Sym MB10A7-A series User manual

Symba 100
Service Manual
FOREWORD CONTENTS
HOW TO USE THIS MANUAL MECHANICAL LAYOUT
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Foreword
This service manual contains the technical data of each component inspection and
repair for the SANYANG MB10A7-A series motorcycle. The manual is shown with
illustrations and focused on “Service Procedures”, “Operation Key Points”, and
“Inspection Adjustment”, providing technician with service guidelines. Copyright
reserved.
If the style and construction of the motorcycle, MB10A7-A series motorcycle, are
different from that of the photos, pictures shown in this manual, the actual vehicle
layout should be followed. Specifications may be changed without notice.
Service Department
SANYANG INDUSTRY CO., LTD.
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How to Use This Manual
This service manual describes basic information of individual parts and system inspection
& service for SANYANG MB10A7-A series motorcycle. In addition, please refer to the
manual contents for detailed information for the model year.
The first chapter covers general information and troubleshooting.
The second chapter covers maintenance information and special tools catalog.
The third to the 9th chapters cover engine, fuel and driving systems.
The 10th and 11th chapters contain the parts of vehicle frame.
The 12th chapter is electrical appliances.
The 13th chapter is wiring diagram.
Please see index of content for brief information and quick guide.
There are 4 buttons, “Foreword”, “Contents”, “How to Use This Manual” and “Mechanical
Layout” on the PDF version homepage, and can access these items by clicking of the
mouse.
If technician wants to see the content of one specific chapter, click on the title of each
chapter on the Index page. There are two buttons on the upper part of each page,
“Homepage” and “contents”. The user can click on the “Homepage” button or the
“Contents” button to go back to the homepage or contents index. Therefore, to check one
paragraph inside the chapter, click on the paragraph index to go to the desired paragraph. In
addition, there is a “To This Chapter Contents” button at the upper side of each page, by
clicking the button; you can go back to the paragraph selection index of this specific
chapter.
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Contents
Page Content Index
1-1 ~ 1-24 General Information / Troubleshooting
1
2-1 ~ 2-20 Maintenance Information
2
3-1 ~ 3-16 Fuel System 3
4-1 ~ 4-20 Clutch / Transmission / Lubrication System 4
5-1 ~ 5-10 AC Generator / Starting Clutch 5
6-1 ~ 6-6 Engine Removal 6
7-1 ~ 7-18 Cylinder Head / Valve 7
8-1 ~ 8-10 Cylinder / Piston 8
9-1 ~ 9-16 Crankshaft / Crankcase / Shifting Gear / Kick Starter 9
10-1 ~ 10-20 Steering / Front Wheel / Front Suspension / Front Brake 10
11-1 ~ 11-16 Rear Wheel / Rear Suspension / Rear Brake 11
12-1 ~ 12-26 Electrical System 12
13-1 ~ 13-10 Emission Control System 13
14-1 ~ 14-2 Electrical Diagram 14
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Mechanical Layout
Homepage Contents
Air Filter
FR. Brake Lever
Meter
Headlight
Muffler
Engine Oil Dipstick
Shifting Pedal
Headlight /
Starting Switch
Headlight Dimmer /
Winker / Horn Switch
Main Switch
Taillight
Fuel Tank Cap
Rear Brake Pedal
Battery / Fuse / CDI /
Regulator Rectifier
Kick Starter
RR. Winker
Ignition Coil
Winker Relay
Horn / Start Motor
FR. Winker
Electrical Resisto
r
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1. General Information
1-1
Symbols and Marks ··················1-1
General Safety···························1-2
Service Precautions··················1-3
Specifications····························1-9
Torque Reference Values·········1-10
Engine Torque Values···············1-10
Frame Torque Values················1-11
Troubleshooting························1-12
Cable & Wire Routing················1-19
Lubrication Points·····················1-24
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 Serious injury or even death may occur if procedures are not followed.
Caution Equipment damages may occur if procedures are not followed.
Engine oil
Recommended oil: Bramax motor oil or equivalent motor oil, SAE 10W-30
API SH class oil. Warranty will not cover the damage which is caused by
not applying with the recommended engine oil.
Grease King Mate G-3 is recommended.
