Mio Sport Manual de servicio

Mio 50 / 100 SERVICE MANUAL FORWARD HOW TO USE THIS MANUAL CONTENTS Mechanism Illustrations

1. General Information 1-5 y Lubricate the rotation face with specified lubricant on the lubrication points before assembling. y Check if positio

8. V-Belt Drive System / Kick Starter 8-5 Drive Belt Removal Remove left crankcase cover Hold drive face with universal fixture, and remove nut and

8. V-Belt Drive System / Kick Starter 8-6 Installation Pull out the sliding driven face and then insert the drive belt into the driven pulley. Caut

8. V-Belt Drive System / Kick Starter 8-7 Movable Drive Face Removal Remove left crankcase cover. Hold drive face with universal fixture, and then r

8. V-Belt Drive System / Kick Starter 8-8 Inspection The operation of movable drive face is means of the weight roller to pressing on it with centri

8. V-Belt Drive System / Kick Starter 8-9 Apply with some grease to inside of drive face boss hole, and install drive face boss. Caution z The dri

8. V-Belt Drive System / Kick Starter 8-10 Clutch / Driven Pulley Disassembly Remove drive belt and clutch / driven pulley. Install clutch spring co

8. V-Belt Drive System / Kick Starter 8-11 Clutch lining Measure each clutch lining thickness. Replace it if exceeds service limit. Service limit

8. V-Belt Drive System / Kick Starter 8-12 Clutch Block Replacement Remove snap and washer, and the remove clutch block and spring from driving plat

8. V-Belt Drive System / Kick Starter 8-13 Install snap ring and mounting plate onto setting pin. Replacement of Driven Pulley Bearing R

8. V-Belt Drive System / Kick Starter 8-14 Installation of Clutch / Driven Pulley Assembly Install new oil seal and O-ring onto sliding driven face.

1. General Information 1-6 y When separating a connector, it locker has to be unlocked firstly. Then, conduct the service operation. y Do not

9. Final Drive Mechanism 9-1 Mechanism Illustrations ····················· 9-1 Operational Precautions····················· 9-2 Trouble Diagnosis···

9. Final Drive Mechanism 9-2 Operational Precautions Specification Application gear oil: GEAR OIL SAE 85W-140 Recommended oil: KING MATE serial gear

9. Final Drive Mechanism 9-3 Disassembly of Final Drive Mechanism HU05U Remove the rear wheel (refer to chapter 15). Remove the clutch. Drain gear o

9. Final Drive Mechanism 9-4 Inspection of Final Drive Mechanism Check if the countershaft and the gear are worn out or damage. Check if t

9. Final Drive Mechanism 9-5 Bearing Replacement Caution z Never install used bearings. Once bearing removed, it has to be replaced with new one.

9. Final Drive Mechanism 9-6 Install a new drive shaft bearing onto gear box cover. Then, install the drive shaft. Special Service Tool: Bearing (62

9. Final Drive Mechanism 9-7 Re-assembly of Final Driven Mechanism HU05U Apply with grease onto the oil seal lip of final driven shaft. Install fin

9. Final Drive Mechanism 9-8 Install the driven pulley / clutch outer / belt / movable drive face / drive face. Install the left cranksha

10. Alternator / Starting Clutch 10-1 Mechanism Illustrations ····················· 10-1 Operational Precautions····················· 10-2 Alternato

10. Alternator / Starting Clutch 10-2 Operational Precautions General information y Refer to chapter 5: Engine removal and installation y Refer to

1. General Information 1-7 y Do not let the wire harness contact with rotating, moving or vibrating components as routing the harness. y Keep wi

10. Alternator / Starting Clutch 10-3 Alternator Removal Drain out the engine oil. Remove the right side cover. Remove the exhaust pipe (2 bolts, 2

10. Alternator / Starting Clutch 10-4 Remove the flywheel with the flywheel puller. Special service tools: Flywheel puller SYM-3110000 Caution z I

10. Alternator / Starting Clutch 10-5 Starting Clutch Starting Clutch Removal Hold the starting driven gear with the universal fixture. Remove the 2

10. Alternator / Starting Clutch 10-6 Check the starting driven gear for wear or damage. Measure the ID of the starting driven gear. Service Limit:

10. Alternator / Starting Clutch 10-7 Installation Install the components in the reverse procedures of removal. Caution z Add adhesive onto the th

