Instruction/ maintenance manual of the product Jet 50 SYM
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SER VICE MANU AL Forward Content s How T o Use This Manual Mechanism Illustrations 50/10 0 50/10 0.
FORWARD This service manual contains the technical data of each component inspection and repair for the SANYANG JET 50/100 and JET Euro 50/100 series motorcycle.
How to Use This Manual This service manual describes basic information of different system parts and system inspection & service for Sanyang JET 50/100 and JET Euro 50/100 series motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
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 ~ 4-4 ENGINE REMOVAL 4 5-1 ~ 5-8 CYLINDER HEAD/CYLINDER/PIS.
MODEL ILLUSTRATION JET 50 / 100 Series Head light Front brake lever Rear brake lever Tail light Helmet hook Fuel tank cap Engine number Storage box Muffler Battery / Fuses / C.
MODEL ILLUSTRATION JET Euro Series Head light Front brake lever Rear brake lever Tail light Helmet hook Fuel tank cap Engine number Storage box Muffler Battery / Fuses / C.
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1. GENERAL INFORMATION 1-1 Symbols and Marks···························1-1 General Sa fety ···································1-2 Service .
1. GENERAL INFORMATION 1-2 General Safety Carbon monoxide If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor.
1. GENERAL INFORMATION 1-3 Service Precautions z Always use with Sanyang genuine parts and recommended oils. Using non-designed parts for Sanyang motorcycle may damage the motorcycle. z Special tools are designed for remove and install of components without damaging the parts being worked on.
1. GENERAL INFORMATION 1-4 z The length of bolts and screws for assemblies, cover plates or boxes is different from one another, be sure they are correctly installed. In case of confusion, Insert the bolt into the hole to compare its length with other bolts, if its length out side the hole is the same with other bolts, it is a correct bolt.
1. GENERAL INFORMATION 1-5 Specifications Make SANYANG MODEL JET 50 SERIES Overall Length 1785 mm Front TELESCOPIC Overall Width 630 mm Suspension System Rear UNlT SWING Overall Height 1115 mm Front 1.
1. GENERAL INFORMATION 1-6 Specifications Make SANYANG MODEL JET 100 SERIES Overall Length 1785 mm Front TELESCOPIC Overall Width 630 mm Suspension System Rear UNlT SWING Overall Height 1115 mm Front .
1. GENERAL INFORMATION 1-7 Torque values Standard Torque Values for Reference Type Torque value Type Torque value 5 mm Bolt, nut 0.45 - 0.6 kg-m 5 mm Bolt 0.35 - 0.5 kg-m 6 mm Bolt, nut 0.8 - 1.2 kg-m 6 mm Bolt, SH nut 0.7 - 1.1 kg-m 8 mm Bolt, nut 1.
1. GENERAL INFORMATION 1-8 Frame Item Q’ty Thread Dia. (mm) Torque Value (Kgf-m) Remarks Bolt for engine suspension 1 10 5.0 Bolt for engine suspension bracket 1 12 6.0 Upper bolt for rear shock absorber 1 10 4.0 Lower bolt for rear shock absorber 1 8 2.
1. GENERAL INFORMATION 1-9 Cables and Harness Routing Note the following w hen 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.
1. GENERAL INFORMATION 1-10 High/low beam sw itch Horn switch Rear brake lamp switch Winker switch Speedometer Headlight switch Starter switch Throttle cable Headlight Rear brake cable Speedometer cab.
1. GENERAL INFORMATION 1-11 Throttle cable Rear brake cable Fuel unit cord Fuel filter Speedometer cable Rear brake cable Front brake hose Throttle cable Fuel unit Winker relay Front brake hose Rear b.
1. GENERAL INFORMATION 1-12 Fuel filter Battery C.D.I. UNIT Fuse Purge control valv e Oil control cable Fuel hose Fuel pump Vacuum hose Oil hose Rear brake cable Carburetor Oil lever switch This chapt.
1. GENERAL INFORMATION 1-13 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 gasolin.
1. GENERAL INFORMATION 1-14 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 Engine speed can be increased. Engine speed can not be increased.