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 Use special tools.
Correct Correct installation.
Wrong Wrong installation.
Indication Indication of parts.
Directions Position and operation directions
Parts assembly directions.
Bolt installation direction, --- means that bolt go through the component
(invisible).
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1. General Information
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 a
ventilator.
Caution
‧ Exhaust contains toxic gas, which may cause
one to lose consciousness and even result in
death.
Gasoline
Gasoline is a low ignition point and explosive
material. Work in a well-ventilated place, no flame
or spark allowed in the work place or where
gasoline is being stored.
Caution
‧ Gasoline is highly flammable, and may
explode under some conditions, keep it away
from children.
Used engine oil
Caution
‧Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer
although it might not be verified.
‧We recommend you to wash your hands with
soap and water right after contacting. Keep the
used oil beyond reach of children.
Hot components
Caution
‧ 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 the vehicle is
cooling down.
Battery
Caution
‧ Battery emits explosive gases; flame is strictly
prohibited. Keeps the place well ventilated
when charging the battery.
‧ Battery contains sulfuric acid (electrolyte),
which can cause serious burns, so be careful
not to get the sulfuric acid 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 plenty of water and then go
to hospital to consult an ophthalmologist.
‧ If you swallow it by mistake, drink a lot of
water or milk, and take some laxative such as
vegetable oil and then go to see a doctor.
‧ Keep electrolyte beyond reach of children.
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
˙ Inhaling brake shoe or pad ash may cause
disorders and cancer of the breathing system
Brake fluid
Caution
˙ Spilling brake fluid on painted, plastic, or
rubber parts may cause damage to the parts.
Place a piece of clean cloth on the
above-mentioned parts for protection when
servicing the brake system. Keep the brake
fluid beyond reach of children.
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1. General Information
1-3
Service Precautions
yAlways use with SANYANG genuine parts and
recommended oils. Using non-genuine parts for
SANYANG vehicle may damage it.
ySpecial tools are designed for remove and install
of components without damaging the part. Using
wrong tools may result in damage.
yWhen servicing this bike, use only metric tools.
Metric bolts, nuts, using wrong tools and
fasteners may damage this vehicle.
yClean the outside of the parts or the cover before
removing it from the bike. Otherwise, dirt and
deposit accumulated on the part's surface may
fall into the engine, chassis, or brake system,
and cause damage.
yWash 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.
yNever bend or twist a control cable to prevent
unsmooth control and premature worn out.
yRubber parts may become deteriorated when old,
and easy to be damaged by solvent and oil.
Check these parts before installation to make
sure that they are in good condition, replace if
necessary.
yWhen 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.
yStore complex components such as transmission
parts in the proper assemble order and tie them
together with a wire for ease of installation later.
yNote the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
yComponents not to be reused should be replaced
when disassembled including gaskets metal seal
rings, O-rings, oil seals, snap rings, and split
pins.
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1. General Information
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yThe length of bolts and screws for assembly,
cover plates or boxes is different from one
another; make 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.
yTighten 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.
yWhen oil seal is installed, fill the groove with
grease, install the oil seal with the name of the
manufacturer facing outside, and check the shaft
on which the oil seal is to be installed for
smoothness and for burrs that may damage the
oil seal.
yRemove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.
yThe 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.
yRubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
yThe 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.
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Both of these examples can result in
bearing damage.
Manufacturer's name
Groove
Clamp
Connector
Boots
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1. General Information
1-5
yLubricate the rotation face with specified
lubricant on the lubrication points before
assembling.
yCheck if positions and operation for installed
parts is in correct and properly.
yMake sure service safety each other when
conducting by two persons.
yNote that do not let parts fall down.
yBefore battery removal operation, you have to
remove the battery negative (-) cable first.
Avoid using tools like open-end wrench, which
may contact with body or create spark.
yAfter service completed, make sure all
connection points is secured.
Battery positive (+) cable should be connected
firstly.
yAnd the two posts of battery have to be greased
after connected the cables.
yMake sure that the battery post caps are located
in properly after the battery posts had been
serviced.
yIf fuse burned, it has to find out the cause and
solved it. And then replace with specified
capacity fuse.
