Sym Wolf SB 250 Ni User manual

Wolf SB 250 Ni
SERVICE MANUAL
20120309
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 PD25A series 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.
Copyright reserved.
If the style and construction of the motorcycle, PD25A series motorcycle, are
different from that of the photos, pictures shown in this manual, you should follow
the actual vehicle layout. Specifications may be changed without notice.
Service Department
SANYANG INDUSTRY CO., LTD.
Homepage
Contents

How to use this manual
This service manual describes basic information of individual parts and system
inspection & service for SANYANG PD25A series motorcycle. In addition, please
refer to the manual contents for detailed information for the model year.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance information and special tools
manual.
The third to the 9th chapters cover engine and driving systems.
The 10th chapter covers cooling systems.
The 11th to the 13th chapters contain the parts of vehicle frame.
The 14th chapter is electrical appliances.
The 15th chapter is emission control system.
The 16th chapter is electrical diagram.
Please see index of content for brief information and quick guide.

Content
Page Content Index
1-1 ~ 1-19 General Information
1
2-1 ~ 2-16 Maintenance Information
2
3-1 ~ 3-45 Injection System 3
4-1 ~ 4-14 Lubrication / Clutch / Transmission 4
5-1 ~ 5-8 AC Generator / Starting Clutch 5
6-1 ~ 6-8 Engine Removal 6
7-1 ~ 7-16 Cylinder Head / Valve 7
8-1 ~ 8-10 Cylinder / Piston 8
9-1 ~ 9-14 Crankshaft / Crankcase / Shifting Gear 9
10-1 ~ 10-14 Cooling System 10
11-1 ~ 11-10 Brake System 11
12-1 ~ 12-14 Steering / Front Wheel / Front Fork 12
13-1 ~ 13-12 Rear Wheel / Rear Cushion 13
14-1 ~ 14-26 Electrical System 14
15-1 ~ 15-10 Emission Control System 15
16-1 ~ 16-2 Wiring Diagram 16

Mechanism Illustration
Start /
Engine stop
switch
Main
Switch
RR brake
pedal
Starter relay
Air cleaner
Fuel tank cap
Winker relay
Battery
Headlight
dimmer /
Winker / Horn
switch
Ignition
il
ECU
Headlight
Fuse
Regulator/
Rectifier
Shifting
pedal
Meter
FR. Brake lever
Clutch lever Taillight
FR winker
RR. winker
Muffler

1. General Information
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
Torque Values ···························1-11
Troubleshooting························1-12
Lubrication Points·····················1-17
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 in procedures is 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 10W-30 API SG class oil. Warranty will not cover
the damage that caused by not apply with the limited engine oil.
(Recommended oil: Bramax G-3 oil)
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 goes
through the component (invisibility).
1-1

1. General Information
General Safety
Carbon monoxide Battery
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
1-2
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 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 compressed air 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
clean towel on the above-mentioned parts for
protection when servicing the brake system.
Keep the brake fluid beyond reach of children.

1. General Information
Service Precautions
Always use with SANYANG genuine parts and
recommended oils. Using non-genuine parts for
SANYANG vehicle may damage it.
1-3
Special tools are designed for removal and
installation of components without damaging the
part. Using wrong tools may result in damage.
When servicing this bike, use only metric tools,
metric bolts, and nuts. Using wrong tools and
fasteners may damage this vehicle.
Clean 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.
Wash and clean parts with high ignition point
solvent, and blow them 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
unsmooth control and premature worn out.
Rubber 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.
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
The length of bolts and screws for assemblies,
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 outside the hole is the same with other
bolts, it is a correct bolt. Bolts for the same
assembly should have the same length.
1-4
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 installing oil seal, 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.
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.
Groove
Clamp
Rubber and plastic boots should be properly
reinstalled to the original correct positions as
designed
Connector
Boots
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.
Manufacturer's name
Both of these examples can result in bearing damage.

1. General Information
Lubricate the rotation face with specified
lubricant on the lubrication points before
assembling.
1-5
●Check if positions and operation of installed
parts are correct and proper.
●Make sure service safety each other when
conducting by two persons.
●Note that do not let parts fall down.
Before 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.
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 properly after the battery posts had
been serviced.
●If a fuse is burned, it has to find out the cause
and solved it. And then replace with specified
capacity fuse.
Capacity
verification