10. Alternator / Starting Clutch 10-8 Alternator Coil Set Installation Install the coil set onto right crankcase cover. (2 bolts) Install pulse gene

11. Crankcase / Crankshaft 11-1 Mechanism Illustrations ····················11-1 Operational Precautions····················11-2 Trouble Diagnosis··

11. Crankcase / Crankshaft 11-2 Operational Precautions General information y This Section contains descriptions concerning disassembly of the cran

11. Crankcase / Crankshaft 11-3 Disassembly of Crankcase Remove the cam chain tensioner (hex socket bolt) from the left side of crankcase. Remove th

11. Crankcase / Crankshaft 11-4 Remove the oil seal of left-side crankcase. To this chapter contents

1. General Information 1-8 y Do not let the wire harness been twisted as installation. y Wire harnesses routed along the handlebar should not be

11. Crankcase / Crankshaft 11-5 Crankshaft Inspection Measure left and right clearance of connecting rod big end. Service limit: Replace when it is

11. Crankcase / Crankshaft 11-6 Assembly of Crankcase Install cam chain into the chain hole of the left crankcase, and then split out the cam chain.

11. Crankcase / Crankshaft 11-7 Apply with some grease onto the oil seal lip and then install it onto the left crankcase. Press-fit the

11. Crankcase / Crankshaft 11-8 Notes: To this chapter contents

12. Body Cover 12-1 Mechanism Illustrations ····················12-1 Maintenance Information···················12-2 Front Cover·····················

12. Body Cover 12-2 Maintenance Information Body covers disassemble sequence: z Be careful not to damage various cov

12. Body Cover 12-3 Front Cover Removal Remove the mounting screws (2 screws) of front cover from the front inner cover side. Remove the f

12. Body Cover 12-4 Handle Cover Removal Loosen the handle front cover mounting screws (2 screws) of the handle from the handle rear cover. Push the

12. Body Cover 12-5 Remove the speedometer cable. Disconnect the instrument panel and switch wiring couplers. Remove the ha

12. Body Cover 12-6 Front Fender Remove speedometer cable (1 screw). Remove front brake cable (drum brake type). Remove front brake caliper (disk br

1. General Information 1-9 Specifications MAKER SANYANG MODEL HU05U Overall Length 1710 mm Front TELESCOPE Overall Width 700 mm Suspension System

12. Body Cover 12-7 Front under Spoiler Remove front cover. Remove the 10 screws on left & right both sides of rear-end from the inner cover.

12. Body Cover 12-8 Front Inner Cover Removal Remove the front cover and the front under spoiler. Remove the main switch cap. (1 screw) Rem

12. Body Cover 12-9 Luggage Box Remove the mounting bolts (4 bolts) from the luggage box. Disconnect the engine start control switch coup

12. Body Cover 12-10 Rear Carrier Remove the rear carrier mounting bolts and nuts (2 bolts & 2 nuts) Remove rear carrier. Installa

12. Body Cover 12-11 Side Cover Removal Remove the 2 screws on both left & right sides covers. Remove right and left side covers.

12. Body Cover 12-12 Center Cover Removal Remove center cover upper screw. (1 screw) Remove center cover right and left screws. (2 screws

12. Body Cover 12-13 Body Cover Removal Remove the right and left side covers (2 screws). Remove the luggage box (4 bolts). Remove the rear carrier

12. Body Cover 12-14 Floor Panel Removal Remove the center cover, side covers, luggage box and body cover as well as body cover. Remove the 4 floor

12. Body Cover 12-15 Rear Fender Remove the rear fender rear bolts (2 bolts). Remove the 2 bolts on the two sides. (1 bolts on each side

12. Body Cover 12-16 Rear Mudguard Remove the rear mudguard right side bolt (1 bolt). Loosen air cleaner mounting bolts, and then remove the rear mu

1. General Information 1-10 Specifications MAKER SANYANG MODEL HU10U/W Overall Length 1710 mm Front TELESCOPE Overall Width 700 mm Suspension Syst

13. Brake 13-1 Mechanism Diagram-Front Disc Brake System ················································· 13-1 Mechanism Diagram-Front Drum Brake S

13. Brake 13-2 Mechanism Diagram-Front Drum Brake System 0.8~1.2kgf-m 2.8~3.2kgf-m 5.0~7.0kgf-m To this chapter contents

13. Brake 13-3 Mechanism Diagram-Rear Drum Brake System 2.8~3.2kgf-m 11.0~13.0kgf-m 0.8~1.2kgf-m 0.8~1.2kgf-m To this chapter contents

13. Brake 13-4 Operational Precautions General information Caution ● Inhaling asbestos may cause disorders of respiration system or cancer, there

13. Brake 13-5 Trouble Diagnosis Disc Brake Soft brake lever 1. Air inside the hydraulic system 2. Hydraulic system leaking 3. Worn master piston 4.