Capacity
verification
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1. General Information
1-6
yWhen separating a connector, it locker has to
be unlocked first. Then, conduct the service
operation.
yDo not pull the wires as removing a connector
or wires. Hold the connector body.
yMake sure if the connector pins are bent,
extruded or loosen.
yInsert 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.
yCheck if the connector is covered by the twin
connector boot completely and secured properly.
yBefore terminal connection, check if the boot is
crack or the terminal is loose.
yInsert the terminal completely.
Check if the boot covers the terminal.
Do not let boot open facing up.
ySecure 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.
yWire band and wire harness have to be clamped
secured properly.
yDo not squeeze wires against the weld or its
clamp.
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1. General Information
1-7
yDo not let the wire harness contact with rotating,
moving or vibrating components when routing
the harness.
yKeep wire harnesses far away from the hot parts.
yAvoid wire harnesses from sharp edges or
corners, and also avoid the jutted-out ends of
bolts and screws.
yRoute harnesses so that they neither pull too
tight nor have excessive slack.
yProtect 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.
ySecure the rubber boot firmly as applying it on
wire harness.
yNever use wires or harnesses which insulation
has been broken. Wrap electrical tape around
the damaged parts or replace them.
yNever clamp or squeeze the wire harness when
installing other components.
Never Touch
Never too
Never clamp or
squeeze the
wire harness
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1. General Information
1-8
yDo not let the wire harness been twisted when
installation.
yWire harnesses routed along the handlebar
should not be pulled too tight or have excessive
slack, use rubber covering against adjacent or
surrounding parts in all steering perimeters.
yBefore operating a test instrument, operator
should read the operation manual of the
instrument. And then, conduct test in accordance
with the instruction.
yUse sand paper to clean connector
pins/terminals if rust is found. And then
continue the connection operation.
Do you know how to set
the instrument to its
measurement position and
the insert locations of its
two probes?
Clean rust
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1. General Information
1-9
Specifications
Manufacturer SANYANG Model MB10A7-A
Overall Length 1910 mm Front TELESCOPIC
Overall Width 690 mm
Suspension
System Rear SWING ARM
Overall Height 1055 mm Front 2.50-17 38L
Dimension
Wheel Base 1225 mm
Tire
Specifications Rear 2.50-17 38L
Front 38 kg
Rear 57 kg Front Drum (ø 110 mm)
Curb
Weight Total 95 kg
Brake System
Rear Drum (ø 110 mm)
Passengers/Weight 1 passenger /75 kg Max. Speed Over 80 km/hr
Front 53 kg
Performance Climb Ability Below 20°
Rear 117 kg Primary
Reduction 4.059 (69/17T)
Weight
Total
Weight
Total 170 kg Secondary
Reduction 2.571 (36/14T)
Type Air cooled 4-stroke gasoline
engine Clutch Wet multi-plate, auto
centrifugal clutch
Installation and
arrangement
Vertical, below center,
incline 15°
Reduction
Transmission 4 speed, circulated
Fuel Used Unleaded gasoline Speedometer 0 ~ 120 km/hr
Fuel system Carburetor Horn 80~110 dB
Bore Ø 52.4 mm Muffler Expansion & Pulse Type
Stroke 47 mm
Exhaust Pipe Position and
Direction
Right side, and
Backward
Cylinder
Arrangement Single Cylinder Lubrication System Forced and wet sump
Displacement 101.4 cc Solid Particulate -
Compression Ratio 9.2 : 1 CO Below 1.8 %
Max HP 6.8 ps / 8500 rpm
Exhaust
Concentration
HC Below 2000 ppm
Max Torque 0.69 kg-m / 6000 rpm E.E.C. √
Ignition C.D.I. P.C.V. √
Engine
Starting System Kick/ Electrical Starter Catalytic Converter √
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1. General Information
1-10
Torque Reference Values
The torque values listed in above table are for more important tighten torque values. Please see standard
values for those not listed in the table.