1. GENERAL INFORMATION 1-15 C. Engine runs sluggish (especially in low speed and idling) D. Engine runs sluggish (High speed) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Check for fuel supplying system in automatic fuel cup Check if carburetor clogged 1.
1. GENERAL INFORMATION 1-16 E . CLUTCH, DRIVING AND DRIVING PULLEY 1. Clutch ling spring broken 2. Clutch outer cover stuck with clutch balance w eights 3. Connection parts in clutch and shaft worn out or burned Engine can be started but motorcycle can not be driv ing FAULT CONDITION PROBA BLE CAUSES 1.
1. GENERAL INFORMATION 1-17 Lubrication Points Engine suspension bushing Seat lock Rear wheel bearing Steering shaft bearing Speedometer gear/ front wheel bearing Side stand shaft Main stand shaft Thr.
1. GENERAL INFORMATION 1-18 Note: This chapter Contents.
2. SERVICE MAINTENANCE INFORMATION 2-1 General Information ························· 2-1 Periodical Maintenance Schedule··· 2-2 Air Clean er ···············.
2. SERVICE MAINTENANCE INFORMATION 2-2 Periodical Maintenance Schedule Maintenance kilometer 300KM Every 1000KM Every 3000KM Every 6000KM Every 12000KM Check item Maintenance interval New 1 month 3 month 6 month 1 year Reference ☆ 1. Air cleaner I C R ☆ 2.
2. SERVICE MAINTENANCE INFORMATION 2-3 Air Cleaner • Remove the mounting screw from the air cleaner cover • Remove the air cleaner cover Remove the air cleaner element Clean the element with non-flammable or high-flash point solvent and then squeeze it for dry.
2. SERVICE MAINTENANCE INFORMATION 2-4 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.
2. SERVICE MAINTENANCE INFORMATION 2-5 Oil Pump Control Cable Caution To adjust the oil pump control cable after adjusted the throttle grip play. Remove the body cover. Wide open the throttle valve, and check if the calibration point aligns on the oil pump lever with the mark of pump body.
2. SERVICE MAINTENANCE INFORMATION 2-6 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 Tire size Front: 120 / 90 - 10 Rear: 130 / 90 - 10 Tire pressure (cold) kg/cm 2 1.
2. SERVICE MAINTENANCE INFORMATION 2-7 Rear Brake Free Play: (Drum Brake Type) Measure the free play of the rear brake lever at the end of the lever. Free play: 10-20 mm (3/8-3/4 in) Adjust the free play by turning the front brake adjustment nut if necessary.
2. SERVICE MAINTENANCE INFORMATION 2-8 Brake System Hose: (Front Disc Brake Type) 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.
2. SERVICE MAINTENANCE INFORMATION 2-9 z Remove the pin bolt cap. z Loosen the bolt. z Remove the front wheel shaft bolt. z Take out the front wheel. Remove brake caliper mounting bolt and then remove the brake caliper. Caution Do not operate the brake lever after the clipper removed to avoid clipping the brake lining.
2. SERVICE MAINTENANCE INFORMATION 2-10 Steering System Caution The control cables can not interfere with the rotation of steering handle. Lift the front wheel out of ground, and check if the steering handle turning is smoothly.
2. SERVICE MAINTENANCE INFORMATION 2-11 Transmission Oil Leak Check if the transmission is leak. 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.
2. SERVICE MAINTENANCE INFORMATION 2-12 Control Cable Lubrication Remove the throttle control and the brake cables periodically, and lubricate the moving parts of the cables thoroughly. Driver Belt z Remove left crankcase cover. z Check if the belt is crack or worn out.
2. SERVICE MAINTENANCE INFORMATION 2-13 Carburetor Idle Speed Adjustment Caution z Inspection & adjustment for idle speed have to be performed after all parts in engine had been adjusted in specification. z Idle speed check and adjustment have to be done after engine is being warn up.
2. SERVICE MAINTENANCE INFORMATION 2-14 Headlight Adjustment Loosen headlight mounting bolt. Move the headlight for adjustment its light beam. Tighten the headlight mounting bolt after adjusted. Caution Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting for safety distance.
