head/Cylinder/Piston
Check if cylinder and piston are worn or damaged,
and then clean carbon deposit on exhaust
opening area as the diagram shown.
Caution
Do not scratch both the cylinder and the piston.

Use a straight edge and a feeler gauge to

measure the cylinder head for warp.
Service limit: 0.10 mm

In “X” and “Y” direction, measure the cylinder for

worn out as the three levels shown in the figure.
With the maximal value to decide cylinder wear
out condition.
Service limit: 39.050mm

Measure the OD of piston at the 7 mm from the

bottom of the piston. 7mm
Service limit: 38.935 mm
Calculate the clearance between piston and
cylinder.
Service limit: 0.100 mm

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6. Cylinder Head/Cylinder/Piston
Measure the piston pinhole ID of piston.
Service limit: 12.030mm The ID of piston pinhole

Measure the OD of piston pin. The OD of piston pin

Service limit: 11.970 mm

Piston Ring Inspection

Measure the end gap of each piston ring.
Service limit: 0.40 mm
Caution
With the piston, push each piston ring into
cylinder correctly.

Connecting Rod Inspection

Measure the ID of connecting rod small end.
Service limit: 17.025mm

Install bearing and piston pin onto connecting rod

small end, and then check its clearance.

Clearance

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6. Cylinder Head/Cylinder/Piston
Piston/Cylinder Installation
Install the expanding ring into the groove of 2nd
ring.
Align the ring end with the lock pin in the ring
groove.
nd
Install the top ring and the 2 ring onto the ring
groove respective.
Caution
nd
The top ring and the 2 ring cannot be
changeable each other.
Push the rings into ring groove and then check
rings’ mating condition.
If ring could not be push in the ring groove, it
means that ring groove is dirty or wrong ring
Top ring
groove installation.
Caution 2nd ring

All rings should be installed with the marks Piston ring mark
facing up.

All rings should be replaced at same time,
and it cannot be replaced one ring only.

It should use same brand name piston ring in
an engine and cannot mix with other one. 1T: top ring
nd
2T: 2 ring
Expanding ring

Place a cleaning cloth onto the crankcase

opening to prevent the piston pin snap ring from
falling into the crankcase.
Apply with two-stroke engine oil onto needle
bearing and piston pin, and install needle bearing
into connecting rod small end.
Install piston, and place “EX” mark of the piston
toward to exhaust side, and then install the piston
pin onto piston and connecting rod.

Needle bearing

Install new piston pin snap ring. Piston 〝EX〞

〞mark
Clean all gaskets onto the interfaces of cylinder
and crankcase.
Place a new gasket onto the crankcase.
Make sure that the piston ring aligns with the lock
pin in piston ring groove.
Piston pin
Caution
Make sure that all rings in the piston ring
groove cannot be rotated around the lock pin to
avoid to damaging the rings, piston and Piston pin snap ring
cylinder.

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6. Cylinder Head/Cylinder/Piston
Lubricate cylinder and piston with two-stroke
engine oil.
Hold the piston and then install it into cylinder.
Caution
To avoid to damaging the piston and the
cylinder sliding surface.

Lock pin

4 bolts
Install the cylinder head.
Tighten torque: 1.6~2.0kgf-m

Connection nut
Replace the exhaust pipe washer with new one
and then install exhaust pipe.
Tighten exhaust pipe connection nut.
Tighten torque: 1.0~1.4kgf-m
Tighten exhaust pipe mounting bolt.
Tighten torque: 3.0~3.6kgf-m
Install the removed parts in the reverse order of
removal procedures.
Inspect following item after installation.
Test engine compression pressure.
Check for engine noise. 3 bolts

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6. Cylinder Head/Cylinder/Piston
Note:

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7. A.C. Generator

Maintenance Information ············7-2 Generator Installation·················· 7-4

Generator Removal······················7-3

3.5~4.5kgf-m

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7. A.C. Generator

Maintenance Information
Precautions in Operation

The maintenance service of A.C. generator can be carried out directly on the scooter.

Please refer to Chapter 15 for the relative A.C. generator inspection.

Torque value:
Flywheel 3.5~4.5kgf-m

Special Service Tools:

Flywheel puller SYM-3110A01
Universal holder SYM-2210100

Coil resistance value for the A.C. generator

Y/L Y P Earth
Y/L 50~200Ω
Y 0.2~0.8Ω
P 0.2~0.8Ω
Earth 50~200Ω

AC. generator

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7. A.C. Generator

Generator Removal
Remove the luggage box and rear side cover.
Remove 3 bolts and then take out cooling fan
cover.

3 Bolts

Remove 4 bolts, and then take out the cooling

fan.

4 bolts

10mm flanged nut

Hold flywheel with universal holder.

Support the flywheel and the remove the 10 mm
nut on the flywheel.
Special tool:
Universal holder SYM-2210100

Universal holder

Remove the flywheel with flywheel puller.

Special tool:
Flywheel puller SYM-3110A01

Flywheel puller

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7. A.C. Generator
Disconnect generator wire coupler and pulse coil Generator coupler
coupler.

Pulse coil coupler

Remove the pulse coil and generator coil bolts (4

bolts), and then take out the generator assembly.
Caution
Care to be taken for not damaging the
generator coil.

4 bolts

10mm flanged nut

Generator Installation
Install the generator assembly.
Connect the generator coupler.
Caution
Connect the generator wire harness properly
and then clip the harness with clipper.

Install the woodruff key onto the crankshaft Universal holder

groove.
Caution 10mm flanged nut

Clean dirt and metal pieces inside the
flywheel.

Make sure that there is no foreign material
inside the flywheel.
Install the flywheel.
Tighten the flywheel 10 mm nut.
Torque value: 3.5~4.5kgf-m
Install the removed parts in reverse order of
removal procedures.
Start engine and check its ignition timing.

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8. "V" Type Belt Drive System/Kick-Starter

Maintenance Information ·····················8-3 Drive Belt··············································8-6

Trouble Shooting ·································8-3 Movable Driven Pulley·························8-7
Left Crankcase Cover ··························8-4 Clutch/Driven Pulley ····························8-11
Reassembly Of Kick Starter ················8-5
Installation Of The Left Crankcase Cover
·······························································8-5

5.0~6.0kgf-m 8

3.5~4.5kgf-m

5.5~6.5kgf-m

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8. "V" Type Belt Drive System/Kick-Starter

Maintenance Information
Precautions In Operation
The surfaces of drive belt and driven pulley must be free of grease.

Specification
Item Standard value (mm) Limit (mm)
Drive belt width 18.0 16.5
ID of movable drive face 20.035~20.085 20.120
OD of movable drive face boss 23.964~23.985 23.918
OD of weight roller 15.92~16.08 15.40
ID of clutch outer 107.0~107.2 107.5
Thickness of clutch weight 4.0~4.1 2.0
Free length of driven pulley spring 87.9 82.5
OD of driven pulley 33.965~33.985 33.940
ID of movable driven face 33.000 34.060
ID: Inner Diameter
OD: Outer diameter

Torque Values: Special Service Tools

Movable drive face 5.5~6.5kgf-m Clutch spring compressor SYM-2301000
Driven pulley plate 5.0~6.0kgf-m Clutch nut wrench SYM-9020200
Clutch outer 3.5~4.5kgf-m Universal holder SYM-2210100
Inner bearing puller SYM-6204020
Clutch bearing driver
Clutch seal driver

Trouble Shooting
Engine can be started but motorcycle Insufficient horsepower or poor
cannot be moved high-speed performance
1. Worn drive Belt 1. Worn drive belt
2. Worn ramp plate 2. Insufficient spring capacity of driven pulley
3. Worn or damaged clutch weight 3. Worn weight roller
4. Broken driven pulley spring 4. Driven pulley operation un-smoothly

Shudder or misfire when drive

1. Broken clutch weight
2. Worn clutch weight

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8. "V" Type Belt Drive System/Kick-Starter

Left Crankcase Cover
Left crankcase cover removal
Remove rear left body side cover.
Remove air cleaner (2 bolts).
Remove kick-start arm (1 bolt).
Remove left crankcase cover (9 bolts).

9 bolts

Return spring
Disassembly of Kick Starter
Remove snap clip and thrust washer from left
crankcase cover.
Install kick-start arm, rotate the lever slightly and
then remove driven gear and washer.
Remove the kick-starter arm, kick starter spindle,
and return spring as well as socket.

Starter spindle Driven gear

Inspection of kick Starter

Check if starter spindle, driven gear for wear or damage.

Bolt

Kick start arm

Snap ring

Thrust washer
Return spring

Bush
Thrust washer

Driven gear
Starter spindle

Friction spring

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8. "V" Type Belt Drive System/Kick-Starter

Reassembly of Kick Starter Kick starter spindle
Install bush, return spring and starter spindle as
diagram shown.
Install thrust washer and snap clip onto starter
spindle.

Return spring

Width-tooth Driven gear

Install kick-starter lever temporary.
Slightly rotate the lever and then align driven gear
with width-tooth on the starter spindle.
Install the friction spring of drive gear onto convex
part of the cover.

Convex part Friction spring

Dowel pin
Installation of the Left Crankcase
Cover
Install the dowel pin and gasket.
Install the left crankcase cover.

Install kick-start arm.

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8. "V" Type Belt Drive System/Kick-Starter

Drive Belt Nut
Removal
Remove left crankcase cover.
Hold clutch outer with universal holder, and
remove nut and clutch outer.
Special tool:
Universal holder SYM-2210100
Caution

Using special tools for tightening or
loosening the nut. Universal holder

Fixed rear wheel or rear brake will damage
reduction gear system.
Clutch/drive belt

Push the drive belt into belt groove as diagram

shown so that the belt can be loosened, and then
remove the driven pulley.
Remove driven pulley/clutch. Do not remove
drive belt.
Remove the drive belt from the groove of driven
pulley.

Inspection
Check the drive belt for crack or wear. Replace
it if necessary. Belt tooth
Measure the width of drive belt as diagram
shown.
Service Limit: 16.5 mm
Replace the belt if exceeds the service limit.
Caution

Using the genuine parts for replacement

The surfaces of drive belt or pulley must be
free of grease.

Clean up all grease or dirt before installation.

Movable driven
Installation pulley

Caution

Pull out driven pulley to avoid it closing.
Install drive belt onto driven pulley.

