SANYANG JOYMAX 250 manuels

Sanyang JOYMAX 250 Manuel de service (227 pages)

marque: Sanyang | Catégorie: Scooters | Taille: 6.78 MB |

Anglais

Table des matières

GTS 250

1

JOYMAX 250

1

SERVICE MANUAL

1

Forward

2

Service Department

2

SANYANG INDUSTRY CO., LTD

2

How To Use This Manual

3

Contents

4

Page Content Index

4

Serial Number

5

1. General Information

10

2. Maintenance Information

22

Gear Oil

25

Fuel Lines / Cable

25

P.C.V. system

27

Valve Clearance

27

Steering Handle Top Bearing

31

Cushion

31

Brake Lining Wear

33

Nuts, Bolts Tightness

35

3. Lubrication System

40

Engine Oil

42

Engine Oil Strainer Clean

42

Oil Pump Removal

43

Oil Pump Disassembly

43

Oil Pump Inspection

44

Oil Pump Re-assembly

44

Oil Pump Installation

45

4. Fuel System

48

Carburetor Remove / Install

51

Vacuum Chamber

51

Engine Removal

63

Engine Hanger

67

Removal of Engine Bush

70

Installation of Engine

71

6. Cylinder Head / Valve

72

Cylinder Head Removal

75

Cylinder Head Disassembly

77

Cylinder Head Inspection

79

5.0 mm valve guide reamer

80

Valve Stem Replacement

81

Roughness

82

Old valve seat width

82

Valve seat width

82

Cylinder Head Installation

85

Valve Clearance Adjustment

87

7. Cylinder / Piston

88

7. Cylinder / Piston

89

Cylinder and Piston Removal

90

Remove piston rings

91

Piston Installation

94

Cylinder Installation

94

8. V-Belt Driving System

96

Bearing replacement

99

Drive Belt

100

Installation

101

Caution

101

To this chapter contents

101

Drive Face

102

Inspection

103

Driven pulley installation

104

Clutch Outer/Driven Pulley

105

Clutch lining

106

Driven pulley spring

106

Driven pulley

106

Clutch weight Replacement

107

Assembly

109

9. Final Driving Mechanism

110

Mechanism Diagram

118

Precautions in Operation

119

AC.G. Set Removal

121

Right Cover Bearing

121

Starting Clutch

123

One way clutch Installation

124

Caution

124

AC.G. Flywheel Installation

125

AC.G. Set Installation

126

11. Crankcase / Crank

128

Disassembly of Crankcase

130

Crankshaft Inspection

131

Assembly of Crankcase

133

12. Cooling System

136

Change of coolant

140

Radiator

141

Water Pump

143

Thermostat

147

Technical Data

148

13. Body Cover

150

Handle Cover

152

Front Cover

153

Inner Box

156

Side Cover

158

Luggage Box

160

Rear Body Cover

161

Floor Panel

162

Front Fender

162

Rear Fender

163

14. Brake System

164

Disk Brake System Inspection

167

Front Brake Caliper

170

Rear Brake Caliper

171

Brake Disk

172

Master Cylinder

172

Master Cylinder Inspection

173

Master Cylinder Assembly

173

Master Cylinder Install

174

Operational Precautions

177

Trouble Diagnosis

177

Steering Handle

178

Front Wheel

180

Disassembly

181

Front Cushion

183

Steering Stem

184

Operational Precaution

187

Muffler

188

Rear Wheel

188

Rear Fork

190

Rear Cushion

191

17. Electrical System

192

Battery

195

Inspection on ignition coil

201

Replacement on ignition coil

201

Starting System

202

Removal of Starter motor

203

Removal of meter

205

Installation of meter

205

Replacement headlight bulbs

207

Switch / Horn

210

Left handle switch

211

Brake Switch

211

Fuel Unit

212

Cooling Fan Thermo Switch

213

Thermo Sensor

214

Water Temperature Meter

214

18. Emission Control System

217

1. Visual check:

218

2. Leak test:

218

3. PCV Function Test

218

Construction

220

Warm-up test:

222

1. Construction

223

2. Principle of operation:

223

3. Service Methods

223

Inspection Items

224

19. Electrical Diagram

226

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