3. LUBRICATION SYSTEM 3-1 Lubrication System Diagram ············ 3-1 Precautions In Operation ·················· 3-2 Lubricant ·····················.
3. LUBRICATION SYSTEM 3-2 Precautions In Operation z Be careful not let dirt enter into engine or oil hoses when removing or installing the oil pump. z 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.
3. LUBRICATION SYSTEM 3-3 Oil Pump Removal 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 cable, and remove the control cable. Remove the oil tube, and clip its end side to prevent oil from flowing out.
3. LUBRICATION SYSTEM 3-4 Oil Pump/Oil Tube Air Bleeding Caution The oil tube system has to be conducted air bleeding operation because air will clog or restraint oil flowing so that cause serious engine damage. Caution After disconnect the oil tube, air enters oil tube due to oil leak out without added oil.
3. LUBRICATION SYSTEM 3-5 Oil Tank Removal/Installation Remove the luggage box and seat. Remove the battery and battery box. Remove the R/L. side cover, rear center cover, rear carrier and body cover. Remove the rear fender. Remove the oil input tube from oil pump, and then drain oil to a clean container.
3. LUBRICATION SYSTEM 3-6 NOTES: This chapter Contents.
4. ENGINE REMOVAL 4-1 Maintenance In formation ················ 4-1 Engine re moval ································ 4-2 Engine insta llation ···························· 4-4 Maintenance Information There are parts that require removal of engine for maintenance.
4. ENGINE REMOVAL 4-2 Engine removal Remove body cover. Remove the spark plug cap from the spark plug section. Remove the fuel output and the vacuum tubes from fuel pump. Remove the oil control cable from oil pump. Remove the oil tube from oil pump and then clip the tube.
4. ENGINE REMOVAL 4-3 Remove rear brake cable from engine rear-lower side. Remove air cleaner mounting bolts. (2 bolts) Support the engine and then remove shock absorber lower mounting bolt. Remove two exhaust pipe connection nuts. Remove two bolts beside fan cover and exhaust pipe.
4. ENGINE REMOVAL 4-4 Remove engine mounting nut and bolt. Engine installation Install in the reverse order of removal procedures. Tighten the engine mounting and rear shock absorber upper/lower bolts.
5. CYLINDER HEAD/CYLINDER/PISTON 5-1 Maintenance In formation ·················· 5-2 Troubleshootin g ································ 5-2 Cylinder H .
5. CYLINDER HEAD/CYLINDER/PISTON 5-2 Maintenance Information Precautions In Operation z The inspection and maintenance of the cylinder head, cylinder and piston can be carried as engine mounted on the body. z It should clean the engine to prevent dirt from entering into cylinder and crankcase before removal.
5. CYLINDER HEAD/CYLINDER/PISTON 5-3 Cylinder Head Cylinder Removal Removal body covers. 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 pipe.
5. CYLINDER HEAD/CYLINDER/PISTON 5-4 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.
5. CYLINDER HEAD/CYLINDER/PISTON 5-5 Cylinder/Piston Cylinder Removal 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 Place a clean rag onto crankshaft to cover the piston.
5. CYLINDER HEAD/CYLINDER/PISTON 5-6 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 max.
5. CYLINDER HEAD/CYLINDER/PISTON 5-7 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 Install bearing and piston pin onto connecting rod small end, and then check its clearance.
5. CYLINDER HEAD/CYLINDER/PISTON 5-8 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 then install the piston pin onto connecting rod.
6. ALTERNATOR 6-1 Maintenance In formation ················ 6-2 Alternator Removal ·························· 6-3 Alternator Inst allation······················· 6-4 6 3.
6. ALTERNATOR 6-2 Maintenance Information Precautions in Operation z The maintenance service of A.C. alternator can be carried out directly on the motorcycle. z Please refer to Chapter 15 for the relative alternator inspection. Torque value: Flywheel 3.
6. ALTERNATOR 6-3 Alternator Removal Remove the body cover. Remove two bolts and then take out cooling fan cover. Remove four bolts, and then take out the cooling fan. Hold flywheel with universal holder. Support the flywheel and the remove the 10 mm nut on the flywheel.