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8. "V" Type Belt Drive System/Kick-Starter

Install the driven pulley that has installed the belt Drive face Drive belt Drive shaft
onto drive shaft.

Clutch/driven pulley

Clutch outer
Hold the clutch outer, and then tighten nut to
specified torque value.
Special tool:
Universal holder SYM-2210100 Nut
Torque value: 3.5~4.5kgf-m

Movable Drive Face Universal holder

Removal
Remove fan cover and fan.
Remove left crankcase cover.
Hold generator flywheel with universal holder, and
then remove drive face nut.
Special tool:
Universal holder SYM-2210100

Flywheel

Nut

Remove drive face.

Drive face

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8. "V" Type Belt Drive System/Kick-Starter

Removal Drive face boss Movable drive face
Remove movable drive face set and drive belt
from crankshaft.

Crankshaft

Ramp plate
Remove ramp plate.

Movable drive face

Remove weight rollers from movable face.

Weight roller

Weight roller
Inspection
The weight roller is to press movable driven face
by means of centrifuge force. Thus, if weight
rollers are worn out or damage, the centrifuge
force will be affected.
Check if rollers are wearing out or damage.
Replace it if necessary.
Measure each roller’s outer diameter. Replace it if
exceed the service limit.
Service limit: 15.40 mm

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8. "V" Type Belt Drive System/Kick-Starter

Check if movable drive face boss is worn or Movable drive face
damage and replace it if necessary.
Measure the outer diameter of drive face boss,
and replace it if it exceed service limit.
Service limit: 19.98 mm
Measure the inner diameter of drive face, and
replace it if it exceed service limit.
Service limit: 20.120 mm

Drive face boss

Reassembly / Installation Weight roller

Install weight rollers.

Install ramp plate. Ramp plate

Drive face
Apply with some grease to inside of movable
drive face, and install drive face boss.
Caution

The drive face has to be free of grease.
Clean it with cleaning solvent.

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8. "V" Type Belt Drive System/Kick-Starter

Install movable drive face assembly onto Drive face boss Movable drive face
crankshaft.

Crankshaft

Drive belt
Drive Face Installation Press down

Press drive belt into pulley groove, and then pull

the belt on to crankshaft.

Universal holder
Install drive face, washer and nut.
Caution

Make sure that two sides of drive face have
to be free of grease. Clean it with cleaning
solvent.
Hold flywheel with universal holder.

Flywheel

Nut
Tighten nut to specified torque.
Torque value: 5.5~6.5kgf-m
Install left crankcase cover.

Drive face

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8. "V" Type Belt Drive System/Kick-Starter

Clutch/Driven Pulley Clutch nut
Disassembly wrench

Remove drive belt and clutch/driven pulley.

Install clutch spring compressor onto the pulley
assembly, and operate the compressor to let nut
be installed more easily.
Special tool:
Clutch spring compressor SYM-2301000
Clutch nut wrench SYM-9020200

Clutch spring
Caution compressor

Do not press the compressor too much.

Hold the clutch spring compressor onto bench
vise, and then remove mounting nut with clutch
nut wrench. Socket
Release the clutch spring compressor and
remove clutch and spring from driven pulley.

Remove socket from sliding pulley.

Remove guide pin, guide pin roller, and driven Sliding pulley
Oil seal
Guide pin
pulley, and then remove O-ring & oil seal seat
from sliding pulley.

Or

Guide pin roller

O-ring

Inspection
Clutch outer
Measure the inner diameter of clutch outer friction
face. Replace clutch outer if exceed service limit.
Service limit: 107.5 mm

Inner
diameter
Clutch outer

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8. "V" Type Belt Drive System/Kick-Starter

Clutch weight Clutch weight
Measure each clutch weight thickness. Replace
it if exceeds service limit.
Service limit: 2.0 mm

Driven pulley spring

Measure the length of driven pulley spring.
Replace it if exceeds service limit.
Service limit: 82.5 mm

Free length

Driven pulley Driven pulley

Check following items:

If both surfaces are damage or wear.

If guide pin groove is damage or wear.
Replace damaged or worn components.
Measure the outer diameter of driven pulley and
the inner diameter of sliding pulley. Replace it if
exceeds service limit.
Service limit: Outer diameter 33.94 mm
Inner diameter 34.06 mm
Guide pin groove
Sliding pulley

Driven Pulley Bearing Inspection

Check if the inner bearing oil seal is damage.
Replace it if necessary.
Check if needle bearing is damage or too big
clearance. Replace it if necessary.
Rotate the inside of inner bearing with fingers to Needle bearing
check if the bearing rotation is in smooth and
silent. Check if the bearing outer parts are
closed and fixed. Replace it if necessary.
Caution Outer ball bearing

Some of models are equipped with two ball
bearings.

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8. "V" Type Belt Drive System/Kick-Starter

Clutch Block Replacement Spring
Drive plate
Remove clip and washer, and then remove clutch
weight and spring from drive plate.
Caution

Some of models are equipped with one
mounting plate instead of 3 snap clips.
Check if spring is damage or insufficient elasticity.
Snap clip

Clutch weight

Check if shock absorption rubber is damage or Shock absorption

deformation. Replace it if necessary. rubber
Apply with grease onto lock pins.

Install new clutch weight onto lock pin and then Shock absorption rubber
push to specific location.
Apply with grease onto lock pins. But, the clutch
weight should not be greased. If so, replace it.
Caution

Grease or lubricant will damage the clutch
weight and affect the weight’s connection
capacity.

Clutch block

Install the spring into groove with pliers. Spring

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8. "V" Type Belt Drive System/Kick-Starter

Install snap clip and mounting plate onto lock pin.

Snap clip

Replacement of Driven Pulley Bearing

Remove inner bearing. Outer bearing
Clip
Caution

If the inner bearing equipped with oil seal on
side in the driven pulley, then remove the oil
seal firstly.

If the pulley equipped with ball bearing, it has
to remove snap clip and then the bearing.
Inner ball bearing
Snap clip
Remove snap clip and then push bearing forward Inner needle bearing
to other side of inner bearing.

Place new bearing onto proper position and its

sealing end should be forwarded to outside.
Specified grease
Apply with specified grease.

Snap ring

Outer bearing
Sealing end

Install new inner bearing.

Inner bearing
Sealing end
Caution

Its sealing end should be forwarded to
outside as bearing installation.

Install needle bearing with hydraulic presser.
Install ball bearing by means of hydraulic
presser or driver.
Install snap clip into the groove of drive face.
Align oil seal lip with bearing, and then install the
new oil seal (if necessary).

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8. "V" Type Belt Drive System/Kick-Starter

Installation of Clutch/Driven Pulley Oil seal
Assembly
Install new oil seal and O-ring onto sliding pulley.
Apply with specified grease to lubricate the inside
of sliding pulley.

O-ring
Specified grease

Sliding pulley
Install sliding pulley onto driven pulley. Oil seal
Guide pin
Install guide pin and guide pin roller.

Or

Guide pin roller

O-ring

Install socket.
Socket

Install driven pulley, spring and clutch into clutch

spring compressor, and press down the assembly Mounting nut Clutch nut wrench
by turning manual lever until mounting nut that
can be installed.
Hold the compressor by bench vise and tighten
the mounting nut to specified torque with clutch
nut wrench.
Special tool:
Clutch spring compressor SYM-2301000
Clutch nut wrench SYM-9020200
Remove the clutch spring compressor.
Torque value: 5.0~6.0kgf-m Clutch spring
Install clutch/driven pulley and drive belt onto compressor
drive shaft.

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9. Final Driving Mechanism

Maintenance Information ···················· 9-2 Inspection of Final Driving Mechanism

································································9-6
Troubleshooting ·································· 9-2
Bearing Replacement ···························9-7
Disassembly of Final Driving Mechanism
······························································ 9-3 Re-Assembly of Final Driving Mechanism
································································9-8

9
Bearing 6004UU

x42x
Oil seal 27x x7

Bearing 6201

Bearing 6203

Bearing 6201

Bearing 6203

1.0~1.5kgf-m

2.4~3.0kgf-m

x30x
Oil seal 17x x6

1.0~1.5kgf-m

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9. Final Driving Mechanism

Maintenance Information
Limited usage of gear oil: gear oil #140
Recommended oil: Bramax serial oil.
Oil quantity: 120 c.c. (110 c.c. as replacement)

Torque Values:
Mission cover bolt 2.4~3.0kgf-m
Mission oil drain bolt 1.0~1.5kgf-m
Mission oil check bolt 1.0~1.5kgf-m

Special tools:
Inner type bearing puller SYM-6204020
Outer type bearing puller SYM-6204010
Final shaft oil seal installer SYM-9125500
Drive shaft oil seal installer SYM-9120200
Bearing driver 6201 SYM-9610001
Bearing driver 6203/6004UZ SYM-9620000
R. Crank shaft puller SYM-1130000-R
L. Crank shaft install bush SYM-1130010
Extension bush SYM-1130031 (long)
Extension bush SYM-1130032 (short)

Troubleshooting
Trouble Diagnosis
Engine can be started but scooter cannot be moved
1. Damaged drive gear
2. Burnt out or seized drive gear

Noise
1. Seized, worn or damage gear
2. Worn or loose bearing

Gear oil leaks

1. Excessive gear oil.
2. Worn or damage oil seal

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9. Final Driving Mechanism

Disassembly of Final Driving Oil filling hole

Mechanism
Remove driven pulley
Remove oil drain bolt and filling bolt.
Drain gear oil out from gearbox.

Oil draining hole

Remove muffler and rear wheel.

Rear wheel nut

7 bolts
Remove gearbox cover mounting bolts from the
clutch side (7 bolts).

Remove the cover from the rear wheel side.

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9. Final Driving Mechanism

Remove final gear, final shaft and counter gear,

counter shaft.

Final shaft Counter shaft

Remove the drive shaft from left crankcase.

Caution
The bearing must be replaced when removing
the drive shaft.

Drive shaft

Outer bearing puller

Drive shaft is pulled out with it’s bearing, then
remove the bearing with bearing puller and shaft
protector.
Special tool:
Multi-functional bearing puller or Outer bearing
puller SYM-6204001
Shaft protector SYM-6204010

Remove drive shaft oil seal and bearing from left

crankcase.

Oil seal

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9. Final Driving Mechanism

Remove final gear, final shaft and counter gear,
counter shaft.

