Sym Quad Lander 300 User manual

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HOW TO USE THIS MANUAL SERIAL NUMBER
Quad Lander 300
SERVICE MANUAL

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This service manual contains the technical data of each component inspection and
repair for the SANYANG Quad Lander 300 ATV. 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 ATV, Quad Lander 300, 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.

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HOW TO USE THIS MANUAL
This service manual describes basic information of different system parts and
system inspection & service for SANYANG Quad Lander 300ATV. 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 and special tools
manual.
The third to the 11th chapters cover engine and driving systems.
The 12th chapter is cooling system.
The 13th to the 16th chapter is contained the parts set of assembly frame body.
The 17th chapter is electrical equipment.
The 18th chapter is wiring diagram.
Please see index of content for quick having the special parts and system
information.
There are 4 buttons, “Forward”, “Contents”, “How to use this manual” and
“Mechanism Illustrations” on the CD-R version, and can be access to these items
by click the mouse.
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, onto 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
contents so that clicking the button can back to the contents of this chapter.

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CONTENTS
Page Content Index
1-1 ~ 1-18 GENERAL INFORMATION
1
2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION
2
3-1 ~ 3-8 LUBRICATION SYSTEM 3
4-1 ~ 4-12 FUEL SYSTEM 4
5-1 ~ 5-6 ENGINE REMOVAL 5
6-1 ~ 6-16 CYLINDER HEAD/VALVE 6
7-1 ~ 7-8 CYLINDER/PISTON 7
8-1 ~ 8-16 “V” TYPE BELT DRIVING SYSTEM/KICK-STARTER 8
9-1 ~ 9-19 FINAL DRIVING MECHANISM 9
10-1 ~ 10-10 ALTERNATOR 10
11-1 ~ 11-8 CRANKSHAFT/ CRANKCASE 11
12-1 ~ 12-12 COOLING SYSTEM 12
13-1 ~ 13-14 BODY COVER 13
14-1 ~ 14-14 FRONT BRAKE AND FRONT WHEEL 14
15-1 ~ 15-10 STEERING/FRONT SUSPENSION 15
16-1 ~ 16-18 REAR BRAKE/REAR WHEEL/REAR CUSHION 16
17-1 ~ 17-22 ELECTRICAL EQUIPMENT 17
18-1 ~ 18-2 ELECTRICAL DIAGRAM
18

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SERIAL NUMBER
Frame number
Engine number

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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
Specifications..................................... 1-10
Torque Values.................................... 1-11
Troubles Diagnosis............................ 1-14
Lubrication Points ............................. 1-19
1
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 10W-30 API SG class oil. Warranty will not cover the
damage that caused by not apply with the limited engine oil.
(Recommended oil: KING MATE 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 cross
through the component (invisibility).

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1. GENERAL INFORMATION
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.
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 should be 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 that you 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 cooling off.
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
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.
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
clean towel on the above-mentioned parts for
protection when servicing the brake system.
Keep the brake fluid beyond reach of children.

To this chapter contents
1. GENERAL INFORMATION
Service Precautions
yAlways use with SANYANG genuine parts and
recommended oils. Using non-designed parts for
SANYANG ATV may damage the ATV.
ySpecial tools are designed for remove and install
of components without damaging the parts being
worked on. Using wrong tools may result in parts
damaged.
yWhen servicing this ATV, 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.
yClean the outside of the parts or the cover before
removing it from the ATV. Otherwise, dirt and
deposit accumulated on the part's surface may
fall into the engine, chassis, or brake system to
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 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.
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.
1-3

To this chapter contents
1. GENERAL INFORMATION
yThe 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.
1-4
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.
Groove
Clamp
Connector
yRubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
Boots
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.
Manufacturer's name
Both of these examples can result in
bearing damage.

