Sym EuroMX 125 Manuel utilisateur

SERVICE MANUAL

FORWARD CONTENTS

HOW TO USE THIS MANUAL MECHANISM ILLUSTRATIONS

Forward

This service manual contains the technical data of each component

inspection and repair for the SANYANG Euro MX 125 motorcycle.

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 motorcycle are different from that of the

photos, pictures shown in this manual, the actual vehicle shall prevail.

Specifications are subject to change without notice.

This manual that contains all data, illustration, indication and specifications

is based on current production information. SANYANG reserves the right to

make changes at any time without notice and without incurring any obligation

whatever. No part of this manual can be duplicated by any means without

written permission of SANYANG.

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 Euro MX 125 motorcycles.

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 and special service tools

information.

The third to the eleventh chapters cover engine, fuel systems and driving

systems.

The twelfth to fifteenth chapters are contained the parts set of assembly

body.

The sixteenth chapter is electrical equipment.

The seventh chapter is for wiring diagram.

Please see index of content for quick having the special parts and system

information.

Home page Contents

Contents

Page Content Index

1-1 ~ 1-16 General Information / Trouble Diagnosis

2-1 ~ 2-18 Service Maintenance Information

3-1 ~ 3-8 Lubrication System

4-1 ~ 4-14 Fuel System

5-1 ~ 5-10 Engine Removal

6-1 ~ 6-16 Cylinder Head / Valve

7-1 ~ 7-8 Cylinder / Piston

8-1 ~ 8-14 “V” Type Belt Driving System / Foot-Starter

9-1 ~ 9-6 Final Driving Mechanism

10-1 ~ 10-10 Alternator / Starting Clutch

11-1 ~ 11-6 Crankcase/Crankshaft

12-1 ~ 12-14 Body Cover

13-1 ~ 13-12 Brake System

14-1 ~ 14-8 Steering/Front Wheel/Suspension

15-1 ~ 15-4 Rear Wheel/Suspension

16-1 ~ 16-22 Electrical Equipment

17-1 ~ 17-2 Wiring Diagram

Home page

Model illustration

Horn

Spark plug

Engine number

Engine oil drain plug

Light /

Starter switch

High & Low beam /

Passing /

Turn signal /

Horn switch

Exhaust

muffler

Ignition switch

Gear oil drain

plug

Battery / Fuse

IG. Coil /

Start relay

Fuel tank

Oil level

Oil strainer

Front brake

lever

Rear brake

lever

Air cleaner

Gear oil

Inspection plug

Headlight

Front winker light

Tail light

Winker relay AC. Generator

Carburetor

Seat lock

Rear winker light

Frame number

Home page Contents

1. General Information/Trouble Diagnosis

1-1

Symbols And Marks.................. 1-1

General safety........................... 1-2

Service Precautions.................. 1-3

Specifications............................ 1-9

Torque Values (Engine).......... 1-10

Torque Values (Frame) ........... 1-11

Standard Torque Values for

Reference................................. 1-11

Troubles Diagnosis................. 1-12

Parts To Be Greased............... 1-16

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 10W-30 API SG class oil. Warranty will not cover

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

(Recommended oil: KING MATE G-3 oil)

Grease King Mate G-3 is recommended. (KING MATE G-3)

Gear oil King Mate gear oil (SYM HYPOID GEAR OIL ) is recommended.

(SAE 85W-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 service tools.

correct Meaning correct installation.

wrong Meaning wrong installation.

Indication Indication of components.

directions Indicates position and operation directions.

Components assembly directions each other.

Indicates where the bolt installation direction, --- means that bolt

cross through the component (invisibility).

Home page Contents

1. General Information/Trouble Diagnosis

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

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

Used engine oil

Caution

Hot components

Caution

Battery

Caution

Brake shoe

Do not use an compressed air or a dry brush to

clean components of the brake system, use a

vacuum cleaner or the equivalent to avoid

asbestos dust flying.

Caution

Brake fluid

Caution

Exhaust contains toxic gas which may cause

one to lose consciousness and even result in

death.

•Battery emits explosive gases; flame is

strictly prohibited. Keep the place well

ventilated when charging the battery.

•Battery 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, then go to hospital

to see an ophthalmologist.

•If 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.

•Keep electrolyte beyond reach of children.

Gasoline is highly flammable, and may

explode under some conditions, keep it away

from children.

Prolonged contact with used engine oil (or

transmission oil) may cause skin cancer

although it might not be verdict.

We recommend that you wash your hands

with soap and water right after contacting.

Keep the used oil beyond reach of children.

Inhaling asbestos dust may cause disorders

and cancer of the breathing system.

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 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.

This chapter Contents

1. General Information/Trouble Diagnosis

1-3

Service Precautions

• Always use with SANYANG genuine parts and

recommended oils. Using non-designed parts

for SANYANG motorcycle may damage the

motorcycle.

• Special tools are designed for remove and

install of components without damaging the

parts being worked on. Using wrong tools may

result in parts damaged.