Final shaft Counter shaft

Remove the drive shaft from left crankcase. Oil filling hole

Caution
The bearing must be replaced when removing
the drive shaft.

Drive shaft

Drive shaft is pulled out with it’s bearing, then Outer bearing puller
remove the bearing with bearing puller and shaft
protector.
Special tool:
Multi-functional bearing puller or Outer bearing
puller SYM-6204001
Shaft protector SYM-6204010

Remove drive shaft oil seal and bearing from left

crankcase.

Oil seal

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9. Final Driving Mechanism

Inspection of Final Driving
Mechanism
Check if the drive shaft are burn, wear or damage
and replace it if necessary.
Caution

If remove the drive shaft from the gear box
upper side, then its bearing has to be
replaced.

Check if the countershaft is wear or damage and

replace it if necessary.

Check if the final shaft and gear are burn, wear or

damage and replace it if necessary.

Check bearings on gearbox cover. Oil seal Bearing

Rotate each bearing’s inner ring with fingers.
Check if bearings can be turned in smooth and
silent, and also check if bearing outer ring is
mounted on gear tightly.
If bearing rotation is uneven, noising, or loose
bearing mounted, then replace it.
Check oil seal for wear or damage, and replace it
if necessary.
Check gearbox bearing as the same way above,
and replace it if necessary.

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9. Final Driving Mechanism

Bearing Replacement Inner bearing puller
Remove gearbox bearing from left crankcase and
gearbox cover using following tools.
Special tool:
Inner bearing puller SYM-6204020 or
SYM-6204021
Caution
Never install used bearings. Once bearing
removed, it has to be replaced with new one.

Install new bearings into left crankcase. Bearing driver

Special tool:
Bearing driver 6201 SYM-9610001
Bearing driver 6203/6004UZ SYM-9620000

Install new bearings into gearbox cover.

Special tool:
Bearing driver 6201 SYM-9610001
Bearing driver 6203/6004UZ SYM-9620000

Oil seal driver

Apply with grease onto final shaft oil seal.
Install the oil seal into gearbox cover.
Special tool:
Oil seal driver 27x x42xx7 SYM-9125500

Oil seal

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9. Final Driving Mechanism

Re-Assembly of Final Driving Extension bush Shaft install bush

Mechanism
Install drive shaft.
With the special service tools to install drive shaft
by through the bearing.
Special tool:
R. Crank shaft puller SYM-1130000-R
L. Crank shaft install bush SYM-1130010
Extension bush SYM-1130031 (long)
Extension bush SYM-1130032 (short)

R. Crank shaft puller

Apply with grease onto drive shaft oil seal.

Install the oil seal to left crankcase.
Special tool:
Drive shaft socket & oil seal driver (17x30x6)
SYM-9120200

Oil seal driver

Dowel pins
Install 2 dowel pins & new gasket.

Drive shaft

Install counter shaft, counter shaft side washer

and final shaft into the gearbox.
Install the gearbox cover and tighten the bolts (7
bolts).
Torque value: 2.4~3.0kgf-m
Install driven pulley / clutch outer / belt.
Install movable drive face, drive face and left
crankcase cover.
Install rear wheel.
Add gear oil.
Gear oil quantity: 120c.c. Final shaft Counter shaft Side washer

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10. Crankcase/Crankshaft

Maintenance Information ·····················10-2 Crankshaft Removal ···························· 10-3

Troubleshooting ···································10-2 Crankshaft Inspection ························· 10-4
Crankcase Disassembly ······················10-3 Crankcase Installation························· 10-5

1.0~1.5kgf-m

Apply liquid gasket

10

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10. Crankcase/Crankshaft
Maintenance Information

This chapter concerns disassembly of the crankcase for repair purpose.

Before disassembling crankcase, except removing engine firstly, following components must be
removed too.

Carburetor (chapter 10)

Oil pump (chapter 3)

Reed valve (chapter 10)

Driving belt (chapter 7)

Alternator (chapter 6)

Cylinder head/cylinder/piston (chapter 5)

Except above components are needed be removed, when disassembling L crankcase, following
components must be removed too.

Final driving mechanism (chapter 8)

When assembling both crankcase and crankshaft, it has press the inner ring edge of the crankshaft
bearing to push the crankshaft into the crankcase hole by using the specified service tools. The old
bearing onto the crankshaft has to be removed. Then install a new bearing onto the crankshaft on the
crankcase side. Oil seal has to be replaced with new one after assembled the crankcase.

Item Standard Limit (mm)

Lateral clearance of the big end of the connecting rod ─ 0.60
Radial clearance of the big end of the connecting rod ─ 0.04
Crankshaft run-out point A ─ 0.10
Crankshaft run-out point B ─ 0.10

Special Tools
Crankcase disassemble tool SYM-1120100-G5
Outer bearing puller SYM-6204010
R. Crank shaft puller SYM-1130000-R
R. Crank shaft install bush SYM-1130020
L. Crank shaft puller SYM-1130000-L
L. Crank shaft install bush SYM-1130010
Extension bush SYM-1130031 (long)
20x31x7 Oil seal driver SYM-9120200
Bearing driver6204 SYM-9110400

Torque Values:
Crankcase bolt 1.0~1.5kgf-m

Troubleshooting
Engine noise
1. Worn bearing of connecting rod bog end
2. Bend connecting rod
3. Worn crankshaft bearing

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10. Crankcase/Crankshaft
Crankcase Disassembly
Remove the crankcase bolts.

7 Bolts

Crankcase
Install the crankcase puller onto the right
disassemble tool
crankcase with two (2) bolts, 6mm, as the
diagram shown.
Disassemble the right crankcase.
Special Tools:
Crankcase disassemble tool SYM-1120100-G5

Right crankcase

Crankcase
Crankshaft Removal disassemble tool

As the diagram show with 2 special bolts to install

the specified service tool onto the left crankcase.
Remove the crankshaft.
Caution
Do not use iron hammer to knock out the
crankshaft.

Left crankcase

Remove crankshaft bearing with bearing puller.

Remove the right and left side oil seals.
Shaft protection collar
Caution
Replace the oil seal with new one as removing
the crankshaft.

Outer bearing puller

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10. Crankcase/Crankshaft
Crankshaft Inspection
Measure the clearance of connecting rod big end.
Service limit: 0.60 mm

Measure the radial clearance of connecting rod

big end at X-Y directions as diagram show.
Service limit: 0.04 mm

Place the crankshaft on a V-block, measure

run-out points A and B of the crankshaft with dial
A B
gauge.
Service limit: A: 0.10 mm
B: 0.10 mm

70mm
37mm

Check the crankshaft bearing by means of turning Clearance

it with hand. If any noise and bigger clearance
are detected, replace the bearing with new one. Clearance

Lateral Radial

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10. Crankcase/Crankshaft
Crankcase Installation
Clean the crankshaft with solvent and blow it with Bearing driver 6204
compressed air. Then, check for damage or
other foreign materials attached.
Install new bearing into right crankcase.
Caution

All rotation and sliding surfaces have to be
applied with clean engine oil.

Remove all gaskets onto the crankcase
interfaces and flat it with special tool.

Install new bearing into left crankcase.

Special Tools:
Bearing driver6204 SYM-9110400
Bearing driver 6204

L. Crank shaft puller

Install crankshaft onto the left crankcase.
Install left crankshaft puller and install bush onto
crankshaft. Extension bush
Screw the left crankshaft puller onto crankshaft.
Turn the puller in C.W. direction and then
completely screw the puller to bottom.
Lubricate crankshaft bearing and bearing seat
with 2-stroke engine oil.
Special Tools: L. Crank shaft install bush
L. Crank shaft puller SYM-1130000-L
L. Crank shaft install bush SYM-1130010
Extension bush SYM-1130031 (long)

Apply liquid gasket and dowel pin onto the Apply liquid gasket

interface of left crankcase.

Dowel pin

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10. Crankcase/Crankshaft
Assemble the right crankcase with assembly
tools. R. Crank shaft puller
Install right crankcase onto the crankshaft.
R. Crank shaft
Install right crankshaft puller and install bush onto install bush
crankshaft.
Screw the right crankshaft puller onto crankshaft.
Turn the puller in C.W. direction and then
completely screw the puller to bottom.
Lubricate crankshaft bearing and bearing seat
with 2-stroke engine oil.
Special Tools:
R. Crank shaft puller SYM-1130000-R
R. Crank shaft install bush SYM-1130020

Install the bolts and tighten them.

Torque value: 1.0~1.5kgf-m

7 Bolts

R. Crank shaft
With right crankshaft install bush, install new oil install bush
seal into the right crankcase. Its installation depth
is 4mm as the diagram shown.

Oil seal

With the specified tool to install a new oil seal

onto the left crankcase to the depth of 1 mm as
the diagram shown.
Caution
Oil seal driver
Make sure that the crankshaft can be rotated
freely after tightening the bolts.

Install the following components:

~ Final driving mechanism (chapter 9)
~ Alternator (chapter 7)
~ Piston/cylinder/cylinder head (chapter 6)
~ Oil pump (chapter 3)
~ Reed valve and carburetor (chapter 4)
~ Engine remove (chapter 5)

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11. Body Cover

Body Overview·····································11-1 Front under Spoiler····························· 11-9

Maintenance Information ····················11-2 Floor Panel··········································· 11-10
Steering Handle Cover ························11-3 Front Inner Box ··································· 11-11
Front Cover ··········································11-5 Front Fender········································ 11-12
Luggage Box········································11-6 Rear Fender ········································· 11-12
Side Covers··········································11-7 Rear Inner Fender ······························· 11-13
Center Cover ········································11-8 Rear Mudguard···································· 11-13
Body Cover ··········································11-8 Under Cover········································· 11-14
Body Overview
Seat

Battery cover

11
Luggage box Battery case

Center cover
Right rear grip

Handle upper cover Plug maint. cover

Left rear grip
Fuel lid
Right body cover
Handle rear cover

Handle front cover Rear fender

Right rear side cover

Left body
Right side cover cover

Front inner cover Right center

cover
Front cover Rear inner fender

Front cover emblem Left center

cover

Floor panel Rear mudguard

Left rear side cover

Left side cover

Front inner spoiler

Right front under spoiler

Front inner fender

Under cover
Front fender

Left front under spoiler

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11. Body Cover

Maintenance Information
Body covers disassemble sequence:

Handle Front Cover Front Cover Luggage Box / Seat

Handle upper Cover Front Wheel Floor Panel Center Cover

Handlebar Rear Cover Front Fender Front Inner Cover Left / Right Side Cover

Left / Right Side Cover Front Inner Spoiler And Left / Right Rear Side Cover
Right / Left Side Spoiler
Assembly

Under Cover Left / Right Rear grip

Body Cover
Front Fender

Right / Left Center Cover

Rear Mudguard

Rear Fender

Rear inner fender

Be careful not to damage various covers in disassembly or re-assembly operation.