13. Brake 13-6 Hydraulic Brake System Inspection Inspection of Hydraulic Brake System Inspection Visual inspect for brake fluid leaking or damage.

13. Brake 13-7 Remove the master cylinder cap and diaphragm. Add good quality brake fluid and it has to add same brand brake fluid into the master c

13. Brake 13-8 Brake Caliper Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hoses.

13. Brake 13-9 Brake Disc Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replac

13. Brake 13-10 Inspection Check the master cylinder for damage or scratch. Replace it if necessary. Measure the cylinder inner diameter at several

1. General Information 1-11 Torque Values The torque values listed in above table are for more important tighten torque values. Please see standard

13. Brake 13-11 Installation Place the master cylinder onto handlebar, and install the split ring and bolts. The “UP” mark on the split ring shou

13. Brake 13-12 Drum Brake System Brake Drum Removal Use a vacuum cleaner and other suitable tools to clean the brake parts to minimize the hazard

13. Brake 13-13 Removal Caution ● Brake linings must be replaced as a set. Remove brake shoes from the brake panel by pulling out the brake lining

13. Brake 13-14 Installation Front brake panel Apply a thin cost of grease onto the brake cam shaft. Install the brake cam. Apply a thin cost of gr

14. Steering / Front Wheel / Front Cushion 14-1 Mechanism Diagram ··························14-1 Operational Precautions····················14-2 Tro

14. Steering / Front Wheel / Front Cushion 14-2 Operational Precautions General information y Before remove front wheel, use a jack to lift the bod

14. Steering / Front Wheel / Front Cushion 14-3 Steering Handle Removal Remove handle front & rear covers, meter and the front cover (refer to c

14. Steering / Front Wheel / Front Cushion 14-4 Disc Brake Type Remove the 2 bolts of the brake master cylinder, and then take out the master cylind

14. Steering / Front Wheel / Front Cushion 14-5 Front Wheel Removal Disc Brake Support body bottom and lift front wheel free of ground with a stand.

14. Steering / Front Wheel / Front Cushion 14-6 Inspection Wheel axle Set the axle in V-blocks and measure the run-out. Service limit: above 0.2 mm.

1. General Information 1-12 Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value (Kg-m) Remarks Mounting bolt for steering handlebar 1 10

14. Steering / Front Wheel / Front Cushion 14-7 Disassembly (Drum Brake Type) Remove the right dust seal. Remove the bearing with the in

14. Steering / Front Wheel / Front Cushion 14-8 Installation Disc Brake Apply with some grease inside of the dust seal. Install the dust seal and th

14. Steering / Front Wheel / Front Cushion 14-9 Place the front wheel between the front cushions. Drum Brake Align the brake panel slot with the sto

14. Steering / Front Wheel / Front Cushion 14-10 Front Cushion Removal Remove the front fender, front lower spoiler, front cover, and front wheel as

14. Steering / Front Wheel / Front Cushion 14-11 With a plastic hammer tap the steering column slightly, and then remove the top ball bearing seat.

14. Steering / Front Wheel / Front Cushion 14-12 Note: To this chapter contents

15. Rear Wheel / Rear Cushion 15-1 Mechanism Diagram ··························· 15-1 Operational Precautions····················· 15-2 Trouble Diag

15. Rear Wheel / Rear Cushion 15-2 Operational Precautions General information As for the wheel removal, service, and installation procedures, plea

15. Rear Wheel / Rear Cushion 15-3 Exhaust Muffler Removal Remove the front-end nut of the exhaust muffler. (2 nuts) Remove the bolts. (2 bolts) Rem

15. Rear Wheel / Rear Cushion 15-4 Rear Cushion Removal Remove the left & right side covers. (2 screws) Remove the luggage box. (4 bolts) Remov