To this chapter contents
1. GENERAL INFORMATION
yLubricate the rotation face with specified
lubricant on the lubrication points before
assembling.
1-5
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, it has to
remove the battery negative (-) cable firstly.
Notre tools like open-end wrench do not contact
with body to prevent from circuit short and 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

To this chapter contents
1. GENERAL INFORMATION
yWhen separating a connector, it locker has to
be unlocked firstly. 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 terminal is covered by the boot.
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.
1-6

To this chapter contents
1. GENERAL INFORMATION
yDo not let the wire harness contact with rotating,
moving or vibrating components as routing the
harness.
yKeep wire harnesses far away from the hot
parts.
1-7
yRoute wire harnesses to avoid sharp edges or
corners and also avoid the projected 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.
Never Touch
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 as
installing other components.
Never clamp or
squeeze the wire
harness
Never too tight

To this chapter contents
1. GENERAL INFORMATION
yDo not let the wire harness been twisted as
installation.
1-8
yWire harnesses routed along the handlebar
should not be pulled too tight or have excessive
slack, be rubbed against or interfere with
adjacent or surrounding parts in all steering
positions.
yBefore operating a test instrument, operator
should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.
yWith sand paper to clean rust on connector
pins/terminals if found. And then conduct
connection operation later.
Clean rust
Do you know how to set the
instrument to its
measurement position and
the insert locations of its
two probes?

To this chapter contents
1. GENERAL INFORMATION
Specifications
MAKER SANYANG MODEL UA30A
Overall Length 1920 mm Front Double arm
Overall Width 1065 mm Suspension
System Rear Unit Swing
Overall Height 1110 mm Front AT22x7-10 (off road)
Wheel Base 1190 mm Tire Specifications Rear AT22x10-9 (off road)
Front 825 mm Rim Aluminum
Dimension
Wheel tread Rear 805 mm Front Disk (ψ175mm)
Front 130 kg Brake System Rear Disk (ψ220mm)
Rear 105 kg Max. Speed Above 80 km/hr
Curb Weight Total 235 kg Performance Climb Ability Below 25°
Passengers/Weight Two /150 kg
Front 166 kg Primary
Reduction Belt
Rear 219 kg
Weight
Total Weight Total 385 kg Secondary
Reduction Gear / Sprocket
Type 4-Stroke Engine Clutch Centrifugal, dry type
Installation and
arrangement Vertical, below center, incline
Reduction
Transmission C.V.T., auto speed
change
Fuel Used Above 92 unleaded Speedometer 0 ~ 100 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93~112 dB/A
Bore Ø75 mm Muffler
Expansion & Pulse
Type
Stroke 65 mm Exhaust Pipe Position and
Direction Left side, and Backward
Cylinder
Number/Arrange
ment Single Cylinder Lubrication System Forced circulation & splashing
Displacement 2857.2cc Solid Particulate
Compression Ratio 8.8: 1 CO Below 7.0 g/ km
Max. HP 19.2ps / 6500rpm HC Below 1.5g/ km
Max. Torque 2.45 Kg m / 5500rpm
Exhaust
Concentration
Nox Below 0.4g/ km
Ignition C.D.I. E.E.C. ─
Starting System Electrical starter P.C.V. ─
Engine
Air filtration Sponge Catalytic reaction control
system ─
1-9

