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12. Brake System

12-5

Troubleshooting

Disc Brake

Soft brake lever

1. Air inside the hydraulic

system

2.  Hydraulic system leaking
3.  Worn master piston
4.  Worn brake pad
5.  Poor brake caliper
6.  Worn brake lining/disc
7.  Low brake fluid
8.  Blocked brake pipe
9.  Warp/bent brake disc
10. Bent brake lever

Hard operation of brake
lever

1.  Blocked brake system
2.  Poor brake caliper
3.  Blocked brake pipe
4.  Seized/worn master cylinder

piston

5. Bent brake lever

Uneven brake

1.  Dirty brake lining/disc
2.  Poor wheel alignment
3.  Clogged brake hose
4.  Deformed or warped brake

disc

5. Restricted brake hose and

fittings

Tight brake

1.  Dirty brake lining/disc
2.  Poor wheel alignment
3.  Deformed or warped brake

disc

Brake noise

1.  Dirty lining
2.  Deformed brake disc
3.  Poor brake caliper

installation

4. Imbalance brake disc or

wheel

Drum Brake

Poor brake performance

1.  Improper brake adjustment
2.  Worn brake lining
3.  Worn brake drum
4.  Worn brake cam
5.  Improper brake lining

installation

6.  Seized brake cable
7.  Dirty brake lining
8.  Dirty brake drum
9.  Brake pad worn in brake

cam area.

10. Poor contact between brake

arm and camshaft indent

Tight operation or low
return speed of brake lever

1. Worn/broken/crack return

spring

2.  Worn drum
3.  Dirty brake lining
4.  Brake seized caused from

dirty brake drum

5.  Seized brake cable
6.  Worn brake cam
7.  Improper brake lining

installation

Brake noise

1.  Worn brake lining
2.  Worn drum
3.  Dirty brake lining
4.  Dirty brake drum

This chapter Contents

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Summary of Contents for Jet Sport X R50

Page 1: ...SERVICE MANUAL S50 R50 SR50 Forward How to use this manual Contents Model illustration...

Page 2: ...rvice Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the scooters Jet Sport X S50 R50 SR50 series are di...

Page 3: ...ts 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 Ho...

Page 4: ...inder Head Cylinder Piston 6 7 1 7 14 A C Generator 7 8 1 8 6 V Type Belt Driving System Kick Starter 8 9 1 9 6 Final Driving Mechanism 9 10 1 10 10 Crankcase Crankshaft 10 11 1 11 12 Body Cover 11 12...

Page 5: ...aillight Helmet hook Fuel tank cap Engine number Luggage box Muffler Battery Fuses C D I Eng Oil tank cap ENG Stop Starter switch High Low beam Passing Turn signal Horn switch Air cleaner Frame number...

Page 6: ...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...

Page 7: ...engine has been stopped for some time When performing service work on these parts wear insulated gloves and wait until cooling off Battery Caution Battery emits explosive gases flame is strictly proh...

Page 8: ...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 b...

Page 9: ...me 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 be...

Page 10: ...1 General Information 1 5...

Page 11: ...t Total 173 kg Secondary Reduction GEAR Type Gasoline Clutch Centrifugal dry type Installation and arrangement Horizontal below center incline Forman Perce Transmission C V T Fuel Used Unleaded 92 95...

Page 12: ...for more important tighten torque values Please see above standard values for not listed in the table Engine Item Q ty Thread Dia mm Torque Value kgf m Remarks Cylinder head bolt 4 7 1 6 2 0 When eng...

Page 13: ...inder mounting bolts 4 6 1 0 1 4 Brake hose bolts 2 10 3 3 3 7 Brake caliper mounting bolts 2 10 3 1 3 5 Brake shoe guide bolts 2 6 1 5 2 0 Brake shoe guide bolts cap 2 6 0 8 1 2 Brake drain valve 1 6...

Page 14: ...trical tape or tube if they contact a sharp edge or corner Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws Keep wire harnesses far away from the exhau...

Page 15: ...lamp switch Winker switch Speedometer Headlight switch Starter switch Throttle cable Headlight Rear brake cable Speedometer cable Throttle cable Main switch Regulator Resistor Horn Front brake hose Sp...

Page 16: ...cable Rear brake cable Fuel unit cord Fuel filter Speedometer cable Rear brake cable Front brake hose Throttle cable Fuel unit Winker relay Front brake hose Rear brake cable Speedometer cable Throttl...

Page 17: ...1 General Information 1 12 Fuel filter Battery C D I UNIT Fuse Purge control valve Oil control cable Fuel hose Fuel pump Vacuum hose Oil hose Rear brake cable Carburetor Oil lever switch...