Never injure hooks molded on the body covers in disassembly or re-assembly operation.

Align the buckles on the guards with slot on the covers.

Make sure that each hook is properly installed during the assembly.

Never compact forcefully or hammer the guard and the covers during assembly.

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11. Body Cover

Steering Handle Cover 4 screws

Removal
Remove 4 screws from the handle rear cover
upper.

Remove 2 screws from the handle rear cover

under.

Each side 1 screws

3 screws
Remove 3 screws from the handle front cover
under.

Winker light couplers

Remove front winker light electric cord couplers.
Remove handle front cover.

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11. Body Cover

Remove 1 screw from the handle rear cover inner. 1 screw
Remove handle upper cover.

Remove 1 screw from rear by handle rear cover.

1 screw

Remove 2 inner screws.

Disconnect each switch connectors.

2 Screws

Remove speedometer electric cord coupler.

Remove handle rear cover.

Installation
Install in reverse order of removal procedures.
Caution
Push the front connection part of rear handle
cover at first when removing front cover so that
the buckles are out of the cover. Never push it
forcefully to cause buckles broken or cover
damaged. Speedometer coupler

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11. Body Cover

Front Cover
Removal
Remove 10 screws from the front inner box and
front cover.

Each side 5 screws

Remove 1 screw from the front cover.

Screws

Headlight coupler
Remove electric cord coupler from the headlight.
Remove the front cover.

Installation
Install in reverse order of removal procedures.

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11. Body Cover

Luggage Box
Removal
Lift up seat cushion.
Remove oil tank cap and oil guide rubber.

2 nuts 1 bolt
Remove luggage box mounting nuts and bolt (2
nuts & 1 bolt).
Hold the luggage box in both front and rear sides
by two hands, and then lift up the box to remove it.

Installation
Install in reverse order of removal procedures.

Battery Cover Removal / Installation 2 screws

Remove 2 screws, and then remove battery cover.

Install in reverse order of removal procedures.

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11. Body Cover

Side Covers
Removal
Remove 2 screws under side cover front end.

2 screws

Remove 2 screws, and then slide the side cover

backward so that their hooks are out of slots.
Take out the side cover end part and then remove
the cover.

2 screws

Remove 2 screws from rear side cover.

2 screws

Slide the rear side cover backward so that their

hooks are out of slots.
Take out the rear side cover end part and then
remove the cover.

Installation
Install in reverse order of removal procedures.
Caution
The tail of each cover is held with buckles and
slot, never pull them with force, or it would crack
the buckles.

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11. Body Cover

Center Cover
Removal
Remove 2 screws from center cover.
Slide the center cover frontward so that their
hooks are out of slots.
Take out the center cover end part and then
remove the cover.

Installation
Install in reverse order of removal procedures.
Each side 1 screw

Body Cover 4 bolts

Removal
Remove luggage box and center cover.
Remove 4 bolts from rear carrier, and then remove
rear carrier.

Remove 4 screws from right and left body cover.

2 screws

Remove 2 bolts from the rear fender.

Slide the body covers and taillight backward so
that their hooks are out of slots.
Take out the body covers and taillight end part and
then remove the covers.

Installation
Install in reverse order of removal procedures.

2 bolts

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11. Body Cover

Front under Spoiler
Removal
Remove front cover and right / left side covers.
Remove front wheel and front fender.
Remove 6 screws from the front inner box.

Each side 3 screws

Remove 2 screws from the front upper part of the

front spoiler and the front inner box.

2 screws

Pull up the front inner spoiler from holder hook,

and then remove the front inner spoiler and right /
left under spoiler assembly.

Hook

Each side 5 screws

Disassembly
Remove 10 screws, and then remove right / left
under spoiler.

Installation
Install in reverse order of removal procedures.

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11. Body Cover

Floor Panel
Removal
Remove luggage box, rear carrier, center cover,
right & left side cover and body covers.
Remove 4 rubber caps.

4 rubber caps

Remove the floor panel. (4 bolts)

4 bolts

Disassembly
Remove 2 screws from right / left center cover and
floor panel.

2 screws

Remove 2 screws from right / left center cover and

floor panel other side.
Remove right / left center cover.

Installation
Install in reverse order of removal procedures.

2 screws

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11. Body Cover

Front Inner Box
Removal
Remove the front cover.
Remove luggage box, rear carrier, center cover,
right & left side cover, body covers, and floor
panel.
Remove main switch cover.

Main switch cover

Hook & 1 bolt

Remove 1 bolt and hook.

Remove 2 screws from the under spoiler and front

inner box.

2 screws

Remove 6 screws from the front inner box and

under spoiler.
Remove the front inner box.

Installation
Install in reverse order of removal procedures.

Each side 3 screws

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11. Body Cover

Front Fender 1 Bolt Speedometer cable

Removal
Ramoval 1 bolt from left front cushion, and then
remove speedometer cable clamp and front brake
hose clamp.

Front brake hose

Ramoval 4 screws form front fender right and left

side.
Ramoval front fender.

Installation
Install in reverse order of removal procedures.

Each side 2 screws

Rear Fender
Removal
Ramoval luggage box, rear carrier and body
covers.
Ramoval 3 screws, and then removal rear fender.

3 screws

Installation
Install in reverse order of removal procedures.

Each side 1 screw

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11. Body Cover

Rear Inner Fender
Removal
Ramoval luggage box, rear carrier, body covers
and rear fender.
Ramoval 2 screws from rear inner fender upper.

Each side 1 screw

Pull out rear fender front hanger with frame, and

then removal rear inner fender.

Installation
Install in reverse order of removal procedures.

Hanger

Rear Mudguard Left Right

Removal
Ramoval rear mudguard left side screw with air
cleaner.
Ramoval muffler (2 nuts & 3 bolts), pull out muffler
with rear mudguard right side hanger.

1 Screw Hanger

Ramoval rear mudguard right side bolt, and then

remove rear wheel.
Ramoval bolts form rear mudguard left side, and
then remove rear mudguard.

Installation
Install in reverse order of removal procedures.

2 bolts

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11. Body Cover

Under Cover
Removal
Remove right and left side cover.
Remove 1 bolt and 1 nut from the under cover
right side.

1 bolt 1 nut

Remove 1 bolt and 1 nut from the under cover left

side, and then remove under cover.

Installation
Install in reverse order of removal procedures.
1 nut 1 bolt

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12. Brake System

Disc Brake System ·······························12-1 Disc Brake - Caliper····························· 12-8

Rear Drum Brake System·····················12-2 Brake pad replacement ······················· 12-8
Maintenance Information ·····················12-3 Brake Disc ············································ 12-10
Troubleshooting ···································12-5 Disc Brake - Master Cylinder ·············· 12-10
Hydraulic Disc Brake····························12-6 Rear Drum Brake·································· 12-14
Disc Brake -Air Bleed ···························12-7

Disc Brake System

1.0~1.4kgf-m

3.3~3.7kgf-m

12

3.3~3.7kgf-m

3.3~3.7kgf-m

3.1~3.5kgf-m

3.1~3.5kgf-m

4.0~4.5kgf-m

4.0~4.5kgf-m

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12. Brake System

Rear Drum Brake System

10.0~12.0kgf-m

0.8~1.2kgf-m

0.8~1.2kgf-m

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12. Brake System

Maintenance Information
Precautions in Operation
Caution
Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use air hose
or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead.

The brake caliper can be removed without removing the hydraulic system.

After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic
system.

While refilling brake fluid, care should be taken not to let the foreign material entering into the brake
system.

Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage.

Check the operation of the brake system before you go.

Specifications
Item Standard (mm) Limit (mm)

The thickness of front brake disc 4.0 3.5

The thickness of rear brake disc 3.5 3.0

Front brake disc run-out < 0.10 0.3

Front brake master cylinder inner
12.700 ~ 12.743 12.750
diameter
Front brake master cylinder piston
12.657 ~ 12.684 12.654
outer diameter
Rear brake master cylinder inner
11.000 ~ 11.043 11.050
diameter
Rear brake master cylinder piston
10.657 ~ 10.684 10.654
outer diameter
OD of front brake disc 190.0 -

OD of rear brake disc 110.0 -

ID of rear brake drum 110.0 110.5

Thickness of front brake lining 4.0 2.0

Thickness of rear brake lining 4.0 2.0

Torque values
Brake hose bolt 3.3~3.7kgf-m
Bolt for brake caliper 3.1~3.5kgf-m
Bolts for the lining guide pin 1.5~2.0kgf-m
Air-bleed valve 0.8~1.0kgf-m
Bolts for the brake disc 4.0~4.5kgf-m
Nuts for the front wheel axle 5.0~7.0kgf-m
Nuts for the rear wheel 10.0~12.0kgf-m
Bolt for rear brake arm 0.8~1.2kgf-m
Rear brake lever nuts 0.8~1.2kgf-m
Brake master cylinder mounting bolts 1.0~1.4kgf-m

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12. Brake System

Troubleshooting
Disc Brake
Soft brake lever Hard operation of brake Tight brake
1. Air inside the hydraulic lever 1. Dirty brake lining/disc
system 1. Blocked brake system 2. Poor wheel alignment
2. Hydraulic system leaking 2. Poor brake caliper 3. Deformed or warped brake
3. Worn master piston 3. Blocked brake pipe disc
4. Worn brake pad 4. Seized/worn master cylinder
5. Poor brake caliper piston Brake noise
6. Worn brake lining/disc 5. Bent brake lever 1. Dirty lining
7. Low brake fluid 2. Deformed brake disc
8. Blocked brake pipe Uneven brake 3. Poor brake caliper
9. Warp/bent brake disc installation
1. Dirty brake lining/disc
10. Bent brake lever 4. Imbalance brake disc or
2. Poor wheel alignment
3. Clogged brake hose wheel
4. Deformed or warped brake
disc
5. Restricted brake hose and
fittings