1. General Information 1-13 Troubles Diagnosis A. Engine hard to start or can not be started To this chapter contents

16. Electrical Equipment 16-1 Mechanism Diagram ··························16-1 Operational Precautions····················16-2 Specification ·······

16. Electrical Equipment 16-2 Operational Precautions Charging System y When remove the battery, the disconnection sequence of cable terminals shal

16. Electrical Equipment 16-3 Specification Charging System Specification Items HU10U/W HU05U Capacity/type 12V4Ah / YTX5L-BS or GTX5L-BS Chargin

16. Electrical Equipment 16-4 Trouble Diagnosis Charging System No power supply y Dead battery y Disconnect battery cable y Fuse burned out y Faul

16. Electrical Equipment 16-5 Charging System Wire Diagram Current Leakage Inspection Turn the main switch to OFF position, and remove the negat

16. Electrical Equipment 16-6 BATTERY Removal Remove the battery cover (2 screws) Caution z Electrolyte (diluted sulfuric acid) is very toxic.

16. Electrical Equipment 16-7 Voltage Check With a digital voltage meter or multi-meter to measure battery voltage. Voltage: Fully charged: 13.0 ~

16. Electrical Equipment 16-8 Charging Voltage/Current Inspection Caution y Before conducting the inspection, be sure that the battery is fully

16. Electrical Equipment 16-9 Voltage Regulator Inspection Remove the front fender. (4 screws) Disconnect the 4P coupler on the diode, and check the

16. Electrical Equipment 16-10 Alternator charging coil Caution ● The check of alternator charging coil and illumination coil can be done when th

1. General Information 1-14 B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fau

16. Electrical Equipment 16-11 Ignition System Ignition System Circuit Spark plug IGN. Coil C.D.I UnitGB/YGB/R B/W B R Battery Main switch L/

16. Electrical Equipment 16-12 CDI. Unit Removal Remove the battery cover. Remove the CDI. Inspection Disconnect the coupler from the CDI

16. Electrical Equipment 16-13 Ignition coil Removal Remove the luggage box, body cover and floor panel. Remove spark plug cap. Remove the primary c

16. Electrical Equipment 16-14 Secondary coil Attached the spark plug cap, measure the resistance between plug cap side and green terminal. Standard

16. Electrical Equipment 16-15 Start System Start Circuit Start relay inspection Turn main switch ON. Operate the brake lever. Press start

16. Electrical Equipment 16-16 Start Motor Removal Remove the right side cover. (1 screw) Remove the air cleaner mounting bolts. (2 bolts) Firstly,

16. Electrical Equipment 16-17 Remove handle rear cover and meter set (2 bolts & 1 screw). Remove meter mounting screws (3 screws),

16. Electrical Equipment 16-18 Light / Bulb Headlight Bulb Replacement Remove the front cover (3 screws) Disconnect the headlight wire coupler.

16. Electrical Equipment 16-19 Position light Bulb Replacement Remove the front cover (3 screws) Disconnect the headlight and position light wire co

16. Electrical Equipment 16-20 Bulbs Replacement of Tail Light / Brake Light Remove the rear light lens screws. (2 screws) Remove the rea

Forward This service manual contains the technical data of each component inspection and repair for the SANYANG Mio 50 / 100 scooters. The manua

1. General Information 1-15 C. Engine runs sluggish (especially in low speed and idling) D. Engine runs sluggish (High speed)

16. Electrical Equipment 16-21 Bulbs Replacement of Rear Winker Light Remove the rear winker light lens screws. (1 screw) Pull out the b

16. Electrical Equipment 16-22 Switch / Horn Main Switch Check Remove front cover. (3 screws) Disconnect main switch leads coupler. Check coupler te

16. Electrical Equipment 16-23 Right Handle Switch Seat open switch Pin Location BAT HO FREE PUSH ● ● Wire color Black Purple Horn switch Pin

16. Electrical Equipment 16-24 Brake light switch The circuit of black wire and the green/yellow wire on the brake light switch should be in continu

16. Electrical Equipment 16-25 Fuel Unit Fuel Unit Remove Fuel Tank Removal (Please refer to chapter 4 for more detailed.) Disconnect the fuel unit

16. Electrical Equipment 16-26 Note: To this chapter contents

17. Emission Control System 17-1 Names of Mechanisms in the Emission Control System···································· 17-1 Function of Mechanisms