Page 18: ...uit Then blow the hose with air Dry spark plug Wet spark plug Blowing in normal Blowing clogged 1 No fuel in fuel tank 2 Check if the pipes fuel tank to carburetor and intake vacuum are clogged 3 Floa...

Page 19: ...1 General Information 1 14...

Page 20: ...ock Knock 1 Air cleaner clogged 2 Poor fuel supply 3 Lines in fuel tank evaporation system clogged 4 Exhaust pipe clogged 1 Malfunction of CDI 2 Malfunction of AC generator 1 Cylinder piston ring worn...

Page 21: ...1 General Information 1 16...

Page 22: ...ignition timing Normal Abnormal Normal Clogged 1 Incorrect ignition timing malfunction of CDI or AC generator 1 Rich mixture loosen the screw 2 Lean mixture tighten the screw 1 Poor heat insulation ga...

Page 23: ...1 General Information 1 18...

Page 24: ...3 Driving pulley spring broken 4 Clutch ling broken 5 Driving slide shaft gear groove broken 6 Transmission gear damage 7 Transmission gear worn out or burned Engine running and misfire as motorcycle...

Page 25: ...al Information 1 20 Lubrication Points Seat catch Rear wheel bearing Steering shaft bearing Speedometer gear front wheel bearing Side stand shaft Main stand shaft Throttle cable Front rear brake lever...

Page 26: ...1 General Information 1 21 Note...

Page 27: ...ipe Muffle 2 12 Cylinder Compression Pressure Test 2 12 Headlight Adjustment 2 13 Special Tool Manual 2 14 General Information Specification Item Jet Sport X 50 series Tire dimension Front 120 70 12 R...

Page 28: ...ission check in Idling I I 20 Idle speed check I I 21 Fuel lines I I 22 Throttle operation I I 23 Engine bolt tightening I I 24 Engine screw torque I 25 Carbon cleaning for cylinder head cylinder and...

Page 29: ...t Soap the element into cleaning engine oil and then squeeze it out Install the element onto the element seat and then install the air cleaner cover Limit to use SAE 20 JASO FC class engine oil otherw...

Page 30: ...the fuel line for leaking Engine Oil Line Remove the body cover Check the engine oil line and replace damaged parts Remove the filling pipe from the oil pump and drain oil into a cleaning container Lo...

Page 31: ...er and then remove the cover Check if the battery terminals are loosened Remove the battery if its terminals are corroded obviously Battery Removal 1 Remove the Negative battery cable at first 2 Then...

Page 32: ...n or by a depth gauge If the tread bend too much replace the tire If tire wear exceeds limitation replace the tire and check it for un even wear Caution Wear indicator is distributed on average along...

Page 33: ...the cap had been removed Otherwise the brake fluid will spread out if operated the lever Do not mix non compatible brake fluid together Brake Lining Wear Rear Drum Brake Type Replace the brake lining...

Page 34: ...brake lining Pry out the brake lining with a flat driver if lining is clipped Remove brake lining bolt Take out the lining Tighten Torque Mounting bolt 2 9 3 5kgf m Pin bolt 1 5 2 0kgf m Pin bolt cap...

Page 35: ...ve ability Front Shock Absorber Press down the front shock absorber for several times to check it operation Check if the shock absorber assembly is damage Replace it if damage found and can not be rep...

Page 36: ...on the spark plug seat Remove the spark plug Visually inspect the spark plug electrodes for wear The center electrode should have square edges and side electrode should have a constant thickness Repla...

Page 37: ...the right side cooling fan cover Check ignition timing with the timing light When engine speed setting to 1800 rpm and if the mark aligns with F mark then it means that the ignition timing is correct...

Page 38: ...rk plug Insert the compression gauge and wide open the throttle and then rotate the engine by means of the starting motor Compression pressure 7 0 1 kg cm2 Probable causes for low compression pressure...

Page 39: ...tment Turn the headlight adjustment bolt for adjustment its light beam Caution Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting for safety distance This c...

Page 40: ...Nam e L Crankshaft install bush Name R Crankshaft install bush Name Extension bush No SYM 1130010 No SYM 1130020 No SYM 1130031 long SYM 1130032 short 28mm 20mm Nam e Crankcase bush puller Name Crankc...

Page 41: ...2 Service Maintenance Information 2 15 No SYM 9121600 No SYM 9120200 No SYM 9125500...

Page 42: ...YM 9610000 No SYM 9620000 No SYM 9110400 Name Inner bearing puller Name Inner bearing puller Name Outer bearing puller No SYM 6204020 No SYM 6204022 No SYM 6204001 Name Clutch nut wrench Name Clutch s...