6. ALTERNATOR 6-4 Disconnect alternator wire connector and pulse generator connector. Remove the pulse generator and alternator four (4) bolts, and then take out the alternator assembly. Caution Care to be taken for not damaging the alternator coil. Alternator Installation Install the alternator assembly.
7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-1 Maintenance In formation ················ 7-2 Trouble Shoot ing ····························· 7-2 Left C.
7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-2 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.
7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-3 Left Crankcase Cover Left crankcase cover removal Remove left body side cover. Remove air cleaner. Remove kick start arm. Remove left crankcase cover. Disassembly of Kick Starter Remove snap clip and thrust washer from left crankcase cover.
7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-4 Reassembly Of Kick Starter Install bush, return spring and starter spindle as diagram shown. Install thrust washer and snap clip onto starter spindle. Install Kick starter lever temporary. Slightly rotate the lever and then align driven gear with width-tooth on the starter spindle.
7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-5 Drive Belt Removal Remove left crankcase cover. Hold clutch outer with universal holder, and remove nut and clutch outer. Caution y Using special tools for tightening or loosening the nut. y Fixed rear wheel or rear brake will damage reduction gear system.
7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-6 Install the driven pulley that has installed the belt onto drive shaft. Install the clutch with universal holder, and then tighten nut to specified torque value. Torque value: 3.8 kgf-m Movable Drive Face Removal Remove left crankcase cover.
7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-7 Removal Remove movable drive face set and drive belt from crankshaft. Remove ramp plate. Remove weight rollers from movable face. Inspection The weight roller is to press movable driven face by means of centrifuge force.
7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-8 Check if movable drive face boss is worn or 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.
7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-9 Install movable drive face assembly onto crankshaft. Drive Face Installation Press drive belt into pulley groove, and then pull the belt on to crank shaft. Install drive face, washer and nut. Caution y Make sure that two sides of drive face have to be free of grease.
7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-10 Clutch/Driven Pulley Disassembly 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.
7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-11 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.
7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-12 Clutch Block Replacement Remove clip and washer, and then remove clutch weight and spring from drive plate. Caution y Some of models are equipped with one mounting plate instead of 3 snap clips. Check if spring is damage or insufficient elasticity.
7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-13 Install snap clip and mounting plate onto lock pin. Replacement of Driven Pulley Bearing Remove inner bearing. Caution y If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly.
7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-14 Installation of Clutch/Driven Pulley Assembly Install new oil seal and O-ring onto sliding pulley. Apply with specified grease to lubricate the inside of sliding pulley. Install sliding pulley onto driven pulley.
8. FINAL DRIVING MECHANISM 8-1 Maintenance In formation ················· 8-2 Troubleshootin g ······························· 8-2 Disassembly of Final .
8. FINAL DRIVING MECHANISM 8-2 Maintenance Information Limited usage of gear oil ： gear oil #140 Recommended oil ： Bramax serial oil. Oil quantity ： 120 c.
8. FINAL DRIVING MECHANISM 8-3 Disassembly of Final Driving Mechanism Remove driven pulley Drain gear oil out from gearbox. Remove rear wheel. Remove gearbox cover mounting bolts from the clutch side and then remove the cover from the rear wheel side.
8. FINAL DRIVING MECHANISM 8-4 Inspection Of Final Driving Mechanism Check if the drive shaft, counter shaft and final gear shaft are worn or damage. Check if the gear box cover bearing, oil seal and the inner diameter of counter shaft are worn or damage.
8. FINAL DRIVING MECHANISM 8-5 Install countershaft, final driven gear and thrust washer. Install new gasket and lock pin. Install gearbox cover. Install clutch/driven pulley assembly. Install driven pulley, drive belt, and left crankcase side cover. Install body cover.
8. FINAL DRIVING MECHANISM 8-6 Notes: This chapter Contents.
9. CRANKCASE/CRANKSHAFT 9-1 Maintenance In formation ····················9-2 Troubleshootin g ··································9-2 Crankcase Disa.
9. CRANKCASE/CRANKSHAFT 9-2 Maintenance Information z This chapter concerns disassembly of the crankcase for repair purpose. z Before disassembling crankcase, except removing engine firstly, following components must be removed too.