Standard Torque Values for Reference
Tighten Torque Tighten Torque
Type kgf-m N-m Type kgf-m N-m
5mm bolt、nut 0.45~0.6 4.4~6 4mm screw 0.1~0.15 1.0~1.5
6mm bolt、nut 0.8~1.2 8~12 5mm screw 0.35~0.5 3.4~5
8mm bolt、nut 1.8~2.5 18~25 6mm screw、SH nut 0.7~1.1 7~11
10mm bolt、nut 3.0~4.0 29~39 6mm bolt、nut 1.0~1.4 10~14
12mm bolt、nut 5.0~6.0 49~59 8mm bolt、nut 2.4~3.0 24~29
3mm screw 0.05~0.08 0.5~0.8 10mm bolt、nut 3.5~4.5 34~44
Engine Torque Values Torque Value
Item Q’ty Thread
Dia. (mm) kgf-m N-m Remarks
Cylinder head nut 4 8 1.0~1.2 10~12
Cylinder head left bolt 1 6 0.8~1.2 7.8~12
Cylinder stud bolt 4 8 0.7~1.0 7~10
Cylinder head side cover bolt 3 6 0.8~1.2 7.8~12
Tappet adjustment hole cap 2 6 0.8~1.2 7.8~12
Tappet adjustment screw nut 4 5 0.7~1.1 7~11 Apply oil to thread
Cam gear bolt 2 6 1.0~1.2 10~12
Spark plug 1 10 1.0~1.2 10~12
Carburetor insulator bolt 2 6 0.7~1.1 7~11
Engine oil draining bolt 1 12 1.5~2.0 15~20
Clutch nut 1 14 3.8~4.5 38~45
Engine oil strainer cap 2 6 0.8~1.2 7.8~12
Engine oil pump cover screw 2 6 0.3~0.4 3~4
Engine oil pump screw 3 6 0.4~0.6 4~6
Right crankcase cover bolt 10 6 0.8~1.2 7.8~12
Left crankcase cover bolt 8 6 0.8~1.2 7.8~12
Left crankcase rear cover bolt 2 6 0.8~1.2 7.8~12
Driving 2 6 0.8~1.2 7.8~12
ACG. Flywheel nut 1 12 3.5~4.3 35~43
Starting clutch bolt 3 6 1.0~1.4 10~14 Apply glue to thread
Crankcase bolt 7 6 0.8~1.2 7.8~12
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1. General Information
1-11
Frame Torque Values Torque Value
Item Q’ty Thread Dia.
(mm) (kgf-m) (N-m)
Remarks
Handlebar luck bolt 4 8 3.0~3.5 29~35
Handlebar post locknut 1 10 4.0~4.5 39~49
Steering stem locknut 1 25.4 6.0~8.0 59~78
Steering top cone race 1 25.4 0.15~0.25 1.5~2.5
Front wheel axle nut 1 10 4.0~5.0 39~49
Rear wheel axle nut 1 12 5.0~6.0 49~59
Final driven sprocket nut 1 16 6.0~7.0 59~69
Drive sprocket nut 4 8 2.7~3.3 26~32
Front cushion mounting bolt 2 8 3.0~3.5 29~35
Rear cushion upper connection bolt 2 10 3.0~4.0 29~39
Rear cushion lower connection bolt 2 10 3.0~4.0 29~39
Brake lever nut 2 6 0.8~1.2 7.8~12
R
ear brake drum mountin
g
bolt 1 8 1.5~2.5 15~25
Engine hanger link nut 2 8 3.0~3.5 44~54
Foot stand bolt 4 8 2.4~3.0 24~29
Kick starter bolt 1 6 1.6~1.8 15.7~17.6
Gear chan
g
e
p
edal
b
olt 1 6 1.4~1.5 13.7~14.7
R
ear fork mountin
g
bolt 1 10 3.0~4.0 29~39
Muffler mountin
g
nut 2 6 1.0~1.4 10~13.7
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1. General Information
1-12
Troubleshooting
A. Engine hard to start or can not be started
Check and adjustment Fault condition Possible causes
Loosen carburetor drain bolt
to check if there is gasoline
inside the carbureto
r
Fuel supplied to
carburetor sufficient No fuel is supplied to carbureto
r
Remove spark plug, install it
into spark plug cap, and
perform a spark test.
Perform cylinder
compression pressure test.
Good sparks Weak sparks, no spark
at
a
ll
Cylinder compression
pressure normal Low compression pressure or no pressure
Re-start by following the
starting procedures
No ignition There are some signs of
ignition; but engine
cannot be started.