Drum Brake
Poor brake performance Tight operation or low Brake noise
1. Improper brake adjustment return speed of brake lever 1. Worn brake lining
2. Worn brake lining 1. Worn/broken/crack return 2. Worn drum
3. Worn brake drum spring 3. Dirty brake lining
4. Worn brake cam 2. Worn drum 4. Dirty brake drum
5. Improper brake lining 3. Dirty brake lining
installation 4. Brake seized caused from
6. Seized brake cable dirty brake drum
7. Dirty brake lining 5. Seized brake cable
8. Dirty brake drum 6. Worn brake cam
9. Brake pad worn in brake 7. Improper brake lining
cam area. installation
10. Poor contact between brake
arm and camshaft indent

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12. Brake System

Hydraulic Disc Brake
Close the drain valve of the hydraulic disc brake.
Replace the brake fluid.
Before the brake fluid reservoir is removed, turn
the handle so that the brake fluid reservoir
becomes horizontal, and then remove the brake
fluid reservoir.
Cover the painted surfaces, plastic or rubber
components with a rag when servicing brake
system.
Caution
Lower level
Spilled brake fluid on painted surfaces, plastic
or rubber components may result in their
damages.
Remove the master cylinder cap and diaphragm. Cap
Use brake fluid to clean the dirty brake disc.
Diaphragm
Caution
Upper level
The dirty brake lining or disc will reduce the
brake performance.
Brake fluid
Refill up same grade brake fluid into the reservoir.
Caution
To mixed non-compatible brake fluid will reduce
brake performance. Foreign materials will block
the system causing brake performance to be
reduced or totally lost. Drain valve
Air bubble
Connect drain hose to drain valve.
Open the drain valve on the caliper and operate
the brake lever until the old brake fluid is entirely
drained out. Close the drain valve and add
specified brake fluid into the brake master
cylinder.
Recommended brake fluid: WELLRUN DOT 3
brakes fluid
Caution
To reuse the spent brake fluid will affect brake
Drain hose
performance.
Connect one end of transparent hose to the drain
valve, and put the other end into a container.
Open the drain valve around 1/4 turns, and at the
same time hold the brake lever until the there is
no air bubble in the drain hose and also feeling
resistance on the brake lever.
Close the drain valve when finishing the brake
system refilling fluid procedure, and operate the
brake lever to check whether air bubble is in
brake system or not. If brake is still soft, please
bleed the system as described below.

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12. Brake System

Disc Brake -Air Bleed Air bubble Drain valve
Tightly hold the brake lever and open the drain
valve around 1/4 turns, and then close the valve.
Caution

Do not release the brake lever before the
drain valve is closed.

Always check the brake fluid level when
carrying out the air bleeding procedure to
avoid air enters into the system.

Slowly release the brake lever, and wait for a few Drain hose
seconds until it reaches its top position.
Repeat the steps 1 and 2 until there is no air Front brake
bubble at the end of the hose.
Tightly close the drain valve.
Make sure the brake fluid is in the UPPER level of
the master cylinder, and refill the fluid if
necessary.
Cover the cap.
Drain valve

Rear brake Drain valve

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12. Brake System

Disc Brake - Caliper Brake hose bolt
Removal
Place a container under the brake caliper, and
loosen the brake hose bolt and finally remove the Caliper bolt
brake hoses.
Caution
Do not spill brake fluid on painted surfaces.
Remove two caliper bolts and the caliper.

Installation
Install the brake caliper and tighten the attaching
bolts securely.
Torque: 3.1~3.5kgf-m Brake hose bolt

Caution

Use M8 x 35 mm flange bolt only.

Long bolt will impair the operation of brake
disc.
Use two seal washers and hose bolts to lock the
hose and brake caliper in place.
Torque: 3.3~3.7kgf-m
Refill up the brake fluid to the reservoir and make
necessary air bleeding.
Caliper bolt Pad guide bolt x 1

Front brake
Brake pad replacement
Front brake
Loosen the 2 pad guide pin bolts.
Remove brake caliper.

Lining guide bolts

Remove the brake pad guide pin bolts, and then

remove brake pads.

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12. Brake System

Install the new brake pads onto brake caliper. Locking spring
Install the brake pad guide pin bolts.
Install the brake caliper and tighten the mounting
bolts.
Torque: 3.3~3.7kgf-m
Tighten the lining guide pin bolts.
Torque: 1.5~2.0kgf-m

Rear brake
Loosen the 1 lining guide pin bolt.
Remove brake caliper.

Caliper bolt Lining guide bolt x 1

Remove the brake pad guide pin bolt and locking

spring, and then remove brake pads.

Locking spring
Install the new brake pads onto brake caliper.
Install the brake pad guide pin bolt and.
Install the brake caliper and tighten the mounting
bolts.
Torque: 3.3~3.7kgf-m
Tighten the lining guide pin bolt.
Torque: 1.5~2.0kgf-m

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12. Brake System

Brake Disc Brake disc
Inspection
Visually check the brake disc for wear or break.
Measure the thickness of the disc at several
places. Replace the disc if it has exceeded the
service limit.
Allowable limit:
Front brake disc 3.5mm
Rear brake disc 3.0mm Micrometer

Remove the brake disc from wheel.

Check the disc for deformation and bend.
Allowable limit: 0.30 mm

Disc Brake - Master Cylinder Master cylinder

Master Cylinder Removal
Caution

Do not let foreign materials enter into the
cylinder.

The whole set of master cylinder; piston,
spring, diaphragm and cir clip should be
replaced as a set.
Remove the leads of brake light switch.
Drain out the brake fluid. Brake hose

Remove the brake lever from the brake master

cylinder.
Remove the brake hose.
Remove the master cylinder seat and the master
cylinder.

2 bolts

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12. Brake System

Install the rubber pad into groove properly.
Remove the rubber pad.
Remove the cir clip.
Remove the piston and the spring.
Clean the master cylinder with recommended
brake fluid.

Master Cylinder Inspection

Check the master cylinder for damage or scratch.
Replace it if necessary.
Measure the cylinder inner diameter at several
points along both X and Y directions.
Replace the cylinder if the measured values
exceed allowable limit.
Allowable limit:
Front brake 12.750 mm
Rear brake 11.050 mm

Measure the outer diameter of the piston.

Replace the piston if its measured value exceeds
allowable limit.
Allowable limit:
Front brake 12.654 mm
Rear brake 10.654 mm

Master Cylinder Assembly

Caution

It is necessary to replace the whole set
comprising piston, spring, piston cup, and cir
clip.

Make sure there is no dust on all
components before assembling.
Apply clean brake fluid to the piston cup, and
then install the cup onto the piston.
Install the larger end of the spring onto the master
cylinder.
The master cup’s cavity should be face inside of
master cylinder when installing the master cup.
Install the cir clip.
Caution

Never install cup lip in the opposite direction.

Make sure the cir clip is seated securely in
the groove.

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 12. Brake System
Piston
Clip

Rubber pad

Piston

Spring
Micrometer

Master cylinder

Rubber Sub-cup
bush
Cylinder gauge
Cir clip

Piston
Sub-cup

Spring

Master cylinder
Master cylinder

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12. Brake System

Place the master cylinder onto handlebar, and
install the bolts.

2 bolts

Install the brake lever, and connect leads to brake Master cylinder
light switch.

Brake hose

Connect brake hoses with 2 new washers.

Tighten the brake hose bolt to the specified Washers
torque value.
Make sure the hose is installed correctly.
Install all wires, hoses, and components carefully
so avoid to twisting them together.
Caution
Improper routing may damage leads, hoses or
pipes.

Caution
Kink of brake leads, hose or pipe may reduce
brake performance.
Add specified brake fluid and bleed the system.

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12. Brake System

Rear Drum Brake
To use vacuum cleaner or other alternatives to
avoid danger caused from dusts.
Caution

Inhaling brake lining ashes may cause
disorders of respiration system, therefore,
never use compressed air or dry brush to
clean brake parts.

Brake performance will be reduced by
grease on brake lining.
Rear brake drum
Remove wheel and brake drum.
Inspection
Check brake drum for damage or wear out, and
replace it if necessary.
Measure the inner diameter of brake drum and
record the max. value.
Allowable limit: rear (110.5mm)
Caution

Clean the rust onto the brake drum with
#120 sandpaper.

Measure the inner diameter of brake drum
with micrometer.

Measure the thickness of brake lining at three

points (both ends and center).
If the thickness is less than specified value or if it
is contaminated by oil or grease, replace as a set.
Service limit: Rear: 2.0 mm

Brake lining

Brake shoe spring

Removal
Caution
Brake linings must be replaced as a shoe.
Remove the brake shoes from brake panel.
Brake shoes

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12. Brake System

Installation Bolt

Apply with a thin coat of grease to the brake cam

and the anchor pin.
Install brake cam.
Never allow brake linings to be contaminated by
oil or grease.
Wipe off the excessive grease from brake cam
and the anchor pin.
Caution
Brake efficiency will be reduced if brake shoe is
contaminated by oil or grease. Rear brake arm

Install the brake cam and arm after aligning it with

the punched point.
Tighten the bolts and nuts to specified torque: Bolt
Torque value: 0.8~1.2kgf-m

Brake arm

Brake shoes
Use a brake cleaner to clean brake hub and
replace the two brake shoes if brake linings are
contaminated.
Caution
Brake efficiency will be reduced if brake lining
is contaminated by oil or grease.
Install spring onto the brake shoes.
Install the brake shoes to the brake panel one
after one, and make sure the shoe springs are in Brake shoe spring
correct position.
Install the wheel.

