Sym JOYRIDE 125 Manuel utilisateur

Joyride 125 / 200i EVO

X’PRO RV125 / 200 EFi

SERVICE MANUAL

Foreword

How to Use This Manual

Contents

Mechanism Illustration

Foreword

This service manual contains the technical data of each component inspection

and repair for the Sanyang JOYRIDE 125/200i EVO, X’PRO RV 125/200 EFi

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, JOYRIDE 125/200i EVO, X’PRO

RV 125/200 EFi, 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.

Homepage Contents

HowtoUseThisManual

This service manual describes basic information of different system parts and

system inspection & service for Sanyang JOYRIDE 125/200i EVO, X’PRO RV

125/200 EFi 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 information.

Th third to the thirteenth chapter covers the engine and driving systems.

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

The eighteenth chapter is electrical equipment.

The nineteenth chapter is special tool.

The twentieth chapter is wiring diagram

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

information.

There are 4 buttons, “Foreword”, “Contents”, “How to Use This Manual” and

“Mechanism Illustration” in the PDF version, and can be access to these items

by clicking on the buttons.

If user wants to look for the content of each chapter, selecting the words of

each chapter on the contents can reach to each chapter. There are two buttons,

“Homepage and contents, on 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 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 “To this Chapter Contents” button at the second

page of each content so that clicking the button can back to the contents of this

chapter.

Homepage Contents

Contents

Page Content Index

1-1 ~ 1-20 General Information

2-1 ~ 2-12 Maintenance Information

3-1 ~ 3-8 Lubrication System

4-1 ~ 4-12 Fuel System-Carburetor

5-1 ~ 5-56 Fuel Injection System

6-1 ~ 6-14 Engine Removal

7-1 ~ 7-14 Cylinder Head / Valve

8-1 ~ 8-8 Cylinder / Piston

9-1 ~ 9-14 V-Belt Drive System

10-1 ~ 10-8 Final Drive Mechanism

11-1 ~ 11-8 AC Generator / Starting Clutch

12-1 ~ 12-8 Crankshaft / Crankcase

13-1 ~ 13-12 Cooling System

14-1 ~ 14-10 Body Cover

15-1 ~ 15-10 Brake System

16-1 ~ 16-12 Steering / Front Wheel / Front Cushion

17-1 ~ 17-6 Muffler / Rear Wheel / Rear Cushion

18-1 ~ 18-22 Electrical System

19-1 ~ 19-12 Special Tools

20-1 ~ 20-4 Wiring Diagram

Homepage Contents

Mechanism Illustration

Front winker

Fuel tank

cap

Luggage box

Light switch / start switch /

engine stop (hazard) switch

Dimmer switch / winker switch /

horn switch / seat open (passing)

switch

Muffler

Reserved tank

cap

Coolant filler

cap

Ignition / Seat open

switch

Fuse

Main switch

Fuel tank /

fuel pump

Side stand

ECU /

throttle body

ack mirror

Battery

Front brake

lever

Rear brake

lever

Home page Contents

Main stand

Air cleaner

Taillight /

rear winker

1. GENERAL INFORMATION

1-1

Symbols and Marks .............................. 1-1

General Safety....................................... 1-2

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

Specifications........................................ 1-5

Torque Values ....................................... 1-9

Cables and Harness Routing..............1-11

Troubleshooting-Carburetor model ...1-12

Troubleshooting-EFi model ................1-16

Lubrication Points ...............................1-20

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.

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).

Contents

Homepage

1.GENERALINFORMATION

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 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

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 and 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 verified.

We recommend that you wash your hands

with soap and water right after contacting.

Keep the used oil beyond reach of children.

Inhaling brake shoe or pad ash 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 the 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.

To 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

unsmooth 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.

To this chapter contents

1.GENERALINFORMATION

1-4

zThe 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.

zTighten 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.

zWhen 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.

zRemove residues of the old gasket or sealant

before reinstallation, grind with a grindstone if

the contact surface has any damage.

zThe 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.

zRubber and plastic boots should be properly

reinstalled to the original correct positions as

designed.

zThe 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.

zLubricate the rotation face as assembling.

Check if positions and operation for installed

parts is in correct and properly.

Manufacturer's

name

Groove

Clamp

Connection

Boots

To this chapter contents

1. GENERAL INFORMATION

1-5

Specifications

Maker SANYANG MODEL LF12W-6/F

Overall Length 2100 mm Front Telescopic Fork

Overall Width 760 mm Suspension

System Rear Unit Swing

Overall Height 1390 mm Front 110 / 90-13 56P

Wheel Base 1440 mm Tire

Specifications Rear 130 / 70-12 64L

Front 63 kg Front

Disk (ψ273mm)

Rear 93 kg

Curb

Wei

Total 156 kg

Brake System Rear Disk (ψ200mm)

Passengers/

Weight Two /170 kg Max. Speed >100 km/hr

Front 97 kg Climb Ability 28°

Rear 229 kg Primary Reduction Belt

WEIGHT DIMENSION

Total Weight

Total 326 kg Secondary

Reduction Gear

Type Gasoline Clutch

3-piece centrifugal, dry

type

Position and

arrangement Horizontal, below

center, CYL incline 80°

PERFORMANCE

Transmission C.V.T.

Fuel Used >92 Unleaded gasoline Speed meter 0 ~ 140 km/hr

Cycle/Cooling 4-stroke/water cooled Horn 93 – 112 dB/A

Bore Ø 57 mm Muffler Expansion & Pulse Type

Stroke 48.8 mm

Exhaust Pipe Position

and Direction Right Side & Backward

Cylinder

Number/Arran

gement Single Cylinder Lubrication System Forced Circulation &

Splashing

Displacement 124.5 cc Co

〈 2.0 g/km

Compression Ratio 10.5 : 1 HC 〈 0.8 g/km

Max. HP 13 ps / 8500 rpm

Exhaust

Concentratio

NOx 〈 0.15 g/km

Max. Torque 1.1 kg-m / 6500 pm E.E.C. -

Ignition C.D.I P.C.V. -

ENGINE

Starting System Kick & Electrical Starter Catalytic Converter Equipped

To this chapter contents

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