Page 43: ...utions In Operation 3 2 Lubricant 3 2 Trouble Shooting 3 2 Oil Pump Removal 3 3 Oil Pump Installation 3 3 Oil Pump Oil Tube Air Bleeding 3 4 Oil Tank 3 5 Lubrication System Diagram Oil pump Oil output...

Page 44: ...SAE 20 JASO FC class oil Otherwise warranty shall not cover the damage Recommended oil MAX 2 oil Oil tank capacity 1 2 lit Trouble Shooting Too much smoke carbon in spark plug 1 Improperly oil pumps...

Page 45: ...Check if pump body is damaged Check if pump gear is damaged Check for oil leaking Caution The oil pump cannot be disassembled Oil Pump Installation Install the oil pump onto the crankcase Caution App...

Page 46: ...with oil Then install the tube onto oil pump Make sure whether air is in the oil tube or not after installation Caution After bleeding the oil tube and oil pump the oil tube has to be conducted air bl...

Page 47: ...Remove the battery and battery case 1 bolt Remove the oil input tube from oil pump and then drain oil to a clean container Remove the oil level switch wire coupler of the oil indicator Remove the mou...

Page 48: ...3 Lubrication System 3 6 Notes This chapter Contents...

Page 49: ...e 4 4 Auto By Starter 4 4 Float Float Valve Jet 4 6 Flaot Level Inspection 4 7 Carburetor Installation 4 7 Reed Valve 4 7 Fuel Pump 4 8 Air Cleaner 4 9 4 Fuel tank Fuel unit Fuel filter Vacuum tube Fu...

Page 50: ...l 8 8 1 0mm Air screw opener 1 3 8 Idle speed 2000 100 rpm Throttle handle free play 2 6 mm Troubleshooting Engine cannot be started 1 No fuel in fuel tank 2 Fuel can not reach to carburetor 3 Too muc...

Page 51: ...sealed cap carburetor upper part and throttle valve spring Connect the throttle valve cable to the throttle valve Install the throttle valve into the carburetor body Caution Align the groove inside t...

Page 52: ...to the terminals of auto by starter and then measure its resistance If the resistance value exceeds specification too much it means that the PTC in the auto by starter is malfunction Then replace the...

Page 53: ...ure that the auto by starter is in normal Engine is running If the resistor is in open circuit then current will not flow into the PTC Thus the auto by starter is not operated However if the resistor...

Page 54: ...screw forcedly to avoid to damaging the valve seat Remove main jet needle jet seat and idle jet and clean them and each component with compressed air Installation Install the idle jet the needle jet...

Page 55: ...ith bolts Install fuel and vent pipes onto carburetor Install the carburetor upper part Tighten the connection hose Tighten the draining screw Connect the automatic by starter connector Install air cl...

Page 56: ...ing after installed Fuel Pump Inspection Remove the rear side cover Warm up the engine and adjust idle speed Remove fuel hose from carburetor and then wait for 5 minutes Measure the output of fuel pum...

Page 57: ...tallation Remove air cleaner and rear inner fender mounting screw Loosen connection hose clamp Remove 2 bolts and then remove the air cleaner Install in the reverse order of removal procedures 1 screw...

Page 58: ...4 Fuel System 4 10 Notes This chapter Contents...

Page 59: ...5 Engine Removal 5 1 Maintenance Information 5 2 Engine removal 5 3 Engine installation 5 6 5 2 4 3 0kgf m 2 4 3 0kgf m 5 5 6 5kgf m 5 5 6 5kgf m 5 5 6 5kgf m 4 5 5 5kgf m Home page Contents...

Page 60: ...shaft Related bolts tightening torque for removal of engine Engine hanger bolt 5 5 6 5kgf m Engine hanger bracket bolt 4 5 5 5kgf m Rear cushion upper mounting bolts 3 5 4 5kgf m Rear cushion lower mo...

Page 61: ...control cable from oil pump Remove the oil tube from oil pump and then clip the tube Remove the wire couplers of auto by starter and ACG Remove the upper parts of the carburetor from its upper side Re...

Page 62: ...Disc type rear brake Remove rear brake caliper 2 bolts from engine rear upper side Remove brake hose from hose clamp Remove air cleaner and rear inner fender mounting screw Loosen connection hose cla...

Page 63: ...n cover and exhaust pipe Support the engine and then remove cushion lower mounting bolt Remove engine mounting nut and bolt Each side 1 bolt and 1 nut Remove the engine Engine mounting nut This chapte...

Page 64: ...e 4 5 5 5kgf m Engine installation Install in the reverse order of removal procedures Tighten the engine mounting bolts and rear cushion upper lower bolts Torque value Engine hanger bolt 5 5 6 5kgf m...