Brake shoe spring

Brake shoes

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12. Brake System

Notes:

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13. Steering / Front Wheel / Front Cushion

Maintenance Information ·····················13-2 Front Wheel ·········································· 13-5

Troubleshooting ···································13-2 Front Cushion ······································ 13-9
Steering Handle ····································13-3 Steering Stem······································· 13-10

1.0~1.4kgf-m

4.0~4.5kgf-m

1.0~1.2kgf-m

13
2.4~3.0kgf-m 0.2~0.3kgf-m

5.0~7.0kgf-m 3.1~3.5kgf-m

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13. Steering / Front Wheel / Front Cushion

Maintenance Information
Specification
Item Standard value (mm) Limit (mm)
Shaft bending ─ 0.2 (0.01 in)
Radial ─ 2.0 (0.08 in)
Rim wobbling
Axial ─ 2.0 (0.08 in)

Torque Value
Steering handle nut 4.0~4.5kgf-m
Brake master cylinder mounting bolts 1.0~1.4kgf-m
Front wheel axle 5.0~7.0kgf-m
Brake disc bolt 4.0~4.5kgf-m
Front cushion mounting nut 2.4~3.0kgf-m
Front brake caliper bolt 3.1~3.5kgf-m
Steering stem mounting nut 1.0~1.2kgf-m
Top cone race 0.2~0.3kgf-m

Special Tools
Inner bearing puller SYM-6204022
Bearing driver 6201

Troubleshooting
Hard To Steer The Front Wheel Wobbling
1. The steering shaft bolt is too tight. 1. The rim is bent.
2. The steering shaft bearing are damaged 2. The wheel axle nut is not tightened
3. The ball and the top cone of the steering improperly
shaft are damaged. 3. Bend wheel rim
4. Insufficient tire pressure. 4. Side-worn or poor tire.
5. The bearing play of the wheel axle is too
The Steering Handle Is Tilted large.
1. Uneven arrangement of the front cushions.
2. The front fork is bent. Soft Cushion
3. The front wheel axle is bent. 1. Weak front cushion spring

Noise In Front Cushion

1. Cushion outer tube noise
2. The joint of the cushion gets loose.

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13. Steering / Front Wheel / Front Cushion

Steering Handle 2 bolts

Removal
Remove handle cover and front cover (refer to
chapter 11).
Remove front brake master cylinder (disc brake)
after 2 bolts removed.

Remove throttle grip and right handle switch after

right handle switch mounting screws removed. (2
screws)

2 screws

2 bolts
Remove rear brake master cylinder (disc brake)
after 4 bolts removed.
Remove rear brake lever bracket (drum brake)
after mounting bolt removed.

Remove left handle switch after left handle switch

mounting screws removed. (2 screws)

2 screws

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13. Steering / Front Wheel / Front Cushion

Remove handle mounting bolt and nut, and then
remove the handle.

Installation
Installs handle and align with bolt hole.
Install bolt and nut and then tighten it.
Torque value: 4.0~4.5kgf-m
Handle mounting nut and bolt

Lock pin
Apply with grease onto throttle cable and the
sliding surface of handle grip.
Align the lock pin of the right handle switch with
the hole on the handle, and then install the right
handle switch.
Tighten the screws. (2 screws)
Align the lock pin of the left handle switch with the
hole on the handle, and then install the left handle
switch.
Tighten the screws. (2 screws)
Hole

Hole
Place master cylinder (disc brake) or brake lever
bracket (drum brake) onto steering handle.
Align the lock pin on mounting holder with lock pin
hole on the handle.
Tighten the upper part bolt, and then tighten lower
bolt.

Lock pin

Check hoses and cords dispose. Clip Front brake hose

Install all components in reverse order of removal
procedures. Meter cord
Throttle cable
Conduct following adjustment: Left handle

Oil pump control cable. switch cord

Throttle operation.

Brake lever free play (drum brake).
Right handle
Rear brake hose switch cord
(Rear brake cable)
Steering handle pipe

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13. Steering / Front Wheel / Front Cushion

Front Wheel
Removal
Support body bottom and lift front wheel free of
ground with a stand.
Remove speedometer cable from speedometer
gear box (1 screw).

Speedometer cable

Remove front wheel axle nut, and then pull out

the axle and remove the wheel.

Axle nut

Inspection
Place the axle onto a V-block to measure its
run-out with a dial gauge.
The dial gauge indicated 1/2 run-out.
Service limit: 0.20 mm

Wheel axle

Free play
Place the wheel on to a rotation seat, and turn the
wheel to check its bearing free play. If the
bearing is noisy or its free play is too much, Free play

replace it.

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13. Steering / Front Wheel / Front Cushion

Place the wheel on to a rotation seat to check its
rim wobbling. Turn the wheel with hand and
measure its rim wobbling value with a dial gauge.
Service limit:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)

3 bolts

Bearings replacement
Remove 3 bolts and brake disc.

Remove left side dust seal, bearing and dist.

collar.

Special tools
Inner bearing puller (SYM-6204020)

Dust seal
Dist. collar
Installation
Fill out the block of bearing by grease.
Drive the left bearing, dust seal into wheel rim and Bearing
install the dist. collar.
Bearing
Install the right bearing and dust seal.
Caution

Carefully install the bearing in correct and
evenly.

Bearing outer face should be faced up as Dust seal
bearing installation.

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13. Steering / Front Wheel / Front Cushion

Install the brake disc and then tighten the bolts 3 bolts
(disc brake).
Torque value: 4.0~4.5kgf-m

Lubricate the speedometer gear with grease and

install the gear into the wheel hub.
Align the flange part on the speedometer gear
with the slot of wheel hub.
Caution
Contaminated brake lining will reduce brake
performance so the brake lining, brake drum
and disc must be free of grease.

Apply with grease onto the left side dust seal.

Install the left side collar.

Place the front wheel between the front cushions.

Caution
Align the front cushion groove with the Stopper
speedometer gear box stopper flange.

Front cushion groove

Insert the wheel axle into the wheel, and then

install the wheel axle nut.
Tighten the nut to specified torque.
Torque value: 5.0~7.0kgf-m
Connect the speedometer cable to the
speedometer gear box.

Shaft nut Speedometer cable

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13. Steering / Front Wheel / Front Cushion

Front Cushion Hose clamp

Removal
Remove front cover, front fender and front wheel.
Remove the caliper mounting bolt and the caliper.
Take out the hose from hose clamp.

2 bolts Brake caliper

4 bolts
Remove the front cushion upper bolts and the
front cushion.

Installation
Align the cover flange with upper level of the
cushion clamp, and then tighten bolts.
Torque value: 2.4~3.0kgf-m

Install the removed components in reverse order

of removal procedures.

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13. Steering / Front Wheel / Front Cushion

Steering Stem Steering stem
Removal mounting nut

Remove steering handle, front wheel and front

cushion.
Remove the steering stem mounting nut.
Remove top cone race and front fork.
Caution
Place the steel ball onto a parts container to
prevent from missing.
Top cone race

Slightly tap the top and bottom ball bearing seats

with a plastic hammer to remove the seats.
Remove bottom cone race body with a punch.
Caution
Do not damage the steering stem.

Steering stem mounting nut

Installation
Top cone race
Install a new bottom cone race onto the steering
stem. Top ball
Push the cone race until to mounted position. bearing seat

Caution Bottom ball

bearing seat
Do not tilt the ball bearing seats as installation.
Steel balls
Apply with grease onto the ball bearing seats, and
install steel balls onto the seats.
Bottom cone race
(Top: 26 balls, bottom: 29 balls)

Steering lock nut

Lubricate the top cone race seat with grease.
Screw the cone race in to top ball bearing seat till
touching, and then screw out the cane race Return 1/2 turns

1/4~3/8 turns.
Torque value: 0.2~0.3kgf-m
Caution
Check the steering stem that should be rotated Locking to
freely and no clearance in vertical direction. 1/4~3/8 turns

Top cone-race

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13. Steering / Front Wheel / Front Cushion

Install the steering stem mounting nut and tighten Steering stem mounting nut
the nut by means of holding the top cone race
body.
Torque value: 1.0~1.2kgf-m

Install in reverse order of removal procedures.

Top cone race

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14. Rear Wheel / Rear Cushion

Maintenance Information ····················· 14-2 Rear Wheel ············································14-3

Troubleshooting ··································· 14-2 Rear Cushion·········································14-5

10.0~12.0kgf-m

4.0~4.5kgf-m

14
10.0~12.0kgf-m

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14. Rear Wheel / Rear Cushion

Maintenance Information
Specification
Item Standard value (mm) Limit (mm)
Rear wheel rim run out — 2.0 (0.08 in)

Torque Value
Rear cushion upper mounting bolt 3.5~4.5kgf-m
Rear cushion lower mounting bolt 2.4~3.0kgf-m
Rear wheel nut 10.0~12.0kgf-m
Bolts for the brake disc 4.0~4.5kgf-m
Exhaust muffler nut 1.0~1.4kgf-m
Exhaust muffler bolt 3.0~3.6kgf-m

Troubleshooting
Rear wheel wobbling
1. Bend wheel rim
2. Poor tire
3. Loosen wheel shaft

Cushion too soft

1. Insufficient cushion spring force

Poor brake performance

1. Poor brake adjustment
2. Contaminated brake lining
3. Worn brake lining cam
4. Worn brake cam lever
5. Worn brake drum
6. Improper installation of brake arm gear set.

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14. Rear Wheel / Rear Cushion

Rear Wheel Connection nuts
Remove
Remove exhaust pipe nut. (2 connection nuts)

Bolts
Remove exhaust muffler bolt (3 bolts), then
remove the muffler.

Shaft nut
Remove rear wheel shaft nut and then remove
the rear wheel.

Inspection
As the diagram shown, measure wheel rim
wobbling with a dial gauge.
Service limit:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)

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14. Rear Wheel / Rear Cushion

Brake disc removal / install 4 bolts
Remove 4 bolts, and then remove brake disc.
Check item refer chapter 12.
Install by reverse order of removal procedures.

Shaft nut
Installation
Install the rear wheel and tighten the nut.
Tighten torque: 10.0~12.0kgf-m

3 bolts 2 nuts
Install exhaust pipe & muffler.
Tighten torque (bolt): 3.0~3.6kgf-m
Tighten torque (nut): 1.0~1.4kgf-m

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14. Rear Wheel / Rear Cushion

Upper mounting bolt
Rear Cushion
Removal
Remove luggage box.
Remove air cleaner.
Remove rear cushion upper & lower bolts.
Remove rear cushion.