9. CRANKCASE/CRANKSHAFT 9-3 Crankcase Disassembly Remove the crankcase bolts. Install the crankcase puller onto the right crankcase with two (2) bolts, 6mm, as the diagram shown. Disassemble the right crankcase. Crankshaft Removal As the diagram show with 3 special bolts to install the specified service tool onto the left crankcase.
9. CRANKCASE/CRANKSHAFT 9-4 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 gauge.
9. CRANKCASE/CRANKSHAFT 9-5 Crankcase Installation Clean the crankshaft with solvent and blow it with compressed air. Then, check for damage or other foreign materials attached. Install new bearing into right crankcase. Caution y All rotation and sliding surfaces have to be applied with clean engine oil.
9. CRANKCASE/CRANKSHAFT 9-6 Assemble the right crankcase with assembly tools. Install right crankcase onto the crankshaft. Install right crankshaft puller and install bush onto crankshaft. Screw the right crankshaft puller onto crankshaft. Turn the puller in C.
10. FUEL SYSTEM 10-1 Maintenance In formation ················· 10-2 Troubleshootin g ······························· 10-2 Throttle Va lve ······.
10. FUEL SYSTEM 10-2 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.
10. FUEL SYSTEM 10-3 Throttle Valve 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 Installation Place the fuel needle onto the throttle valve and clip it with needle clamp.
10. FUEL SYSTEM 10-4 Carburetor Remove Remove the body cover. Disconnect the auto by-starter connector. Loosen draining screw and then drain out fuel inside the carburetor. Loosen carburetor upper part and remove carburetor upper part. Remove fuel and oil hoses from carburetor.
10. FUEL SYSTEM 10-5 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.
10. FUEL SYSTEM 10-6 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.
10. FUEL SYSTEM 10-7 Flaot Level Inspection Measure 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. Carburetor Installation Caution Do not let foreign materials into the carburetor.
10. FUEL SYSTEM 10-8 Inspection 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.
10. FUEL SYSTEM 10-9 Air Cleaner Removal/Installation Loosen connection hose clamp. Remove 2 bolts and then remove the air cleaner. Install in the reverse order of removal procedures.
10. FUEL SYSTEM 10-10 Notes: This chapter Contents.
11. BRAKE SYSTEM 11-1 Front Disc Brake System ··············· 11-1 Rear Drum Br ake System ·············· 11-2 Maintenance In formation ··············· 11-3.
11. BRAKE SYSTEM 11-2 Rear Drum Brake System 2.5 kgf-m 11.0 kgf-m 0.55 kgf-m This chapter Contents.
11. BRAKE SYSTEM 11-3 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.
11. BRAKE SYSTEM 11-4 Troubleshooting Disc Brake Soft brake lever 1. Air inside the hydraulic system 2. Hydraulic system leaking 3. Worn master piston 4. Worn brake pad 5. Poor brake caliper 6. Worn brake lining/disc 7. Low brake fluid 8. Blocked brake pipe 9.
11. BRAKE SYSTEM 11-5 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, then remove the brake fluid reservoir.
11. BRAKE SYSTEM 11-6 Disc Brake -Air Bleed 1. Tightly hold the brake lever and open the drain valve around 1/4 turns, and then close the valve. Caution y Do not release the brake lever before the drain valve is closed. y Always check the brake fluid level when carrying out the air bleeding procedure to avoid air enter into the system.
11. BRAKE SYSTEM 11-7 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: 2.0 mm Remove the brake disc from wheel.
11. BRAKE SYSTEM 11-8 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.
11. BRAKE SYSTEM 11-9 Install the rubber pad into the groove correctly. Place the master cylinder onto handlebar, and install the bolts. Install the brake lever, and connect leads to brake lamp switch. Connect brake hoses with 2 new washers. Tighten the brake hose bolt to the specified torque value.
11. BRAKE SYSTEM 11-10 Rear Drum Brake To use vacuum cleaner or other alternatives to avoid danger caused from dusts. Caution y Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use compressed air or dry brush to clean brake parts.