17. Emission Control System 17-2 Fuel Evaporative Emission Control System (E.E.C.) 1. Construction: y Reduce HC to pollute air. y To absorber fuel

17. Emission Control System 17-3 Evaporative Emission Control System (EEC) 1. Visual check: 1) Check the outside of canister for damage. 2) Check

17. Emission Control System 17-4 Catalytic Converting System (CATA) 1. Construction: 2. Description: 1) The function of the catalytic converter

1. General Information 1-16 E. Clutch, Driving And Driving Pulley 1. Clutch ling spring broken 2. Clutch outer cover stickled

17. Emission Control System 17-5 Positive Crankcase Ventilation System (P.C.V.) 1. Construction 2. Principle of operation: y Install a separated

17. Emission Control System 17-6 Inspection Items Secondary air injection system 1. Visual inspect the reed valve, air injection cut valve, and sec

17. Emission Control System 17-7 Countermeasure for Emission Pollutants Not Within Standard as In Idle Speed (4-Stroke Engine)

17. Emission Control System 17-8 Note: To this chapter contents

18. Electrical Diagram 18-1 HU05U Electrical Diagram Home pageContents

18. Electrical Diagram 18-2 HU10U/W Electrical Diagram Home pageContents

1. General Information 1-17 Lubrication Points Steering shaft bearing Seat lockerClutch bearing Main stand shaft Side stand shaft Spee

1. General Information 1-18 Note: To this chapter contents

2. Maintenance Information 2-1 Precautions in Operation... 2-1 Periodical Maintenance Schedule... 2-2 Lubrication System...

2. Maintenance Information 2-2 Periodical Maintenance Schedule No item Initial 300KM1 Monthevery 1000KM3 month every 3000KM 6 monthevery 6000KM1 yea

2. Maintenance Information 2-3 Lubrication System Engine Oil Capacity Caution y The vehicle must be parked on a level ground when checking oil cap

2. Maintenance Information 2-4 Gear Oil Inspection Check gear oil if leaking. Park the motorcycle with main stand on flat level place. Turn off engi

2. Maintenance Information 2-5 Air Cleaner Element Remove the air cleaner cover (7 screws) Remove element. Check the element if dirt or

2. Maintenance Information 2-6 Primary adjustment is conducted from cable button side. Loosen fixing nut, and adjust by turning the adjustment nut.

How To Use This Manual This service manual describes basic information of different system parts and system inspection & service for SANYANG M

2. Maintenance Information 2-7 Valve clearance inspection and adjustment Check & adjust valve clearance with feeler gauge after open the valve a

2. Maintenance Information 2-8 Ignition System Ignition Timing Caution z C.D.I ignition system is set by manufacturer so it can not be adjusted z

2. Maintenance Information 2-9 Cylinder Compression Pressure Warn up engine and then turn off the engine. Remove the trunk and the central cover. Re

2. Maintenance Information 2-10 Steering System Caution z Check all wires and cables if they are interfered with the rotation of steering handle b

2. Maintenance Information 2-11 Front Disk Brake System Brake System Hose Make sure the brake hoses for corrosion or leaking oil. Brake Fluid

2. Maintenance Information 2-12 ADDED BRAKE FLUID Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 WELL RUN brake fluid

2. Maintenance Information 2-13 Drum Brake System Front Brake Free Play: (Drum brake) Measure free play of rear brake level at the end of the lever.

2. Maintenance Information 2-14 BRAKE LAMP SWITCH The brake light switch lit up brake light as brake applied. Make sure that electrical starter can

2. Maintenance Information 2-15 Battery Battery Removal Open the seat cushion and then the battery cap. (2 screws) Battery cables removal: 1. At

2. Maintenance Information 2-16 Special Service Tools Catalogue Name Puller/presser for crankcase bushing Name Puller/presser for crankcase bushi

Contents Page Content Index 1-1 ~ 1-18 General Information 1 2-1 ~ 2-18 Service Maintenance Information 2 3-1 ~ 3-8 Lubrication System 3 4-1 ~

2. Maintenance Information 2-17 Name Bearing remover (inner type) Name Bearing remover (outer type) Name clutch spring compressor Parts no. SYM-

2. Maintenance Information 2-18 NOTE: To this chapter contents

3. Lubrication System 3-1 Mechanism Illustrations ····················· 3-1 Operational Precautions····················· 3-2 Trouble Diagnosis······