Installation
Install the rear cushion.
Tighten the upper & lower mounting bolts to
specified torque.
Torque value:
Upper mounting bolt: 3.5~4.5kgf-m
Lower mounting bolt: 2.4~3.0kgf-m
Press down the tail of the scooter for several
times to check cushion operation.
Install all components in reverse order of removal
procedures. Lower mounting bolt

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14. Rear Wheel / Rear Cushion

Note:

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15. Electrical Equipment

Maintenance Information ···················· 15-2 Starting System ································· 15-錯

Troubleshooting ·································· 15-3 誤! 尚未定義書籤。
Battery ·················································· 15-4 Oil Level Switch ································· 15-13
Charging System ································· 15-6 Fuel Unit ············································· 15-15
Ignition System···································· 15-錯 Switch/Horn········································ 15-16
誤! 尚未定義書籤。 Bulb Replacement······························ 15-19

Resistor Comp

Winker Relay
Reg. Rec. Comp

Horn

Main Switch

Horn / Winker /
Dimmer Switch Start / ENG. Stop Switch

Fuel Unit
15

Spark Plug

IG. Coil

AC. Generator
Carburetor heater

Oil Level Switch Fuse

Battery
Thermo Switch

Start Relay
CDI Unit

Power filter

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15. Electrical Equipment

Maintenance Information
Precautions in Operation

When remove the battery, the disconnection sequence of cable terminals shall be strictly observed.
(First disconnect the negative cable terminal, next, the positive cable terminal.)

The model of the spark plug and the tightening torque.

The ignition timing.

Adjustment of headlight.

Removal and installation of AC generator.

The maintenance-free battery requires no inspection of electrolyte level and refilling of distilled water.

To recharge the battery, remove the battery from the motorcycle without removing ventilation caps.

Unless in emergency, never rapid charge the battery.

The voltage must be checked with the voltmeter while charging the battery.

As C.D.I assembly does not require an ignition timing check. In case ignition timing is incorrect, check
C.D.I and AC generator. Verify with an ignition timing light after replacement if necessary.

The starter motor can be removed after the engine is removed.

Specification
Charging System
Item Specification

Type TTZ 7SL

Battery Capacity 12V6Ah

Charging rate 0.7A / 5~10 hours (standard), 3A / 1 hour (fast charging)

Leak current < 1 mA

Charging current 1.2 A / 5000 rpm ↑

Control voltage in charging 14.0~15.0 V / 5000 rpm

Ignition System
Item Specification

Model NGK BR8HSA (Recommended)

Spark plug
Gap 0.6~0.7 mm

Primary coil 0.19~0.23 Ω

Ignition coil and resistance
Secondary coil 2.8~3.4 KΩ

Ignition timing “F” mark 17° BTDC / 1800 rpm

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15. Electrical Equipment

Troubleshooting
No voltage Charging system does not operate

Battery discharged properly

The cable disconnected
Burnt fuse

The fuse is blown
Poor contact, open or short circuit

Improper operation of the main switch
Poor regulator

Poor AC.G.
Low voltage

The battery is not fully charged Engine does not crank smoothly

Poor contact
Primary coil circuit

Poor charging system - Poor ignition coil

Poor regulator rectifier - Poor connection of cable and couplers
- Poor main switch
No spark produced by spark plug
Secondary coil circuit

The spark plug is out of work - Poor ignition coil

The cable is poorly connected, open or - Poor spark plug
short-circuited - Poor ignition coil cable
- Between AC.G. and C.D.I. - Current leakage in the spark plug cap

Poor connection between C.D.I. and ignition
Incorrect ignition timing
coil - Poor AC.G.
- Poor connection between C.D.I. and the main - Improper installation of the pulse sensor
switch - Poor C.D.I.

Poor main switch

Poor C.D.I. Weak starter motor

AC.G. is out of work
Poor charging system

The battery is not fully charged
Starter motor does not work
Poor connection in the windings

The fuse is blown
The motor gear is jammed by foreign material

The battery is not fully charge

Poor main switch Starter motor is working, but engine does

Poor starter switch not crank

The front and rear brake switches do not
Poor starter motor pinion
operate correctly
The starter motor run in reverse direction

Starter relay is out of work
Poor battery

The ignition coil is poorly connected, open or
short-circuited

The starter motor is out of work

Intermittent power supply

The coupler of the charging system becomes
loose

Poor connection of the battery cable

Poor connection or short-circuit of the
discharging system

Poor connection or short-circuit of the power
generation system

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15. Electrical Equipment

Battery Negative terminal Positive terminal
Battery Removal/Installation
Turn off main switch.
Open seat, remove 2 screws and then open
battery cover.
Disconnect the negative cable terminal first, then
the positive cable terminal.
Remove the battery from the scooter.
Install the battery in reverse order of removal.

Voltage Check
Open seat and battery cover.
Remove wires from battery.
Check battery voltage.
Voltage:
Fully charged: 13.0~13.2V
Undercharged: 12 V

Charging
Remove the battery.
Connect the positive terminal (+) of the charger to
the battery positive terminal (+).
Connect the negative terminal (-) of the charger to
the battery negative terminal (-).
Standard charging current/time: 0.7A/5~10 hrs.
Fast charging current/hrs: 3A/1 hr.
Caution

Strictly keep flames and sparks away while
recharging to avoid to explosion causing by
hydrogen.

Stop charging battery when electrolyte
temperature is over 45℃(117℉).

Fast charging the battery is for in emergency
only. Battery should be charged in standard.

Current Leakage Inspection

Turn the main switch to OFF position, and remove Ammeter
the negative cable terminal (-) from the battery.
Connect an ammeter between the negative cable Battery (-) terminal
terminal and the battery negative terminal.
Caution Ground circuit

In the current leakage test, set the current

range at larger scale, then gradually
decrease to the lower scale as the test
process goes to avoid possible damage to
the ammeter and the fuse.

Do not turn the main switch to ON position
during test.
If the leaked current exceeds the specified value, it
may indicate a short circuit.
Allowable current leakage: Less than 1 mA
Disconnect each cable one by one and take
measurement of the current of each cable to
locate the short circuit.

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15. Electrical Equipment

Charging Voltage Inspection
Digital voltmeter
Connect a tachometer.
Turn on the headlight to high beam and start the
Ammeter engine.
Accelerate the engine to the specified revolution
per minute and measure the charging voltage.
Specified Charging Current: 1.2 A / 5000 rpm
Control Charging Voltage: 14.0~15.0 V / 5000
rpm
Caution
To replace the old battery, use a new battery
Fuse connector with the same current and voltage.

Caution The following problems are related to the charging

system; follow the instructions provided in the

Before conducting the inspection, be sure
checking list to correct it if any one of the problems
that the battery is fully charged. If
takes place.
undercharged, the current changes
(1) The charging voltage cannot exceed the
dramatically.
voltage between two battery terminals and

Use a fully charged battery having a voltage
the charging current is in the discharging
larger than 13.0 V
direction.

While starting the engine, the starter motor
(2) The charging voltage and current are too
draws large amount of current from the
much higher than the standard values.
battery.
After the engine is warmed up, replace original
battery with a fully charged battery. Connect a
digital voltmeter to the battery terminals. The following problems are not related to the
Connect an ammeter between both ends of the charging system; correct it if any by following
main fuse. steps indicate in the checking list.
Caution (1) The standard charging voltage and current
can only reach when the revolution of the
When the probe is reversibly connected, use an engine exceeds the specified rpm.
ammeter having an indication that shows both - Bulbs used exceed their rate and
positive and negative direction current. The consume too much power.
measurement would be at zero, if the ammeter - The replacement battery is aged and does
is one direction only. not have enough capacity.
Caution (2) The charging voltage is normal, but the
current is not.

Do not use short-circuit cable. - The replacement battery is aged and does

It is possible to measure the current by not have enough capacity.
connecting an ammeter between the battery - Battery used does not have enough
positive terminal and the + cable position electricity or is over charged.
terminal, however, while the starter motor is - The fuse of the ammeter is blown.
activated, the surge current of the motor - The ammeter is improperly connected.
draws from the battery may damage the (3) The charging current is normal, but the
ammeter. Use the kick-starter to start the voltage is not.
engine. - The fuse of the voltmeter is blown.

The main switch shall be turned to OFF
position during the process of inspection.
Never tamper with the ammeter and the
cable while there is current flowing through. It
may damage the ammeter.

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15. Electrical Equipment

Charging System
Fuse 15A R Red
B Black
Main switch REG. REC. G Green
OFF Y Yellow
ON P Pink

B R B G Y P

Resistor 8Ω 5W
Fuse 15A P

G/B
R
Y
To other electric equipment

Battery
Auto by- starter
AC. Generator

Regulator rectifier Inspection Regulator rectifier coupler

Check the each pins of coupler on the regulator

rectifier.

Regulator rectifier

Inspection Probable cause

Check voltage between battery terminal (red) and ground Blown fuse.
(green).
Check voltage between main switch terminal (black) and Blown fuse or poor main switch contact
ground (green). (main switch ON)
Check continuity between ground (green) and frame. Open-circuit wire.
Check charging coil (yellow to pink) if its resistance is within Open-circuit in alternator charging coil.
0.2~1.0Ω
If wire circuit check is in normal and there is no loose in the pins of regulator rectifier coupler, then
measure the resistance among pins on the couplers of regulator rectifier.

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15. Electrical Equipment

Regulator rectifier Inspection

+ Black
R B G P Y Green
-
R ∞ ∞ ∞ ∞ Pink
B 2.8MΩ 522.1Ω 1.5MΩ 1.7MΩ
G 2.7MΩ 522.1Ω 1.5MΩ 1.7MΩ
P 1.5MΩ 29.2MΩ 29.2MΩ 30MΩ
Y 1.6MΩ 26.3MΩ 26.3MΩ 2.7MΩ
If the resistance values are abnormal among the
pins, replace the regulator rectifier. Yellow
Red
Caution

If the probe is touched by finger, then the
resistance values will be incorrect.

It contains semi-conductor in circuit so the
measured resistance value will be in different
if different testers are used. Thus, these
values cannot be judged with standards.

AC Generator Inspection
Remove luggage box.
Disconnect the generator harness coupler.
Measure the resistance on charging coil (the
yellow to pink).
Resistance Measurement: (20℃)
Ω
Charging coil (yellow ~ pink): 0.2~1.0Ω Yellow

Pink

AC. Generator
harness coupler

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15. Electrical Equipment

Ignition System

DC. CDI. Unit

To tachometer
Main switch

G
B B/Y L/Y
R
B/Y

Fuse 15A

Ignition Coil

Spark plug
AC. Generator

Pulse
Generator
L/Y

Battery ENG. Stop switch

Ignition Coil Inspection

Remove lower side cover.
Remove ignition coil wire pins.

Ignition Coil

Measure the primary coil resistance.