11. BRAKE SYSTEM 11-11 Installation 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.
11. BRAKE SYSTEM 11-12 Notes: This chapter Contents.
12. BODY COVER 12-1 Body Overview ······························· 12-1 Maintenance Information ··············· 12-2 Side Cove rs·············.
12. BODY COVER 12-2 Maintenance Information Body covers disassemble sequence: y Be careful not to damage various covers in disassembly or re-assembly operation. y Never injure hooks molded on the body covers in disassembly or re-assembly operation. y Align the buckles on the guards with slot on the covers.
12. BODY COVER 12-3 Side Covers 1. Removal: y Remove 3 screw (front/middle) from two side covers. y Slide the side cover backward so that their hooks are out of slots. y Take out the side cover end part and then remove the cover. 2. Installation: y Install in reverse order of removal procedures.
12. BODY COVER 12-4 Body Cover 1. Removal: y Remove 4 bolts from rear carrier, and then remove rear carrier. y Remove 1 screw and 2 nuts and 1bolt from luggage box, and then remove luggage box. z Remove 3 screws from the tail cover,.and then remove the tail cover.
12. BODY COVER 12-5 Remove 2 screw form of the body cover Remove the body cover. 2. Installation: y Install in reverse order of removal procedures. Bolts This chapter Contents.
12. BODY COVER 12-6 Front Cover 1. Removal: y Remove 2 bolts from the front side reflector, and then remove front side reflector. y Remove 2 screws from the front inner box and front cover. y Remove 1 screw from the front cover. y Remove electric cord coupler from the head light.
12. BODY COVER 12-7 Front Under Spoiler 1. Removal: y Remove right and left side cover. (6 screws) y Remove 4 screws from the front inner box. y Remove 2 screws from the front upper part of the front spoiler and the front inner box. y Remove the front spoiler.
12. BODY COVER 12-8 Front Inner Box 1. Removal: y Remove the front cover. y Remove the front under spoiler. y Remove hook and 1 screw. y Remove key set cover. y Remove 2 bolts from the floor panel. y Remove the front inner box. 2. Installation: y Install in reverse order of removal procedures.
12. BODY COVER 12-9 Floor Panel 1. Removal: y Remove 6 screws and the side cover. y Remove 6 screws and the body cover. y Remove the floor panel. (4 bolts) 2. Installation: y Install in reverse order of removal procedures. Front Fender Removal: y Ramoval 1 bolt and fr brake hose clamp.
12. BODY COVER 12-10 Steering Handle Cover 1. Removal: y Remove 6 screws from the handle rear cover. y Remove handle front cover. y Remove front winker electric cord coupler y Remove 1 screw from rear side by handle rear cover. y Remove 2 inner screws.
12. BODY COVER 12-11 Under Cover 1. Removal: y Remove 2 bolts from the under cover. y Remove under cover. 2. Installation: y Install in reverse order of removal procedures.
12. BODY COVER 12-12 Note: This chapter Contents.
13. STEERING/FRONT WHEEL/SUSPENSION 13-1 Maintenance In formation ················· 13-2 Troubleshootin g ······························· 13-2 Steering .
13. STEERING/FRONT WHEEL/SUSPENSION 13-2 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 4.5 kgf-m Front brake caliper bolt 3.
13. STEERING/FRONT WHEEL/SUSPENSION 13-3 Steering Handle Removal Remove handle cover, front cover and inner box. Remove throttle grip after mounting screw removed. Remove master cylinder (disc brake) after 2 bolts removed. Remove rear brake lever bracket after mounting bolt removed.
13. STEERING/FRONT WHEEL/SUSPENSION 13-4 Place master cylinder onto handle and align its connection surface with bolt hole on the handle (disc brake). Install the mounting seat. Tighten the upper part bolt, and then tighten lower bolt. Install all components in reverse order of removal procedures.
13. STEERING/FRONT WHEEL/SUSPENSION 13-5 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 Place the wheel on to a rotation seat, and turn the wheel to check its bearing free play.
13. STEERING/FRONT WHEEL/SUSPENSION 13-6 Remove dust seal, bearing and side collar. Special tools Inner bearing puller (SYM-6204020) Installation Fill out the block of bearing by grease. Drive the left bearing and install the dist. collar. Install the right bearing.