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1. GENERAL INFORMATION
Specifications
MAKER SANYANG MODEL UA25A1
Overall Length 1,890 mm Front Double arm
Overall Width 1,055 mm Suspension
System Rear Unit Swing
Overall Height 1,115 mm Front AT22x7-10 (on road)
Wheel Base 1,200 mm Tire Specifications Rear AT22x10-9 (on road)
Front 810 mm Rim Aluminum
Dimension
Wheel tread Rear 805 mm Front Disk (ψ175mm)
Front 109 kg Brake System Rear Disk (ψ220mm)
Rear 114 kg Max. Speed Above 80 km/hr
Curb Weight Total 223 kg Performance Climb Ability Below 25°
Passengers/Weight Two /150 kg
Front 142 kg Primary
Reduction Belt
Rear 231 kg
Weight
Total Weight Total 373 kg Secondary
Reduction Gear / Sprocket
Type 4-Stroke Engine Clutch Centrifugal, dry type
Installation and
arrangement Vertical, below center, incline
Reduction
Transmission C.V.T., auto speed
change
Fuel Used Above 92 unleaded Speedometer 0 ~ 100 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93~112 dB/A
Bore Ø71 mm Muffler
Expansion & Pulse
Type
Stroke 63 mm Exhaust Pipe Position and
Direction Left side, and Backward
Cylinder
Number/Arrange
ment Single Cylinder Lubrication System Forced circulation & splashing
Displacement 249.4 cc Solid Particulate
Compression Ratio 10.5 : 1 CO Below 7.0 g/ km
Max. HP 13.2kw / 7000rpm HC Below 1.5g/ km
Max. Torque 20.6Nm / 5500rpm
Exhaust
Concentration
Nox Below 0.4g/ km
Ignition C.D.I. E.E.C. ─
Starting System Electrical starter P.C.V. ─
Engine
Air filtration Sponge Catalytic reaction control
system ─
1-10

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1. GENERAL INFORMATION
Torque Values
The torque values listed in above table are for more important tighten torque values. Please see standard
values for not listed in the table.
Standard Torque Values for Reference
Type Tighten Torque Type Tighten Torque
5 mm bolt、nut 0.45~0.6kgf-m 5 mm screw 0.35~0.5kgf-m
6 mm bolt、nut 0.8~1.2kgf-m 6 mm screw、SH nut 0.7~ 1.1kgf-m
8 mm bolt、nut 1.8~2.5kgf-m 6 mm bolt、nut 1.0 ~1.4kgf-m
10 mm bolt、nut 3.0~4.0kgf-m 8 mm bolt、nut 2.4 ~3.0kgf-m
12 mm bolt、nut 5.0~6.0kgf-m 10 mm bolt、nut 3.5~4.5kgf-m
Engine Torque Values
Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Cylinder stud bolt 4 10 1.0~1.4
Cylinder head nut 4 8 3.6~4.0
Cylinder head right bolt 2 8 2.0~2.4
Cylinder head side cover bolt 2 6 1.0~1.4
Cylinder head cover bolt 4 6 1.0~1.4
Cylinder head stud bolt (inlet pipe) 2 6 1.0~1.4
Cylinder head stud bolt (EX. pipe) 2 8 2.4~3.0
Air inject pipe bolt 4 6 1.0~1.4
Air inject reed valve bolt 2 3 0.07~0.09
Tappet adjustment screw nut 4 5 0.7~1.1 Apply oil to thread
Spark plug 1 10 1.0~1.2
Tensioner lifter bolt 2 6 1.0~1.4
Carburetor insulator bolt 2 6 0.7~1.1
Oil pump screw 2 3 0.1~0.3
Water pump impeller 1 7 1.0~1.4
Engine left cover bolt 9 6 1.1~1.5
Engine oil draining bolt 1 12 3.5~4.5
Engine oil strainer cap 1 30 1.3~1.7
Mission draining bolt 1 8 1.1~1.5
Mission filling bolt 1 12 3.5~4.5
Shift drum fixing bolt 1 14 3.5~4.5
Clutch driving plate nut 1 28 5.0~6.0
Clutch outer nut 1 14 5.0~6.0
Drive face nut 1 14 8.5~10.5
ACG. Flywheel nut 1 14 5.0~6.0
Crankcase bolts 7 6 0.8~1.2
Mission case bolt 7 8 2.6~3.0
1-11