Page 65: ...6 Cylinder Head Cylinder Piston 6 1 Maintenance Information 6 2 Troubleshooting 6 2 Cylinder Head 6 3 Cylinder Piston 6 5 6 Home page Contents 1 6 2 0kgf m 1 1 1 7kgf m...

Page 66: ...iston pin OD 11 994 12 000 11 970 Clearance between piston and piston pin 0 002 0 014 0 030 Piston ring end gap 0 100 0 250 0 400 Piston ID of connecting rod small end 17 05 17 015 17 025 ID 39 000 39...

Page 67: ...Remove fuel pump tubes Remove spark plug cap Remove fuel pump bracket 2 nuts Remove vacuum tube and oil pump control cable from engine shield Remove fan cover 3 bolts Remove engine shield mounting bol...

Page 68: ...combustion chamber with shown chisel Caution Do not scratch to the interfaces of combustion chamber and cylinder Cylinder Head Inspection Use a straight edge and a feeler gauge to measure the cylinde...

Page 69: ...operation between cylinder and crankcase Or let radiation fan be knocked seriously Piston Removal Place a clean rag onto crankshaft to cover the piston Remove piston pin clip one piece and then push...

Page 70: ...eeler gauge to measure the cylinder head for warp Service limit 0 10 mm In X and Y direction measure the cylinder for worn out as the three levels shown in the figure With the maximal value to decide...

Page 71: ...the end gap of each piston ring Service limit 0 40 mm Caution With the piston push each piston ring into cylinder correctly Connecting Rod Inspection Measure the ID of connecting rod small end Service...

Page 72: ...ix with other one Place a cleaning cloth onto the crankcase opening to prevent the piston pin snap ring from falling into the crankcase Apply with two stroke engine oil onto needle bearing and piston...

Page 73: ...6 Cylinder Head Cylinder Piston 6 9...

Page 74: ...torque 1 6 2 0kgf m Replace the exhaust pipe washer with new one and then install exhaust pipe Tighten exhaust pipe connection nut Tighten torque 1 0 1 4kgf m Tighten exhaust pipe mounting bolt Tighte...

Page 75: ...6 Cylinder Head Cylinder Piston 6 11 Note This chapter Contents...

Page 76: ...7 A C Generator 7 1 Maintenance Information 7 2 Generator Removal 7 3 Generator Installation 7 4 7 3 5 4 5kgf m Home page Contents...

Page 77: ...y on the scooter Please refer to Chapter 15 for the relative A C generator inspection Torque value Flywheel 3 5 4 5kgf m Special Service Tools Flywheel puller SYM 3110A01 Universal holder SYM 2210100...

Page 78: ...and then take out the cooling fan Hold flywheel with universal holder Support the flywheel and the remove the 10 mm nut on the flywheel Special tool Universal holder SYM 2210100 Remove the flywheel wi...

Page 79: ...rator wire harness properly and then clip the harness with clipper Install the woodruff key onto the crankshaft groove Caution Clean dirt and metal pieces inside the flywheel Make sure that there is n...

Page 80: ...rmation 8 3 Trouble Shooting 8 3 Left Crankcase Cover 8 4 Reassembly Of Kick Starter 8 5 Installation Of The Left Crankcase Cover 8 5 Drive Belt 8 6 Movable Driven Pulley 8 7 Clutch Driven Pulley 8 11...

Page 81: ...8 V Type Belt Drive System Kick Starter 8 2...

Page 82: ...Inner Diameter OD Outer diameter Torque Values Movable drive face 5 5 6 5kgf m Driven pulley plate 5 0 6 0kgf m Clutch outer 3 5 4 5kgf m Special Service Tools Clutch spring compressor SYM 2301000 Cl...

Page 83: ...her from left crankcase cover Install kick start arm rotate the lever slightly and then remove driven gear and washer Remove the kick starter arm kick starter spindle and return spring as well as sock...

Page 84: ...mporary Slightly rotate the lever and then align driven gear with width tooth on the starter spindle Install the friction spring of drive gear onto convex part of the cover Installation of the Left Cr...

Page 85: ...y Remove driven pulley clutch Do not remove drive belt Remove the drive belt from the groove of driven pulley Inspection Check the drive belt for crack or wear Replace it if necessary Measure the widt...

Page 86: ...rsal holder SYM 2210100 Torque value 3 5 4 5kgf m Movable Drive Face Removal Remove fan cover and fan Remove left crankcase cover Hold generator flywheel with universal holder and then remove drive fa...