3. Lubrication System 3-2 Operational Precautions General Information z This chapter contains maintenance operations for the engine oil pump, engin

3. Lubrication System 3-3 Engine OIL Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstick Do

3. Lubrication System 3-4 Cleaning Engine Oil Strainer Remove the oil strainer cap. Remove oil strainer and spring Clean oil strainer (recommended u

3. Lubrication System 3-5 Oil Pump Oil Pump Removal Remove the alternator (refer to chapter 10). Remove the engine right cover. Remove the one-way c

3. Lubrication System 3-6 Oil Pump Inspection Check the clearance between oil pump body and outer rotor Limit：below 0.12mm Check clearance

3. Lubrication System 3-7 Install driving gear and clamp. Caution z Make sure if the oil pump can be rotated smoothly. Oil Pump Installa

3. Lubrication System 3-8 Gear Oil Oil Level Inspection Park the motorcycle on flat surface with main stand Turn off engine and remove both engine o

Mechanism Illustrations HU05U / HU10U / HU10W Exhaust mufflerHome pageContents Air cleaner Fuel tank cap Start / headlight switch Battery / Fuse /

4. Fuel System 4-1 Mechanism Illustration ...4-1 Operational Precautions...4-2 Trouble Diagnosis...

4. Fuel System 4-2 Operational Precautions General Information Warning Gasoline is a low ignition point and explosive materials, so always work in

4. Fuel System 4-3 Trouble Diagnosis Poor engine start y No fuel in fuel tank y Clogged fuel tube y Too much fuel in cylinder y No spark from sp

4. Fuel System 4-4 Carburetor Carburetor Removal Remove the luggage box and seat. Loosen the adjustment nut and fixing nut of throttle valve cable,

4. Fuel System 4-5 Air Cut-off Valve Removal Removal the throttle cable seat (screws x 2) Remove the screws (screw x 2) of the air cut-off va

4. Fuel System 4-6 AUTOMATIC BY-STARTER Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two term

4. Fuel System 4-7 FLOAT CHAMBER Disassembly Remove 4 mounting screws and then the float chamber cover. Remove the float pin and float valve.

4. Fuel System 4-8 Assembly Install main jet, fuel needle jet holder, nozzle, idle jet and air-fuel mixture adjustment screw. Caution z Set the ad

4. Fuel System 4-9 Fuel Tank Fuel meter gauge removal Remove the left and right side covers. Open seat. Remove the luggage box. Remove rear carrier.

4. Fuel System 4-10 Fuel tank removal Remove the left and right side covers. Open seat. Remove the luggage box. Remove rear carrier. Remove the left

1. General Information 1-1 Symbols and Marks····························1-1 General Safety ····································1-2 Service Precautio

4. Fuel System 4-11 Air Cleaner Removal the element of the air cleaner Remove the air cleaner cover (7 screws). Remove air cleaner element.

4. Fuel System 4-12 Removal of Air Cleaner Open the seat. Remove the luggage box (chapter 12). Remove the left side cover (chapter 12). Loose the ai

5. Removal & Installation of Engine 5-1 Mechanism Illustrations ····················· 5-1 Operational Precautions····················· 5-2 Engin

5. Removal & Installation of Engine 5-2 Operational Precautions General Information y Engine must be supported by a bracket or adjustable tool

5. Removal & Installation of Engine 5-3 Engine Removal Open the seat. Remove the luggage box (Bolt× 4, Nut×1). Remove battery cover. Remove the

5. Removal & Installation of Engine 5-4 Remove the fuel line, vacuum hose, and throttle valve cable from the carburetor. Loose the strap screw o

5. Removal & Installation of Engine 5-5 Remove the rear cushion lower bolt (1 bolt). Remove the engine hanger nuts and bolts (engin

5. Removal & Installation of Engine 5-6 Removal of Engine Bush If engine hanger frame and the cushion rubber of rear cushion bush damaged. Then,

5. Removal & Installation of Engine 5-7 Engine Hanger Removal Remove the right side bolt of engine hanger. (1 bolt on each side) Remov

5. Removal & Installation of Engine 5-8 Installation of Engine Install the engine according to the reversing order of removal. Caution z Note

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

6. Cylinder Head / Valve 6-1 Mechanism Illustrations ····················· 6-1 Operational Precautions····················· 6-2 Troubleshooting·····