1. GENERAL INFORMATION
1-12

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1. GENERAL INFORMATION
Frame Torque Values
Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Handlebar upper holder bolt 4 6 2.40
Steering shaft nut 1 10 5.00
Steering tie-rod nut 4 10 5.00
Knuckle nut 2 10 5.00
Steering shaft holder bolt 2 8 3.40
Tie rod lock nut 4 10 3.60
Handlebar under holder nut 2 8 4.00
Front wheel nut 8 10 2.40
Front axle castle nut 2 14 5.00
Rear axle castle nut 2 14 5.00
Rear wheel nut 8 10 2.40
Engine hanger nut 4 12 8.50
Rear axle holder bolt 4 12 9.20
Drive gear bolt 2 10 4.6
Driven gear nut 4 10 4.6
Swing arm pivot bolt 1 14 9.20
Front suspension arm nut 4 10 5.00
Front / Rear cushion mounting bolt 6 10 4.60
Brake lever nut 2 6 1.00
Brake hose bolt 13 10 3.50
Brake caliper bolt 6 6 3.25
Brake disk mounting bolt 11 8 4.25
Air-bleed valve 3 5 0.50
Exhaust muffler mounting bolt 2 8 3.00
Exhaust muffler connection nut 2 7 1.20
1-13

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1. GENERAL INFORMATION
Troubles Diagnosis
A. Engine hard to start or can not be started
1-14
Check and adjustment Fault condition Probable causes
Loosen carburetor drain bolt to
check if there is gasoline inside
the carburetor yNo fuel in fuel tank
yCheck if the pipes, fuel tank to carburetor
and intake vacuum, are clogged.
yFloat valve clogged
yLines in fuel tank evaporation system
clogged
yMalfunction of fuel pump
Fuel supplied tom
carburetor sufficient No fuel is supplied to carburetor
yLoosen or damaged fuel pump vacuum
hose
Remove spark plug, install it
into spark plug cap, and perform
a spark test against engine
g
round.
yFuel filter clogged
yMalfunction of spark plug
ySpark plug foul
yMalfunction of CDI set
yMalfunction of AC generator
yIgnition coil is in open or short circuit
yIgnition coil leads open or short circuit
yMalfunction of main switch
Check if sparks Weak sparks, no spark at
all
Perform cylinder compression
pressure test.
Cylinder compression
pressure normal Low compression pressure or no pressure yPiston ring seized
yMalfunction of cylinder valves
yWorn cylinder and piston ring
yCylinder gasket leak
ySand hole in compression parts
yMalfunction of throttle valve operation
yAir sucked into intake manifold
yIncorrect ignition timing
Re-start by following the starting
procedures
No ignition There are some signs of
ignition; nut engine can
not be started
Remove the spark plug again
and check it.
yFuel level in carburetor too high
Remove carburetor after 30
minutes and connect a hose
onto fuel rich circuit. Then blow
the hose with air
Dry spark plug Wet spark plug yMalfunction of throttle valve operation
yThrottle valve opening too wide
Blowing in normal Blowing clogged yMalfunction of automatic by- starter

To this chapter contents
1. GENERAL INFORMATION
B. Engine run sluggish (Speed does not pick up, lack of power)
1-15
Check and adjustment Fault condition Probable causes
Try gradual acceleration and
check engine speed
yAir cleaner clogged
yPoor fuel supply
Engine speed can be
increased. Engine speed can not be increased.
yLines in fuel tank evaporation system
clogged
yExhaust pipe clogged
yFuel nozzle clogged in carburetor.
Check ignition timing (Using
ignition lamp) yFuel nozzle clogged in carburetor.
Check cylinder compression
pressure (using compression
pressure
gauge)
Ignition timing correct Incorrect ignition timing yMalfunction of CDI
yMalfunction of AC alternator
yCylinder & piston ring worn out
yCylinder gasket leaked
ySand hole in compression parts
yValve deterioration
ySeized piston ring
yRemove foreign
yRemove dirt
yIncorrect spark plug heat range
Compression pressure
correct No compression pressure
Check if carburetor jet is
clogged
No clogged Clogged
Remove spark plug
No foul or discoloration Fouled and discoloration
Check if engine over heat yPiston and cylinder worn out
yLean mixture
yPoor fuel quality
yToo much carbon deposited in
combustion chamber
yIgnition timing too advanced
No knock Knock
yPoor circuit on the cooling system
Normal Engine overheat
Continually drive in acceleration
or high speed
yToo much carbon deposited in
combustion chamber
yLean mixture
yPoor fuel quality
yIgnition timing too advanced