Page 87: ...e driven face by means of centrifuge force Thus if weight rollers are worn out or damage the centrifuge force will be affected Check if rollers are wearing out or damage Replace it if necessary Measur...

Page 88: ...mm Measure the inner diameter of drive face and replace it if it exceed service limit Service limit 20 120 mm Reassembly Installation Install weight rollers Install ramp plate Apply with some grease t...

Page 89: ...ft Install drive face washer and nut Caution Make sure that two sides of drive face have to be free of grease Clean it with cleaning solvent Hold flywheel with universal holder Tighten nut to specifie...

Page 90: ...to bench vise and then remove mounting nut with clutch nut wrench Release the clutch spring compressor and remove clutch and spring from driven pulley Remove socket from sliding pulley Remove guide pi...

Page 91: ...diameter of sliding pulley Replace it if exceeds service limit Service limit Outer diameter 33 94 mm Inner diameter 34 06 mm Driven Pulley Bearing Inspection Check if the inner bearing oil seal is da...

Page 92: ...amage or deformation Replace it if necessary Apply with grease onto lock pins Install new clutch weight onto lock pin and then push to specific location Apply with grease onto lock pins But the clutch...

Page 93: ...lace new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified grease Install new inner bearing Caution Its sealing end should be forwarded to outside as...

Page 94: ...nd press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut to specified torque with clutch nut wrench Sp...

Page 95: ...8 V Type Belt Drive System Kick Starter 8 16...

Page 96: ...Mechanism 9 3 Inspection of Final Driving Mechanism 9 6 Bearing Replacement 9 7 Re Assembly of Final Driving Mechanism 9 8 9 Home page Contents Bearing 6201 Bearing 6203 Bearing 6201 Bearing 6203 Oil...

Page 97: ...Final shaft oil seal installer SYM 9125500 Drive shaft oil seal installer SYM 9120200 Bearing driver 6201 SYM 9610001 Bearing driver 6203 6004UZ SYM 9620000 R Crank shaft puller SYM 1130000 R L Crank...

Page 98: ...Remove oil drain bolt and filling bolt Drain gear oil out from gearbox Remove muffler and rear wheel Remove gearbox cover mounting bolts from the clutch side 7 bolts Remove the cover from the rear wh...

Page 99: ...the drive shaft Drive shaft is pulled out with it s bearing then remove the bearing with bearing puller and shaft protector Special tool Multi functional bearing puller or Outer bearing puller SYM 62...

Page 100: ...ve shaft Drive shaft is pulled out with it s bearing then remove the bearing with bearing puller and shaft protector Special tool Multi functional bearing puller or Outer bearing puller SYM 6204001 Sh...

Page 101: ...he final shaft and gear are burn wear or damage and replace it if necessary Check bearings on gearbox cover Rotate each bearing s inner ring with fingers Check if bearings can be turned in smooth and...

Page 102: ...one Install new bearings into left crankcase Special tool Bearing driver 6201 SYM 9610001 Bearing driver 6203 6004UZ SYM 9620000 Install new bearings into gearbox cover Special tool Bearing driver 62...

Page 103: ...crankcase Special tool Drive shaft socket oil seal driver 17x30x6 SYM 9120200 Install 2 dowel pins new gasket Install counter shaft counter shaft side washer and final shaft into the gearbox Install...

Page 104: ...9 Final Driving Mechanism 9 9...

Page 105: ...aft 10 1 Maintenance Information 10 2 Troubleshooting 10 2 Crankcase Disassembly 10 3 Crankshaft Removal 10 3 Crankshaft Inspection 10 4 Crankcase Installation 10 5 10 Apply liquid gasket 1 0 1 5kgf m...

Page 106: ...e old bearing onto the crankshaft has to be removed Then install a new bearing onto the crankshaft on the crankcase side Oil seal has to be replaced with new one after assembled the crankcase Item Sta...

Page 107: ...agram show with 2 special bolts to install the specified service tool onto the left crankcase Remove the crankshaft Caution Do not use iron hammer to knock out the crankshaft Remove crankshaft bearing...

Page 108: ...ions as diagram show Service limit 0 04 mm Place the crankshaft on a V block measure run out points A and B of the crankshaft with dial gauge Service limit A 0 10 mm B 0 10 mm Check the crankshaft bea...

Page 109: ...10400 Install crankshaft onto the left crankcase Install left crankshaft puller and install bush onto crankshaft Screw the left crankshaft puller onto crankshaft Turn the puller in C W direction and t...

Page 110: ...n them Torque value 1 0 1 5kgf m With right crankshaft install bush install new oil seal into the right crankcase Its installation depth is 4mm as the diagram shown With the specified tool to install...

