Sym Fiddle III 50 Manuel utilisateur

SYM

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

TROUBLES DIAGNOSIS ..................... 1-12

LUBRICATION POINTS ....................... 1-1

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.

Cauti n Means that equipment damages may result if procedures are not followed.

Engine il

Limits to use SAE 10W-30 API SH/CD class oil. Warranty will not cover the

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

Gear il

Limits to use SAE 85W-140 class oil. Warranty will not cover the damage

that caused by not apply with the limited gear oil.

Grease King Mate G-3 is recommended.

L cking 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 t ls Special service tools.

C rrect Meaning correct installation.

Wr ng Meaning wrong installation.

Indicati n

Indication of components.

Directi ns Indicates position and operation directions.

Components assembly directions each other.

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

through the component (invisibility).

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

SYM

1-2

GENERAL SAFETY

Carb n m n xide

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.

Cauti n

Gas line

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.

Cauti n

Used engine il

Cauti n

H t c mp nents

Cauti n

Battery

Cauti n

Brake sh e

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.

Cauti n

Brake fluid

Cauti n

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.

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.

SYM

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.

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

SYM

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

SYM

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 .

 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

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

SYM

1-6

 When separating a connector, it locker has to

be unlocked firstly. Then, conduct the

service operation.

 Do not pull the wires as removing a

connector or wires. Hold the connector

body.

 Make sure if the connector pins are bent,

extruded or loosen.

 Insert the connector completely. If there are

two lockers on two connector sides, make

sure the lockers are locked in properly.

Check if any wire loose.

 Check if the connector is covered by the twin

connector boot completely and secured

properly.

 Before terminal connection, check if the boot

is crack or the terminal is loose.

 Insert the terminal completely. Check if the

terminal is covered by the boot. Do not let

boot open facing up.

 Secure wires and wire harnesses to the

frame with respective wire bands at the

designated locations. Tighten the bands so

that only the insulated surfaces contact the

wires or wire harnesses.

 Wire band and wire harness have to be

clamped secured properly.

 Do not squeeze wires against the weld or its

clamp.

SYM

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

1-7

 Do not let the wire harness contact with

rotating, moving or vibrating components as

routing the harness.

 Keep wire harnesses far away from the hot

parts.

 Route wire harness to avoid sharp edges or

corners and also avoid the projected ends of

bolts and screws.

 Route harnesses so that they neither pull too

tight nor have excessive slack.

 Protect wires or wire harnesses with electrical

tape or tube if they contact a sharp edge or

corner. Thoroughly clean the surface where

tape is to be applied.

 Secure the rubber boot firmly as applying it

on wire harness.

 Never use wires or harnesses which

insulation has been broken. Wrap electrical

tape around the damaged parts or replace

them.

 Never clamp or squeeze the wire harness as

installing other components.

Do not touch it.

Do not extend

it too much.

Please do not clip or

squeeze the wire.

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

SYM

1-8

 Do not let the wire harness been twisted as

installation.

 Wire harnesses routed along the handlebar

should not be pulled too tight or have

excessive slack, be rubbed against or

interfere with adjacent or surrounding parts in

all steering positions.

 Before operating a test instrument, operator

should read the operation manual of the

instrument. And then, conduct test in

accordance with the instruction.

 With sand paper to clean rust on connector

pins/terminals if found. And then conduct

connection operation later.

Do you know how to set the

instrument to its measurement

position and the insert locations

of its two probes?

Clean rust.

SYM

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

1-9

SPECIFICATIONS

MAKER SANYANG MODEL XA05W-6

Overall Length 1890mm Front TELESCOPIC FORK

Overall Width 95mm

Suspen

sion

System

Rear UNIT SWING ARM

Overall Height 1135mm Front 110/70-12

DIMENSION

Wheel Base 1300 mm

Tire

Specifi

cations

Rear 120/70-12

Front 43 kg

Rear 4 kg

Front DISK (ø 190 mm)

Curb Weight

Total 107 kg

Brake

System

Rear DRUM (ø 130 mm)

Passengers/

Weight Two men/179 kg Max. Speed Less than 45 km/hr

Front 78kg

Performa

nce

Climb Ability 22° Below

Rear 179 kg Primary Reduction

C.V.T.

