Sym DD 50 Manuel utilisateur

DD 50

SERVICE MANUAL

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HOW TO USE THIS MANUAL

CONTENTS

MECHANISM ILLUSTRATIONS

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This service manual contains the technical data of each component inspection

and repair for the SANYANG DD 50 series scooter. 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 scooter, DD 50 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.

Home page Contents

How to Use This Manual

This service manual describes basic information of different system parts and

system inspection & service for Sanyang DD 50 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.

Th third to the tenth nine chapters covers engine and driving systems.

The tenth to the fourteenth is contained the parts set of assembly body.

The fifteenth chapter is electrical equipment.

The sixteenth 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 ~ 1-16 GENERAL INFORMATION

2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION

3-1 ~ 3-6 LUBRICATION SYSTEM

4-1 ~ 4-6 ENGINE REMOVAL

5-1 ~ 5-8 CYLINDER HEAD/CYLINDER/PISTON

6-1 ~ 6-4 ALTERNATOR

7-1 ~ 7-14 “V” TYPE BELT DRIVING SYSTEM/KICK-STARTER

8-1 ~ 8-6 FINAL DRIVING MECHANISM

9-1 ~ 9-6 CRANKCASE/CRANKSHAFT

10-1 ~ 10-10

FUEL SYSTEM

11-1 ~ 11-12

BRAKE SYSTEM

12-1 ~ 12-14

BODY COVER

13-1 ~ 13-10

STEERING/FRONT WHEEL/SUSPENSION

14-1 ~ 14-4 REAR WHEEL/SUSPENSION

15-1 ~ 15-18

ELECTRICAL EQUIPMENT

16-1 ~ 16-2 ELECTRICAL DIAGRAM

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MODEL ILLUSTRATION

FT05V

Head light

Front brake lever Rear brake lever

Tail light /

Rear turn signal

Helmet hook

Fuel tank cap

Engine number

Storage box

Muffler

Battery / Fuses / C.D.I. /

Eng. Oil tank cap

Light / Starter switch

High & Low beam /

Turn signal / Horn switch

Air cleaner

Frame number

Front turn signal

Ignition switch

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MODEL ILLUSTRATION

FT05T

FT05U

FT05W

Home page Contents

1. GENERAL INFORMATION

1-1

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

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

Service Precautions ·························1-3

Specifications ···································1-5

Torque values···································1-6

Cables and Harness Routing ··········1-8

Troubleshooting·······························1-11

Lubrication Points····························1-15

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.

Warning Means that serious injury or even death may result if procedures are not

followed.

Caution Means that equipment damages may result if procedures are not

followed.

Engine oil Limits to use SAE 20 JASO FC class oil. Warranty will not cover the

damage that caused by not apply with the limited engine oil.

(Recommended oil: MAX-2 serial oils)

Grease King Mate G-3 is recommended.

Gear oil King Mate gear oil serials are recommended. (Bramax HYPOID GEAR

OIL # 140)

Locking

sealant Apply sealant, medium strength sealant should be used unless otherwise

specified.

Oil seal Apply with lubricant.

Renew Replace with a new part before installation.

Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid.

Special tools Special tools.

OCorrect Meaning correct installation.

XWrong 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).

Home page Contents

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.

Caution

Exhaust contains toxic gas which may cause

one to lose consciousness and even result in

death.

Gasoline

Gasoline is a low ignition point and explosive

material. Work in a well-ventilated place, no

flame or spark should be allowed in the work

place or where gasoline is being stored.

Caution

Gasoline is highly flammable, and may explode

under some conditions, keep it away from

children.

Used engine oil

Caution

Prolonged contact with used engine oil (or

transmission oil) may cause skin cancer

although it might not be verified.

We recommend that you wash your hands with

soap and water right after contacting. Keep the

used oil beyond reach of children.

Hot components

Caution

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.

Battery

Caution

yBattery emits explosive gases; flame is

strictly prohibited. Keep the place well

ventilated when charging the battery.

yBattery contains sulfuric acid (electrolyte)

which can cause serious burns so be careful

do not be spray on your eyes or skin. If you

get battery acid on your skin, flush it off

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

ophthalmologist.

yIf you swallow it by mistake, drink a lot of

water or milk, and take some laxative such

as castor oil or vegetable oil and then go to

see a doctor.

yKeep electrolyte beyond reach of 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.

Caution

Inhaling dust may cause disorders and cancer

of the breathing system.

Brake fluid

Caution

Spilling brake fluid on painted, plastic, or

rubber parts may cause damage to the parts.

Place a clean towel on the above-mentioned

parts for protection when servicing the brake

system. Keep the brake fluid beyond reach of

children.

This chapter Contents

1. GENERAL INFORMATION

1-3

Service Precautions

zAlways use with Sanyang genuine parts and

recommended oils. Using non-designed parts

for Sanyang motorcycle may damage the

motorcycle.

zSpecial tools are designed for remove and

install of components without damaging the

parts being worked on. Using wrong tools may

result in parts damaged.

zWhen servicing this motorcycle, use only metric

tools. Metric bolts, nuts, and screws are not

interchangeable with the English system, using

wrong tools and fasteners may damage this

vehicle.

zClean the outside of the parts or the cover

before removing it from the motorcycle.

Otherwise, dirt and deposit accumulated on the

part's surface may fall into the engine, chassis,

or brake system to cause a damage.

zWash 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.

zNever bend or twist a control cable to prevent

stiff control and premature worn out.

zRubber parts may become deteriorated when

old, and prone to be damaged by solvent and oil.

Check these parts before installation to make

sure that they are in good condition, replace if

necessary.

zWhen loosening a component which has

different sized fasteners, operate with a

diagonal pattern and work from inside out.

Loosen the small fasteners first. If the bigger

ones are loosen first, small fasteners may

receive too much stress.

zStore complex components such as

transmission parts in the proper assemble order

and tie them together with a wire for ease of

installation later.

zNote the reassemble position of the important

components before disassembling them to

ensure they will be reassembled in correct

dimensions (depth, distance or position).

zComponents not to be reused should be

replaced when disassembled including gaskets

metal seal rings, O-rings, oil seals, snap rings,

and split pins.

Caution

In addition to damaging paint finish, brake oil

can also damage the structural integration of

plastic or rubber parts.

This chapter Contents

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