Page 111: ...11 Seat Battery cover Luggage box Battery case Rear fender Rear mudguard Right body cover Left body cover Right rear grip Right side cover Left side cover Handle rear cover Handle front cover Plug mai...

Page 112: ...nstalled during the assembly Never compact forcefully or hammer the guard and the covers during assembly Center Cover Front Cover Front Fender Luggage Box Seat Left Right Side Cover Front Inner Spoile...

Page 113: ...ndle rear cover upper Remove 2 screws from the handle rear cover under Remove 3 screws from the handle front cover under Remove front winker light electric cord couplers Remove handle front cover 4 sc...

Page 114: ...Remove speedometer electric cord coupler Remove handle rear cover Installation Install in reverse order of removal procedures Caution Push the front connection part of rear handle cover at first when...

Page 115: ...front inner box and front cover Remove 1 screw from the front cover Remove electric cord coupler from the headlight Remove the front cover Installation Install in reverse order of removal procedures E...

Page 116: ...nuts 1 bolt Hold the luggage box in both front and rear sides by two hands and then lift up the box to remove it Installation Install in reverse order of removal procedures Battery Cover Removal Insta...

Page 117: ...remove the cover Remove 2 screws from rear side cover Slide the rear side cover backward so that their hooks are out of slots Take out the rear side cover end part and then remove the cover Installati...

Page 118: ...er Removal Remove luggage box and center cover Remove 4 bolts from rear carrier and then remove rear carrier Remove 4 screws from right and left body cover Remove 2 bolts from the rear fender Slide th...

Page 119: ...front upper part of the front spoiler and the front inner box Pull up the front inner spoiler from holder hook and then remove the front inner spoiler and right left under spoiler assembly Disassembl...

Page 120: ...er caps Remove the floor panel 4 bolts Disassembly Remove 2 screws from right left center cover and floor panel Remove 2 screws from right left center cover and floor panel other side Remove right lef...

Page 121: ...nd floor panel Remove main switch cover Remove 1 bolt and hook Remove 2 screws from the under spoiler and front inner box Remove 6 screws from the front inner box and under spoiler Remove the front in...

Page 122: ...ght and left side Ramoval front fender Installation Install in reverse order of removal procedures Rear Fender Removal Ramoval luggage box rear carrier and body covers Ramoval 3 screws and then remova...

Page 123: ...der of removal procedures Rear Mudguard Removal Ramoval rear mudguard left side screw with air cleaner Ramoval muffler 2 nuts 3 bolts pull out muffler with rear mudguard right side hanger Ramoval rear...

Page 124: ...t side cover Remove 1 bolt and 1 nut from the under cover right side Remove 1 bolt and 1 nut from the under cover left side and then remove under cover Installation Install in reverse order of removal...

Page 125: ...5 Hydraulic Disc Brake 12 6 Disc Brake Air Bleed 12 7 Disc Brake Caliper 12 8 Brake pad replacement 12 8 Brake Disc 12 10 Disc Brake Master Cylinder 12 10 Rear Drum Brake 12 14 Disc Brake System 12 3...

Page 126: ...12 Brake System 12 2 Rear Drum Brake System 0 8 1 2kgf m 10 0 12 0kgf m 0 8 1 2kgf m This chapter Contents...

Page 127: ...front brake disc 4 0 3 5 The thickness of rear brake disc 3 5 3 0 Front brake disc run out 0 10 0 3 Front brake master cylinder inner diameter 12 700 12 743 12 750 Front brake master cylinder piston...

Page 128: ...12 Brake System 12 4...

Page 129: ...ng disc 2 Poor wheel alignment 3 Deformed or warped brake disc Brake noise 1 Dirty lining 2 Deformed brake disc 3 Poor brake caliper installation 4 Imbalance brake disc or wheel Drum Brake Poor brake...

Page 130: ...g brake performance to be reduced or totally lost Connect drain hose to drain valve Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out Cl...

Page 131: ...eeding procedure to avoid air enters into the system Slowly release the brake lever and wait for a few seconds until it reaches its top position Repeat the steps 1 and 2 until there is no air bubble a...

Page 132: ...m Caution Use M8 x 35 mm flange bolt only Long bolt will impair the operation of brake disc Use two seal washers and hose bolts to lock the hose and brake caliper in place Torque 3 3 3 7kgf m Refill u...

Page 133: ...ke Loosen the 1 lining guide pin bolt Remove brake caliper Remove the brake pad guide pin bolt and locking spring and then remove brake pads Install the new brake pads onto brake caliper Install the b...

Page 134: ...n and bend Allowable limit 0 30 mm Disc Brake Master Cylinder Master Cylinder Removal Caution Do not let foreign materials enter into the cylinder The whole set of master cylinder piston spring diaphr...