13. STEERING/FRONT WHEEL/SUSPENSION 13-7 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.
13. STEERING/FRONT WHEEL/SUSPENSION 13-8 Front Shock Absorber Removal y Front cover y Front under spoiler y Front fender y Front wheel Disc Brake Remove the caliper mounting bolt and the caliper. Take out the hose from hose clamp. Remove the front shock absorber upper bolt and the shock absorber.
13. STEERING/FRONT WHEEL/SUSPENSION 13-9 Front Fork Removal y Handle y Front wheel y Front shock absorber 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.
13. STEERING/FRONT WHEEL/SUSPENSION 13-10 Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body. Torque value: 1.
14. REAR WHEEL/SUSPENSION 14-1 Maintenance In formation ················· 14-2 Troubleshootin g ······························· 14-2 Rear Wh eel ···.
14. REAR WHEEL/SUSPENSION 14-2 Maintenance Information Specification Item Standard value (mm) Limit (mm) Rear wheel rim run out - 2.0 (0.08 in) Torque Value Rear shock absorber upper mounting bolt: 4.0 kgf-m Rear shock absorber lower mounting bolt: 2.
14. REAR WHEEL/SUSPENSION 14-3 Rear Wheel Remove Remove exhaust pipe nut. (2 connection nuts) Remove exhaust muffler bolt (3 bolts), then remove the muffler. Remove rear wheel shaft nut and then remove the rear wheel. Inspection As the diagram shown, measure wheel rim wobbling with a dial gauge.
14. REAR WHEEL/SUSPENSION 14-4 Brake Hub Replacement Remove 4 nuts of cover and wheel rim, and then remove the wheel hub. Install the wheel hub and tighten the nuts. Tighten torque: 2.5 kgf-m Installation Install the rear wheel and tighten the nut. Tighten torque: 11.
15. ELECTRICAL EQUIPMENT 15-1 Maintenance Information ··············· 15-2 Troubleshootin g ····························· 15-3 Battery ··········.
15. ELECTRICAL EQUIPMENT 15-2 Maintenance Information Precautions in Operation y When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positiv e cable terminal.
15. ELECTRICAL EQUIPMENT 15-3 Troubleshooting No voltage y Battery discharged y The cable disconnected y The fuse is blown y Improper operation of the main switch Low voltage y The battery is not full.
15. ELECTRICAL EQUIPMENT 15-4 Battery Battery Removal/Installation Turn off main switch. Open seat. Remove screw and the open battery cover. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery from the scooter.
15. ELECTRICAL EQUIPMENT 15-5 Charging System JET 50 / JET 100 JET EURO 50 / JET EURO 100 AC. Gen era tor Auto by - starter Regulator rectifier Main Switch Fuse 15A Battery Green Red Black Yellow Yellow Yellow Yellow White Yellow Green Red Resistor 10.
15. ELECTRICAL EQUIPMENT 15-6 Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery.
15. ELECTRICAL EQUIPMENT 15-7 Caution To replace the old battery, use a new battery with the same current and voltage. The following problems are related to the charging system, follow the instructions provided in the checking list to correct it if any one of the problems takes place.
15. ELECTRICAL EQUIPMENT 15-8 Voltage Regulator Inspection – JET 50/100 Check the each pins of connector on the voltage regulator. Inspection Probable cause Check voltage between battery terminal (red) and ground (green). Blown fuse or poor main switch contact Check continuity between ground and frame.
15. ELECTRICAL EQUIPMENT 15-9 Inspection on SCR – JET EURO 50/100 Remove the front cover. Disconnect 4P connectors to remove the SCR. Item Check Points Standard Value Main switch connection R – B Battery voltage (ON) Battery connection R – G Battery voltage Charging coil Y – Y 0.
15. ELECTRICAL EQUIPMENT 15-10 Ignition System JET 50/100 series JET EURO 50/100 series Black/Red Blue/Yellow Black/White Black/Yellow Green Blue/Yellow Green Black/Yellow Black/Blue Black Red This ch.