6. Cylinder Head / Valve 6-2 Operational Precautions General Information y This chapter is contained maintenance and service for cylinder head, val

6. Cylinder Head / Valve 6-3 Troubleshooting Engine performance will be affected by troubles on engine top end. The troubles usually can be determin

6. Cylinder Head / Valve 6-4 Cylinder Head Removal Remove the right cooling shroud from the engine outer cover. (5 screws) Remove the lef

6. Cylinder Head / Valve 6-5 Turn the flywheel in counter clockwise motion with T type wrench until the “Timing” mark on camshaft aligned with the m

6. Cylinder Head / Valve 6-6 Cylinder Head Disassembly (HU05U) Remove the valve cover from the cylinder head. Special Service Tool: Cylinder head wr

6. Cylinder Head / Valve 6-7 Cylinder Head Disassembly (HU10U/W) Remove the valve cover from the cylinder head. Special Service Tool: Cylinder head

6. Cylinder Head / Valve 6-8 Remove the camshaft. Camshaft Inspection Inspect cam lobe height for damaged. Service Limit: (Refer to pa

6. Cylinder Head / Valve 6-9 Valve Disassembly Remove the valves Special Service Tool: Valve remover/installer SYM-1471110/20 Caution z Place a r

6. Cylinder Head / Valve 6-10 Cylinder Head Inspection Cylinder Head Check if spark plug and valve holes are crack. Measure cylinder head wrap age w

1. General Information 1-3 Service Precautions y Always use with SANYANG genuine parts and recommended oils. Using non-designed parts for SANYANG A

6. Cylinder Head / Valve 6-11 Caution z If clearance between valve stem and valve guide exceeded service limit, check whether the new clearance th

6. Cylinder Head / Valve 6-12 Valve Seat Inspection and Service Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slight

6. Cylinder Head / Valve 6-13 Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Use 45° cutte

6. Cylinder Head / Valve 6-14 After the valve seat grinded, coat valve seat surface with emery and then slightly press the grinded surface. Clean up

6. Cylinder Head / Valve 6-15 Assembly the cylinder head. Caution z The tangent of rocker shaft of intake valve should match with the bolt hole of

6. Cylinder Head / Valve 6-16 Valve Clearance Adjustment Install the auto-chain tensioner. Loosen valve clearance adjustment nuts and bo

6. Cylinder Head / Valve 6-17 Install the cooling shroud of the engine body outer cover. (5 bolts) Install the engine onto the frame. (

6. Cylinder Head / Valve 6-18 Notes: To this chapter contents

7. Cylinder / Piston 7-1 Mechanism Illustrations ····················· 7-1 Operational Precautions····················· 7-2 Trouble Diagnosis·······

7. Cylinder / Piston 7-2 Operational Precautions General Information y Both cylinder and piston service cannot be carried out when engine mounted o

1. General Information 1-4 y The length of bolts and screws for assemblies, cover plates or boxes is different from one another, be sure they are c

7. Cylinder / Piston 7-3 Cylinder Removal Remove cylinder head. (Refer to chapter 6) Remove cam chain plate. Remove cylinder.

7. Cylinder / Piston 7-4 Inspection Check if the inner diameter of cylinder is worn out or damaged. In the 3 positions (top, center and bottom) of c

7. Cylinder / Piston 7-5 Piston Removal Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other parts falling int

7. Cylinder / Piston 7-6 Measure the outer diameter of piston pin. Service Limit: (Refer to page 2) Measure the inner diameter of connec

7. Cylinder / Piston 7-7 Piston Ring Installation Clean up piston top, ring groove, and piston shirt. Install the piston ring onto piston carefully.

7. Cylinder / Piston 7-8 Piston Installation Install piston and piston pin, and place the IN marks on the piston top side forward to intake valve. I

8. V-Belt Drive System / Kick Starter 8-1 Mechanism Illustrations ····················8-1 Operational Precautions····················8-2 Trouble Dia

8. V-Belt Drive System / Kick Starter 8-2 Operational Precautions General Information y Movable drive face, clutch, and driven pulley can be servic

8. V-Belt Drive System / Kick Starter 8-3 Left Crankcase Cover Left crankcase cover removal Remove body cover Remove air cleaner (2 bolts)

8. V-Belt Drive System / Kick Starter 8-4 Remove the inner plate inside of left crankcase cover. (6 screws) Install kick starter arm, ro