Page 135: ...s measured value exceeds allowable limit Allowable limit Front brake 12 654 mm Rear brake 10 654 mm Master Cylinder Assembly Caution It is necessary to replace the whole set comprising piston spring p...

Page 136: ...12 Brake System 12 12 Rubber bush Cir clip Piston Spring Sub cup Sub cup Master cylinder Cylinder gauge Master cylinder Piston Micrometer Rubber pad Clip Piston Master cylinder Spring...

Page 137: ...hose bolt to the specified torque value Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together Caution Improper routing may dama...

Page 138: ...it if necessary Measure the inner diameter of brake drum and record the max value Allowable limit rear 110 5mm Caution Clean the rust onto the brake drum with 120 sandpaper Measure the inner diameter...

Page 139: ...g it with the punched point Tighten the bolts and nuts to specified torque Torque value 0 8 1 2kgf m Use a brake cleaner to clean brake hub and replace the two brake shoes if brake linings are contami...

Page 140: ...12 Brake System 12 16 Notes This chapter Contents...

Page 141: ...1 Maintenance Information 13 2 Troubleshooting 13 2 Steering Handle 13 3 Front Wheel 13 5 Front Cushion 13 9 Steering Stem 13 10 13 4 0 4 5kgf m 2 4 3 0kgf m 1 0 1 2kgf m 3 1 3 5kgf m 5 0 7 0kgf m 0 2...

Page 142: ...earing puller SYM 6204022 Bearing driver 6201 Troubleshooting Hard To Steer 1 The steering shaft bolt is too tight 2 The steering shaft bearing are damaged 3 The ball and the top cone of the steering...

Page 143: ...oved Remove throttle grip and right handle switch after right handle switch mounting screws removed 2 screws Remove rear brake master cylinder disc brake after 4 bolts removed Remove rear brake lever...

Page 144: ...andle and then install the left handle switch Tighten the screws 2 screws Place master cylinder disc brake or brake lever bracket drum brake onto steering handle Align the lock pin on mounting holder...

Page 145: ...nd then pull out the axle and remove the wheel Inspection Place the axle onto a V block to measure its run out with a dial gauge The dial gauge indicated 1 2 run out Service limit 0 20 mm Place the wh...

Page 146: ...d brake disc Remove left side dust seal bearing and dist collar Special tools Inner bearing puller SYM 6204020 Installation Fill out the block of bearing by grease Drive the left bearing dust seal int...

Page 147: ...13 Steering Front Wheel Front Cushion 13 7...

Page 148: ...o the brake lining brake drum and disc must be free of grease Apply with grease onto the left side dust seal Install the left side collar Place the front wheel between the front cushions Caution Align...

Page 149: ...aliper Take out the hose from hose clamp Remove the front cushion upper bolts and the front cushion Installation Align the cover flange with upper level of the cushion clamp and then tighten bolts Tor...

Page 150: ...til to mounted position Caution Do not tilt the ball bearing seats as installation Apply with grease onto the ball bearing seats and install steel balls onto the seats Top 26 balls bottom 29 balls Lub...

Page 151: ...11 Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body Torque value 1 0 1 2kgf m Install in reverse order of removal procedures Steering stem mounting...

Page 152: ...14 Rear Wheel Rear Cushion 14 1 Maintenance Information 14 2 Troubleshooting 14 2 Rear Wheel 14 3 Rear Cushion 14 5 14 4 0 4 5kgf m 10 0 12 0kgf m Home page Contents 10 0 12 0kgf m...

Page 153: ...12 0kgf m Bolts for the brake disc 4 0 4 5kgf m Exhaust muffler nut 1 0 1 4kgf m Exhaust muffler bolt 3 0 3 6kgf m Troubleshooting Rear wheel wobbling 1 Bend wheel rim 2 Poor tire 3 Loosen wheel shaft...

Page 154: ...exhaust muffler bolt 3 bolts then remove the muffler Remove rear wheel shaft nut and then remove the rear wheel Inspection As the diagram shown measure wheel rim wobbling with a dial gauge Service lim...

Page 155: ...k item refer chapter 12 Install by reverse order of removal procedures Installation Install the rear wheel and tighten the nut Tighten torque 10 0 12 0kgf m Install exhaust pipe muffler Tighten torque...

Page 156: ...stall the rear cushion Tighten the upper lower mounting bolts to specified torque Torque value Upper mounting bolt 3 5 4 5kgf m Lower mounting bolt 2 4 3 0kgf m Press down the tail of the scooter for...

Page 157: ...14 Rear Wheel Rear Cushion 14 6 Note This chapter Contents...