15. ELECTRICAL EQUIPMENT 15-11 Ignition Coil Inspection y Remove body cover. Measure the primary coil resistance Resistance :0.19~0.23K Ω (A) → (B) Measure the secondary coil resistance Resistance : 8.2~9.3K Ω (A) → (C) Remove the high voltage coil cap, and measure its negative (-) terminal for the secondary coil resistance.
15. ELECTRICAL EQUIPMENT 15-12 Electrical System Circuit Inspection Pulse Generator/Exciting Coil Remove body cover. Disconnect alternator connector. Resistance Measurement: (20 ℃ ) Pulse generator coil (blue/yellow - ground): 50~200 Ω Exciting (yellow - ground): 400~800 Ω CDI Electrical System Circuit Inspection Remove body cover.
15. ELECTRICAL EQUIPMENT 15-13 Starting System Starter Relay Inspection Remove luggage box. Connect both the green/yellow (-) and the yellow/red (+) pins to battery posts directly. If the red and red/white pins are also in continuity, it means it is in normal.
15. ELECTRICAL EQUIPMENT 15-14 Starter Motor Removal/Disassembly Remove body cover. Remove bolt and oil pump control cable. Disconnect starter motor harness connector. Remove 2 bolts for separation starter motor and gasket. Remove 2 bolts for disassembly the starter motor.
15. ELECTRICAL EQUIPMENT 15-15 Oil Level Switch Troubleshooting y If the oil level in oil tank is in specified level, but the oil level indicator still goes on . 1. Remo ve body cover. 2. Disconnect oil gauge wire, and turn the main switch to ON position.
15. ELECTRICAL EQUIPMENT 15-16 Fuel Unit Removal/Installation Remove 4 bolts and floor panel. Disconnect fuel unit connector. Remove the fuel unit plastic cap. Turn the snap ring in CCW direction and then remove the fuel unit. Caution Do not bend the float arm.
15. ELECTRICAL EQUIPMENT 15-17 Switch / Horn Remove handle covers and front cover. Remove front inner box. Check continuity on each switch. The connected circles with a line are that they should be in continuity.
15. ELECTRICAL EQUIPMENT 15-18 Light Switch Wire color Brown Yellow Pink Mark HL CI RE OFF ● ● ON ● ● Start Switch Wire color Yellow / Red Green Mark ST E FREE PUSH ● ● Front / Rear Brake Light Switch If the switch is in continuity as braking, it is in normal.
15. ELECTRICAL EQUIPMENT 15-19 Bulb Replacement Headlight/position light JET EURO 50/100 Remove front cover. Remove bulb seat and replace the bulb. Install the all removed parts. JET 50/100 Remove front cover. Loosen the headlight bulb stop plate and replace the bulb.
15. ELECTRICAL EQUIPMENT 15-20 Rear winker light Remove rear winker lens. Replace winker light bulb. Front winker light Remove 6 screws and then remove handle front cover Replace winker light bulb 6 S.
15. ELECTRICAL EQUIPMENT 15-21 Clock unit – JET EURO 50/100 Remove 6 screws and then remove handle front cover Remove 2 screws and then remove clock unit. Meter Remove handlebar front cover. Take out the bulb seat from the bottom of instrument panel.
15. ELECTRICAL EQUIPMENT 15-22 Notes: This chapter Contents.
16. ELECTRICAL DIAGRAM 16-1 JET 50 ELECTRICAL DIAGRAM 16 Home page Contents.
16. ELECTRICAL DIAGRAM 16-2 JET 50 EURO ELECTRICAL DIAGRAM Home page Contents.
16. ELECTRICAL DIAGRAM 16-3 JET 100 ELECTRICAL DIAGRAM Home page Contents.
16. ELECTRICAL DIAGRAM 16-4 Notes: Home page Contents.
An important point after buying a device SYM Jet 50 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought SYM Jet 50 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data SYM Jet 50 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, SYM Jet 50 you will learn all the available features of the product, as well as information on its operation. The information that you get SYM Jet 50 will certainly help you make a decision on the purchase.
If you already are a holder of SYM Jet 50, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime SYM Jet 50.
However, one of the most important roles played by the user manual is to help in solving problems with SYM Jet 50. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device SYM Jet 50 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