• When 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.

• Clean 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.

• 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.

• Never bend or twist a control cable to prevent

stiff control and premature worn out.

• Rubber 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.

• When 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.

• Store complex components such as

transmission parts in the proper assemble

order and tie them together with a wire for

ease of installation later.

• 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.

This chapter Contents

1. General Information/Trouble Diagnosis

1-4

• 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. Bolts for the same

assembly should have the same length.

• 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.

• 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

smoothness and for burrs that may damage

the oil seal.

• Remove residues of the old gasket or sealant

before reinstallation, grind with a grindstone if

the contact surface has any damage.

• The ends of rubber hoses (for fuel, vacuum, or

coolant) should be pushed as far as they can

go to their connections so that there is enough

room below the enlarged ends for tightening

the clamps.

• Rubber and plastic boots should be properly

reinstalled to the original correct positions as

designed.

• The tool should be pressed against two (inner

and outer) bearing races when removing a ball

bearing. Damage may result if the tool is

pressed against only one race (either inner

race or outer race). In this case, the bearing

should be replaced. To avoid damaging the

bearing, use equal force on both races.

Both of these examples can result in bearing

damage.

Manufacturer's name

Groove

Clamp

Connector

Boots

This chapter Contents

1. General Information/Trouble Diagnosis

1-5

• Lubricate the rotation face with specified

lubricant on the lubrication points before

assembling.

• Check if positions and operation for installed

parts is in correct and properly.

• Make sure service safety each other when

conducting by two persons.

• Note that do not let parts fall down.

• Before battery removal operation, it has to

remove the battery negative (-) cable firstly.

Notre tools like open-end wrench do not

contact with body to prevent from circuit short

and create spark.

• After service completed, make sure all

connection points is secured.

Battery positive (+) cable should be connected

firstly.

And the two posts of battery have to be

greased after connected the cables.

• Make sure that the battery post caps are

located in properly after the battery posts had

been serviced.

• If fuse burned, it has to find out the cause and

solved it. And then replace with specified

capacity fuse.

capacity

verification

This chapter Contents

Table des matières

Autres manuels Sym Scooter

Sym

Sym JOYRIDE 125 Manuel utilisateur

Sym

Sym CRUiSYM A Manuel utilisateur

Sym

Sym JOYRIDE 125 Manuel utilisateur

Sym

Sym ORBIT III XE05W2-EU Series Manuel utilisateur

Sym

Sym Scooter Manuel utilisateur

Sym

Sym Mio 100 Manuel utilisateur

Sym

Sym Joymax Z+ Manuel utilisateur

Sym

Sym RS-50 Manuel utilisateur

Sym

Sym Jet 100 Manuel utilisateur

Sym

Sym FS05W1-EU Series Manuel utilisateur

Sym

Sym Symphony cargo AY05W9-EU Series Manuel utilisateur

Sym

Sym Citycom.300i Manuel utilisateur

Sym

Sym MAXSYM 400 Manuel utilisateur

Sym

Sym Jet 4 125 Manuel utilisateur

Sym

Sym Symply50 Manuel utilisateur

Sym

Sym RV 250i Manuel utilisateur

Sym

Sym 2009 FIDDLE II 125 Manuel utilisateur

Sym

Sym JET 4 R 50 Series Manuel utilisateur

Sym

Sym JET 50 series Manuel utilisateur

Sym

Sym Symphony ST XB05W4-EU Series Manuel utilisateur

Sym

Sym Fiddle III 50 Manuel utilisateur

Sym

Sym HU05 Series Manuel utilisateur

Sym

Sym AK12W Series Manuel utilisateur

Sym

Sym DD 50 Manuel utilisateur

Manuels Scooter populaires d'autres marques

TEKTRO

TEKTRO CHEETAH Manuel utilisateur

Douglas

Douglas Vespa Sprint Guide d'installation

PLAYTIVE

PLAYTIVE AS-2448 Manuel utilisateur

Ebinger

Ebinger DONKEY XL Manuel utilisateur

Flyer

Flyer Mountain Guide de l'utilisateur

BackCountry eBikes

BackCountry eBikes Storm Manuel utilisateur

equipmed

equipmed FreeRoam II Manuel utilisateur

Yoto

Yoto Lion Manuel utilisateur

WESTHILL BIKES

WESTHILL BIKES LINK Manuel utilisateur

BAnff

BAnff eProdigy series Manuel utilisateur

Winther

Winther 475 Manuel utilisateur

Jetson

Jetson JBZL17 Manuel utilisateur

First Choice Mobility

First Choice Mobility Roma Medical Corella S741 Manuel utilisateur

Carrera

Carrera impel Manuel utilisateur

Afikim

Afikim Superlight SL-3 Manuel utilisateur

CareCo

CareCo ZOOM Manuel utilisateur

Douglas

Douglas Vespa G.S. Manuel utilisateur

Gazelle

Gazelle with BOSCH System Manuel utilisateur