Page 158: ...15 Oil Level Switch 15 13 Fuel Unit 15 15 Switch Horn 15 16 Bulb Replacement 15 19 15 Spark Plug AC Generator Fuse Battery IG Coil Fuel Unit Main Switch Reg Rec Comp Start ENG Stop Switch Start Relay...

Page 159: ...charge the battery The voltage must be checked with the voltmeter while charging the battery As C D I assembly does not require an ignition timing check In case ignition timing is incorrect check C D...

Page 160: ...rter motor is out of work Intermittent power supply The coupler of the charging system becomes loose Poor connection of the battery cable Poor connection or short circuit of the discharging system Poo...

Page 161: ...to explosion causing by hydrogen Stop charging battery when electrolyte temperature is over 45 117 Fast charging the battery is for in emergency only Battery should be charged in standard Current Leak...

Page 162: ...r Turn on the headlight to high beam and start the engine Accelerate the engine to the specified revolution per minute and measure the charging voltage Specified Charging Current 1 2 A 5000 rpm Contro...

Page 163: ...nd green and frame Open circuit wire Check charging coil yellow to pink if its resistance is within 0 2 1 0 Open circuit in alternator charging coil If wire circuit check is in normal and there is no...

Page 164: ...resistance values will be incorrect It contains semi conductor in circuit so the measured resistance value will be in different if different testers are used Thus these values cannot be judged with st...

Page 165: ...pins Measure the primary coil resistance Resistance 0 19 0 23 A B Measure the secondary coil resistance Resistance 8 2 9 3K A D A B C R L Y B B Y G L Y B Y AC Generator Battery Fuse 15A Main switch E...

Page 166: ...to diagnosis related ignition components Item Measure at Standard at 20 Main Switch Black Green Continuity battery voltage as main switch ON Pulse Generator Blue Yellow Green 50 200 Primary Black yel...

Page 167: ...nnect both the green yellow and the yellow red pins to battery posts directly If the red and red white pins are also in continuity it means it is in normal Starter relay Battery Starter relay Starter...

Page 168: ...motor pinion in reverse order of removal Starter Motor Pinion Inspection Pinion reduction gear for wear out or damage replace it with new one Gear journal for wear out or damage replace it with new o...

Page 169: ...It may be short circuiting if dark surface on the shifter found Caution Do not clean the shifter surface with sandpaper Check continuity 1 both the shifter surface and shaft 2 among the shifter surfa...

Page 170: ...ire and ground Removal Installation Remove luggage box Drain out oil from oil outlet tube Pull up oil level switch and then remove oil level switch from the oil tank Install the oil level switch in re...

Page 171: ...buretor heater Inspection Carburetor heater resistance 7 10 Remove power filter coupler and thermo switch coupler and then remove power filter and thermo switch This chapter Contents Main switch Power...

Page 172: ...k as installation and then turn the retain plate in clockwise direction until matching to the arrow Inspection 1 Connect the fuel unit coupler Turn the main switch ON Move the float in up and down and...

Page 173: ...ler of the main switch and loosen the mounting bolts 2 bolts Remove the main switch Install the new main switch and tighten the mounting bolts Install the main switch coupler and cap Right handle swit...

Page 174: ...L Horn Switch Wire color Light green Black FREE High Low Beam switch Wire color Black White Blue Passing Switch Wire color Black Blue FREE PASS Front Rear Brake Light Switch If the switch is in contin...

Page 175: ...osition light Meter illuming light Hi beam indicate light Headlight Hi beam Headlight Lo beam Headlight beam switch Winker switch Winker relay Main switch Fuse 15A Battery Right winker indicate light...

Page 176: ...n counter clockwise direction and then remove the bulb Replace with new bulb if necessary Specification Headlight bulb 12V 35W H8 Turn the position light set and then remove the position light bulb se...

Page 177: ...ush and turn the bulb in counter clockwise direction and then remove the bulb Replace with new bulb if necessary Specification Winker light bulb 12V 10W Rear winker light Remove rear winker lens 1 scr...

Page 178: ...rear carrier rear fender and taillight assembly Refer chapter 11 Remove 1 screw from taillight upper side Remove 4 screws and then remove taillight assembly Taillight bulb is LED if necessary to repl...

Page 179: ...Turn the bulb seat in counter clockwise direction and then remove and then take out the bulb seat from the bottom of instrument panel Replace with new bulb if necessary Specification Meter indicator l...

Page 180: ...16 Electrical Diagram 16 1 Jet Sport X 50 Series Electrical Diagram 16 Home page Contents Open fire...

Page 181: ...16 Electrical Diagram 16 2 Notes Home page Contents...

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