WEIGHT

Total Weight

Total 258kg Secondary

Reduction GEAR

Type 4-STROKE ENGINE Clutch Centrifugal, dry type

Installation and

arrangement

Vertical, below center,

incline 80°

Deceleration

equipment

Transmission V-belt

Fuel Used Unleaded (93/95) Speedometer 0 ~ 80 km/hr

Cycle/Cooling 4-stroke/forced air

cooled Horn 80~112 dB/A

Bore 37.0 mm Muffler Expansion & Pulse Type

Stroke 4 .0 mm Exhaust Pipe Position

and Direction

Right side, and

Backward

Cylinder

Number/Arra

ngement Single Cylinder Lubrication System Separated-lubrication

Displacement 49 cc CO <12.0 g/km

Compression

Ratio 12. ±0.2 : 1

Exhaust

Emission HC <1.0 g/km

Idle Speed 2100±100 Inlet:0.05±0.02mm

25km/h

2.3 kw/ 500rpm Valve clearance Exhaust: 0.05±0.02mm

30km/h

2.3 kw/ 500rpm Fuel tank capacity .5L±0.3L

Max. HP

(Maximum

speed) 45km/h

2. kw/7500rpm Air Filtration Paper filter

25km/h

3.3N.m / 500 rpm

Noise Emission < 80dB(A)

30km/h

3.3N.m / 500 rpm

Max. Torque

(Maximum

speed) 45km/h

3.4N.m / 500 rpm

Ignition C.D.I.

ENGINE

Starting System

Electrical & Kick starter

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

SYM

1-10

TORQUE VALUES (ENGINE)

ITEM Q'TY

THREAD DIA

(mm)

TORQUE

VALUE(Kg-m)

REMARKS

Cylinder head bolts 2 0.8~1.2

Cylinder head left side cover bolts 2 0.8~1.2

Cylinder head nuts 4 8 0.8~1.2 Apply oil to thread

Tappet adjust hole cap 2 30 1.0~2.0

Cylinder/cylinder head two-ends bolts 4 0.7~1.1

Tighten to crankcase

Camshaft sprocket bolt 1 8 2.0~2.4

Right crank case cover bolts 10 0.8~1.2

Pulse generator bolts 2 5 0.35~0.5

Valve adjustment fixing nuts 2 5 0.7~1.1 Apply oil to thread

Spark plug 1 10 1.0~1.4

Engine oil filter screen cap 1 30 1.0~2.0

Engine oil drain plug bolt 1 12 3.5~4.5

Gear oil draining plug 1 8 1.0~1.5

Gear oil filling bolt 1 8 1.0~1.5

Oil pump flat screw 2 0.8~1.2

Left crankcase cover bolts 10 0.8~1.2

Camshaft chain tensioner pivot 1 0.8~1.2 Hex socket bolt

Camshaft chain adjuster bolts 2 1.0~1.4

Cooling fan bolts 4 0.8~1.2

Cooling fan cover bolt 2 0.7~1.1

RR. brake shoe anchor fixing nut 1 8 1.5~2.0

Shroud A/B 2 0.8~1.2

Start clutch lock nut 1 20 9.0~10

Flywheel nut 1 10 3.5~4.5

Transmission(Gear box) bolts 7 8 2. ~3.0

Movable drive face nut 1 12 5.0~ .0

Drive pulley nut 1 10 3.5~4.5

A.C. generator flange bolt 2 0.8~1.2

Start motor bolts 2 0.8~1.2

Crankcase bolts 1 0.8~1.2

Air/C connect bracket bolts 2 0.8~1.2

Kick starter arm bolt 1 0.8~1.2

Carburetor nut 2 0.8~1.2

Exhaust pipe bolts 2 8 3.0~3.

Exhaust pipe connecting nuts 2 1.0~1.4

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