Resistance :0.19~0.23ΩΩ (A)→ →(B)
Measure the secondary coil resistance.
Resistance : 8.2~9.3KΩΩ (A)→ →(D)

(A) (C)
(B)
(D)

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15. Electrical Equipment

Remove the plug cap, and measure its negative (-)
terminal for the secondary coil resistance.
Resistance : 3.1~3.2KΩ Ω(A)→→(C)

(A) (C)
(B)
(D)

Electrical System Circuit Inspection

Pulse Generator
Remove luggage box.
Disconnect pulse generator coil coupler.
Resistance Measurement: (20℃ ℃)
Pulse generator coil (blue/yellow ~ ground):
50~200ΩΩ

Pulse generator
coil couple

CDI Electrical System Circuit Inspection

Remove luggage box and body cover. CDI. unit
Disconnect the CDI. unit coupler, and check its
circuit to diagnosis related ignition components.
Green Black

Blue/yellow Black/yellow

Item Measure at: Standard (at 20℃)

Continuity (battery voltage) as main
Main Switch Black ~Green
switch ON
Pulse Generator Blue/Yellow ~ Green 50 ~200Ω
Primary Black/yellow ~ Green 0.19~0.23Ω
Ignition Coil Green ~ high voltage cable ~w/o Cap 3~5KΩ
Secondary
Green ~ high voltage cable ~ w/ Cap 8.2~9.3KΩ

If above checks are in normal but spark plug is still no spark. Then it probable causes from CDI set or
high voltage coil.

If abnormal circuits are found in above checks, at first check all items, and then check each item one
by one.

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15. Electrical Equipment

Starting System

Brake light
Main switch

Stop switch
B G/Y

R R R

Starter relay

Start switch

Y/R R/W
G

Starter motor

G
Battery

Starter Relay Inspection Starter relay

Remove battery box and then remove starter
relay.

Connect both the green/yellow (-) and the Starter relay

yellow/red (+) pins to battery posts directly.
If the red and red/white pins are also in continuity,
it means it is in normal.

Battery

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15. Electrical Equipment

Starter Motor Pinion Removal/Installation Starter motor pinion holder
Remove left crankcase cover and drive face.
Remove starter motor pinion holder, and then
remove starter motor pinion.
Install the starter motor pinion in reverse order of
removal.

Starter motor pinion

Starter Motor Pinion Inspection

Pinion, reduction gear for wear out or damage
→ replace it with new one.

Gear journal for wear out or damage →
replace it with new one.

Check the pinion for sliding in axial direction

smoothly.

The pinion sliding in axial direction not in
smooth → replace it with new one.

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15. Electrical Equipment

Starter Motor Removal/Disassembly Starter motor
Remove body cover.
Remove bolt and oil pump control cable.
Disconnect starter motor harness coupler.
Remove 2 bolts for separation starter motor and
gasket.
Remove 2 bolts for disassembly the starter motor.

2 bolts

Armature Inspection
Check the armature for discoloration or other
damage. It may be short-circuiting if dark surface Armature

on the shifter found.

Spring
Caution
O-ring
Do not clean the shifter surface with sandpaper. Motor housing
Check continuity 1) both the shifter surface and
shaft, 2) among the shifter surfaces. It can be in
continuity among the shifter surfaces, but both the
Carbon bracket
shifter surface and the shaft cannot be in
continuity.

Starter Motor Re-Assembly/Installation

Re-assemble and install the starter motor in
reverse order of removal procedures.

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15. Electrical Equipment

Oil Level Switch
Troubleshooting Main switch Fuse

If the oil level in oil tank is in specified level, but
the oil level indicator still goes on.
1.Remove luggage box.
2.Disconnect oil level switch wire, and turn the
main switch to ON position. Indicator

Indicator light up Indicator not light up

Oil level switch

Short-circuit between Malfunction of oil

indicator and oil level level switch.
switch.
Main switch Fuse

If there is no oil in oil tank or low oil level, but
the oil level indicator still not goes on.
3. Remove body cover.
4. Disconnect oil level switch wire and connect
Indicator
a jump wire among coupler, and then turn
the main switch to ON position.

Indicator not light up Indicator light up

Oil level switch

Poor wire Malfunction of oil

connection. level switch.

5. Disconnect oil level switch coupler, and check

voltage between wire and ground.
No voltage Voltage
Oil level switch

Open-circuit between
Malfunction of oil level

oil level switch and switch.
indicator.
Poor connection of oil

Blown bulb. level switch.

Removal/Installation
Remove luggage box.
Drain out oil from oil outlet tube.
Pull up oil level switch, and then remove oil level
switch from the oil tank.
Install the oil level switch in reverse order of
removal procedures.

Oil level switch

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15. Electrical Equipment

Carburetor Heater
Power filter Thermo switch

Fuse 15A Main switch

R
B
B

G G

To REG. REC. Y

W/Y

Carburetor heater
G
Battery
AC. Generator

Removal/Installation
Remove luggage box, rear carrier and body cover. Wire pins

Remove carburetor heater wire pins.

Remove carburetor heater.
Inspection

Ω
Carburetor heater resistance : 7±10%Ω Carburetor heater

Remove power filter coupler and thermo switch Thermo switch coupler
coupler, and then remove power filter and thermo
switch.

Power filter

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15. Electrical Equipment

Fuel Unit 2 nuts

Removal/Installation
Remove 4 bolts and floor panel.
Remove floor plate (2 nuts).
Remove fuel tank heat guard.

Heat guard

Disconnect fuel unit coupler from front wheel side.

Turns the fuel unit retain plate in

counter-clockwise direction and then remove the
fuel unit retain plate.
Remove the fuel unit. Fuel unit coupler

Caution
Do not bend the float arm.
Install in reverse order of removal procedures.
Remark: Aligning the slot of fuel unit with the
retain plate of fuel tank as installation, and then
turn the retain plate in clockwise direction until
matching to the arrow.

Inspection
1. Connect the fuel unit coupler.
Turn the main switch ON.
Move the float in up and down, and make sure
Fuel unit plastic
that the fuel indicator can be reached to F
(Full) and E (Empty) positions.
Conduct the step 2 if the needle on the fuel Float
indicator is not moved.
2. Measure the coupler resistance while the float
in up and down positions.
Float position Resistance value
Up (full) 3~10Ω
Down (empty) 90~100Ω
Check the fuel indicator if the resistance is in
normal.
Replace the fuel gauge if the resistance is
abnormal.

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15. Electrical Equipment

Switch / Horn
Remove handle covers and front cover.
Check continuity on each switch. Main switch cap
The connected circles with a line are that they
should be in continuity.

Main Switch
Wire color Black Red
LOCK
OFF
ON

Replacement of main switch

Turns the main switch cap in counter-clockwise
direction and then remove the main switch cap.
Disconnect the coupler of the main switch and
loosen the mounting bolts (2 bolts).
Remove the main switch.
Install the new main switch and tighten the
mounting bolts.
Install the main switch coupler and cap.

Main switch coupler

Right handle switch ENG. Stop switch

Remove the front cover.

Disconnect the coupler of right handle switch.
Check the continuity between two points as
indicated in the table below.

Engine Stop Switch

Wire color Blue/Yellow Blue/Yellow

Start switch
Starter Motor Switch
Wire color Yellow / Red Green Right handle
FREE switch coupler

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15. Electrical Equipment

Left handle switch Passing switch

Remove the front cover.

Disconnect the coupler of left handle switch.
Check the continuity between two points as
indicated in the table below High / low beam
switch
Turn signal light switch
Wire color Orange Gray Sky blue
Turn signal switch
FROM R
N PUSH OFF
Horn switch
FROM L

Left handle switch coupler

Horn Switch
Wire color Light green Black
FREE

High/Low Beam switch

Wire color Black White Blue

Passing Switch
Wire color Black Blue
FREE
PASS

Front / Rear Brake Light Switch

If the switch is in continuity as braking, it is in
normal. The switch is non-adjustable.

Horn
If the horn gives out sound as connecting to 12V
battery, it means that it is in normal.

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15. Electrical Equipment

Lights
Tail & stop light

Stop switch GY

Position light

Meter illuming light

B

Hi beam indicate light

Headlight (Hi-beam)

Headlight beam switch

L
Main switch G
L Headlight (Lo-beam)

B
W

Right winker indicate light

R
Winker relay

Winker switch Right winker light

SB
GR
Fuse 15A

O
Left winker light

Left winker indicate light

Battery

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15. Electrical Equipment

Bulb Replacement Position light

Headlight/position light
Remove front cover.

Headlight

Remove the headlight bulb set coupler.

Headlight coupler

Turn the set in counter-clockwise direction, and

then remove the bulb.
Replace with new bulb if necessary.
Specification:
Headlight bulb 12V 35W (H8)

Turn the position light set and then remove the

position light bulb seat.
Replace with new bulb if necessary.
Specification:
Position light bulb 12V 5W

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15. Electrical Equipment

Front winker light
Remove 9 screws and then remove handle front
cover (refer to chapter 11).
Turn the front winker light set in counter-clockwise
direction, and then remove the front winker light
bulb seat.

Push and turn the bulb in counter-clockwise

direction, and then remove the bulb.
Replace with new bulb if necessary.
Specification:
Winker light bulb 12V 10W

Rear winker light

Remove rear winker lens. (1 screw)

1 Screw

1 Screw
Remove rear winker inner lens. (1 screw)
Push and turn the bulb in counter-clockwise
direction, and then remove the bulb.
Replace with new bulb if necessary.
Specification:
Winker light bulb 12V 10W

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15. Electrical Equipment

Tail light / Brake light Taillight coupler
Remove taillight coupler.
Remove body cover, rear carrier, rear fender and
taillight assembly.
(Refer chapter 11)

Remove 1 screw from taillight upper side. 1 screw

Remove 4 screws and then remove taillight 4 Screws

assembly.
Taillight bulb is LED, if necessary to replacement,
you must replacement assembly.

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15. Electrical Equipment

Meter indicator light Rubbers
Remove steering handle front cover.
Remove winker and hi-beam indicator light rubber.

Turn the bulb seat in counter-clockwise direction Winker indicator light bulb

and then remove, and then take out the bulb seat
from the bottom of instrument panel.

Hi-beam indicator light bulb

Replace with new bulb if necessary.

Specification:
Meter indicator light bulb 12V 3.4W

Install the all removed parts.

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16. Electrical Diagram

Open fire
Jet Sport X 50 Series Electrical Diagram
16

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16. Electrical Diagram

Notes:

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