Remove the spark plug again
and check it.
Dry spark plug Wet spark plug
1. No fuel in fuel tank
2. Check if the pipes, fuel tank to carburetor
and intake vacuum, are clogged.
3. Float valve clogged
4. Lines in fuel tank evaporation system
clogged
5. Malfunction of fuel pump
6. Loosen or damaged fuel pump vacuum
hose
7. Fuel filter clogged
1. Malfunction of spark plug
2. Spark plug damaged
3. Malfunction of CDI set
4. Malfunction of AC generator
5. Ignition coil is in open or short circuit
6. Ignition coil wire open or short circuit
7. Main switch malfunction
1. Piston ring seized
2. Malfunction of cylinder valves
3. Worn cylinder and piston ring
4. Cylinder gasket leak
5. Sand hole in compression parts
1. Malfunction of throttle valve operation
2. Air leaking through intake manifold
3. Incorrect ignition timing
1. Fuel level in carburetor too high
2. Malfunction of throttle valve operation
3. Throttle valve opening too wide
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1. General Information
1-13
B. Engine run sluggish (Speed does not pick up, lack of power)
Check and ad
j
ustment Fault condition Possible causes
Try gradual acceleration and
check engine speed
Engine speed increases. Engine speed cannot
increase.
Check ignition timing
(
Usin
g
i
g
nition lamp
)
Check cylinder compression
pressure (using compression
pressure gauge)
Correct ignition timing Incorrect ignition timing
Compression pressure
correct No compression
Check if carburetor jet is
clo
gg
ed
Not clogged Clogged
Remove spark plug
Check if engine over heat
No foul or discoloration Fouled and discoloration
No knock Knock
1. Air cleaner clogged
1. Poor fuel supply
2. Lines in fuel tank evaporation system
clogged
3. Exhaust pipe clogged
4. Fuel level too low in carburetor
5. Fuel nozzle clogged in carburetor.
1. Malfunction of CDI
2. Malfunction of AC alternator
1. Cylinder & piston ring worn out
2. Cylinder gasket leaked
3. Sand hole in compression parts
4. Valve deterioration
5. Seized piston ring
1. Remove foreign object
1. Remove dirt
2. Incorrect spark plug heat range
1. Piston and cylinder worn out
2. Lean mixture
3. Poor fuel quality
4. Too much carbon deposited in
combustion chamber
5. Ignition timing too advanced
6. Poor circuit on the cooling system
Normal Engine overheat
Continually drive in
acceleration or h
igh
1. Too much carbon deposited in
combustion chamber
2. Lean mixture
3. Poor fuel quality
4. Ignition timing too advanced
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1-14
C. Engine runs sluggish (especially in low speed and idling)
Check and ad
j
ustment Fault condition Probable causes
Check ignition timing
(Using ignition lamp)
1. Incorrect ignition timing (malfunction
of CDI or AC alternator)
1. Rich mixture (loosen the screw)
2. Lean mixture (tighten the screw)
1. Poor heat insulation gasket
2. Carburetor lock loose
3. Poor intake gasket
4. Poor carburetor O-ring
5. Vacuum hose crack
1. Spark plug fouled
2. Malfunction of CDI
3. Malfunction of AC generator
4. Malfunction of ignition coil
5. Open or short circuit in spark plug
leads
6. Malfunction of main switch
Good spark Poor
No air sucked in Air sucked in
Good Poor
Normal Abnormal
Air sucked in through
carburetor gasket
Adjust the air screw of
ca
r
bu
r
etor
Remove spark plug, install
spark plug into spark plug
cap and perform spark test
against engine ground
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D. Engine runs sluggish (High speed)
Check for fuel supplying
syste
m in
auto
m
at
i
c
f
ue
l
cup
Check if carburetor clogged
1. Insufficient fuel in fuel tank
2. Fuel filter clogged
3. Restricted fuel tank vent
Good Poor
Check and ad
j
ustment Fault condition Probable causes
Check ignition timing
1. Malfunction of CDI
2. Malfunction of AC alternator
Normal Abnormal
Not clogged Clogged 1. Cleaning
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